THERMACUT EX-TRAFIRE 125HD User manual
Plasma Cutting System
Operating Instructions – EX-6-902-001/N-21611 – CE
Revision 1, 15th June, 2023
EN - 2
EX-TRAFIRE®125HD
Table of contents
1 Identification.............................................................. EN-5
1.1 Marking............................................................................................ EN-5
1.2 Identification plate ......................................................................... EN-5
1.3 Signs and symbols used................................................................ EN-5
1.4 Classification of the warnings....................................................... EN-6
2 Safety ......................................................................... EN-6
2.1 Designated use............................................................................... EN-6
2.2 Obligations of the operator.......................................................... EN-7
2.3 Warning and notice signs.............................................................. EN-7
2.4 Product-specific safety instructions.............................................. EN-7
2.5 Safety instructions for the electrical power supply .................... EN-8
2.6 Safety instructions for plasma cutting.......................................... EN-8
2.7 Personal protective equipment .................................................... EN-8
2.8 Emergency information................................................................. EN-8
3 Scope of delivery ....................................................... EN-9
4 Product description..................................................EN-10
4.1 Assembly and use ........................................................................ EN-10
4.2 Technical data............................................................................... EN-11
4.3 Technical data for cutting torches FHT-EX®125TTH and
FHT-EX®125TTM........................................................................... EN-12
5 Transport and positioning........................................EN-14
6 Setting up the power supply ...................................EN-15
6.1 Connecting to the gas supply..................................................... EN-15
6.2 Connecting the work lead........................................................... EN-15
6.3 Connecting the power supply cable ......................................... EN-15
6.4 Connecting the input power plug.............................................. EN-16
6.4.1 Connection to a generator (optional)........................................ EN-16
6.5 Connecting the cutting torch...................................................... EN-17
6.6 Connecting the CNC interface ................................................... EN-17
6.6.1 Setting the DIP switches.............................................................. EN-18
6.6.2 Enabling the external DC coil with an external power supply EN-19
6.6.3 Enabling the external AC coil with an external power supply EN-19
6.6.4 Enabling the industrially insulated module with an
external power supply................................................................. EN-20
6.7 Installing consumables for the hand and machine
cutting torches.............................................................................. EN-20
6.8 Aligning FHT-EX®125TTM machine cutting torch.................... EN-22
7 Operation of the power supply ...............................EN-23
7.1 LCD description............................................................................ EN-24
7.1.1 Setting the parameters................................................................ EN-24
7.1.2 Selecting the cutting mode......................................................... EN-25
7.1.3 Connecting the work lead with the work lead clamp.............. EN-25
7.2 Powering on the machine ........................................................... EN-26
7.3 Manual cutting process ............................................................... EN-26
7.4 Manual grid cutting and gouging process ............................... EN-26
7.5 Cutting........................................................................................... EN-27
7.6 Piercing.......................................................................................... EN-28
7.7 Gouging ........................................................................................ EN-29
EX-TRAFIRE®125HD
EN - 3
7.7.1 Table for FHT-EX®125TT material removal............................... EN-29
7.8 Stopping the cutting process .....................................................EN-30
8 Disconnecting the unit ............................................ EN-30
9 Maintenance and cleaning ...................................... EN-30
9.1 Maintenance and cleaning intervals .......................................... EN-31
10 Faults and troubleshooting ..................................... EN-33
11 Disassembly ............................................................ EN-38
12 Disposal................................................................... EN-39
12.1 Disposal of materials.................................................................... EN-39
12.2 Disposal of consumables ............................................................ EN-39
12.3 Packaging ...................................................................................... EN-39
13 Warranty.................................................................. EN-40
14 Block diagram ......................................................... EN-41
15 Accessories.............................................................. EN-41
16 FHT-EX®125TTH hand cutting torch unit ................. EN-42
17 FHT-EX®125TTH consumables for
hand cutting torch ................................................... EN-43
17.1 FHT-EX®125TTH consumables for hand
cutting torch 45–65 A................................................................... EN-43
17.1.1 Ordering information................................................................... EN-43
17.2 FHT-EX®125TTH consumables for hand
cutting torch 85–125 A................................................................. EN-44
18 FHT-EX®125TTM machine cutting torch unit........... EN-45
18.1 FHT-EX®125TTM machine cutting torch.................................... EN-45
18.2 FHT-EX®125TTSM short machine cutting torch.......................EN-46
19 FHT-EX®125TTM consumables for machine
cutting torch ............................................................ EN-47
19.1 FHT-EX®125TTM consumables for standard machine
cutting torch 45–65 A................................................................... EN-47
19.2 FHT-EX®125TTM consumables for standard
machine cutting torch 85–125 A................................................. EN-48
19.3 FHT-EX®125TTM consumables for SmoothLine
machine cutting torch.................................................................. EN-49
19.3.1 Ordering information................................................................... EN-49
20 Cutting tables for mechanical cutting ..................... EN-51
20.1 45 A cutting, shielded, with compressed air ............................ EN-52
20.2 65 A cutting, shielded, with compressed air ............................ EN-53
20.3 85 A cutting, shielded, with compressed air ............................ EN-54
20.3.1 85 A cutting, shielded, with compressed air ............................ EN-55
20.4 105 A cutting, shielded with compressed air ........................... EN-56
20.4.1 105 A cutting, shielded with compressed air ........................... EN-57
20.5 125 A cutting, shielded, with compressed air .......................... EN-58
EN - 4
EX-TRAFIRE®125HD
20.5.1 125 A cutting, shielded, with compressed air .......................... EN-59
20.6 30–45 A cutting, SmoothLine, shielded, with
compressed air............................................................................. EN-60
20.6.1 30–45 A cutting, SmoothLine, shielded, with
compressed air............................................................................. EN-61
EX-TRAFIRE®125HD 1 Identification
EN - 5
1 Identification
The EX-TRAFIRE®125HD is a portable plasma arc cutting power supply for
mechanized and manual plasma cutting, gouging, and marking. The
EX-TRAFIRE®125HD uses compressed air or nitrogen to cut almost all
conductive metals. The EX-TRAFIRE®125HD may be operated only with
original Thermacut®parts. This documentation describes the
EX-TRAFIRE®125HD cutting power supply only.
When used in this documentation, the term “device” always refers to the
EX-TRAFIRE®125HD cutting power supply.
1.1 Marking
This product fulfills the requirements that apply to the market to which it
has been introduced. Corresponding marking has been affixed to the
product, if required.
1.2 Identification plate
The EX-TRAFIRE®125HD is labeled by means of an identification plate on
the housing located under the machine.
For inquiries, please have at hand the type and number of the
EX-TRAFIRE®125HD per the identification plate.
1.3 Signs and symbols used
The following signs and symbols are used:
Fig. 1 EX-TRAFIRE®125HD identification plate
General instructions.
Action(s) to be carried out in succession.
Lists.
Cross-reference symbol refers to detailed, supplementary or further
information.
Caption, item description.
1
A
EN - 6
2Safety EX-TRAFIRE®125HD
1.4 Classification of the warnings
The warnings are divided into four different categories and are indicated
prior to potentially dangerous work steps. The following signal words are
used depending on the type of hazard:
2Safety
This chapter warns of hazards that should be kept in mind to operate the
product safely. Non-observance of the safety instructions may result in risks
to the life and health of personnel, environmental damage, or material
damage.
Observe the document entitled “Safety Instructions”.
2.1 Designated use
The EX-TRAFIRE®125HD may be used only for the purpose and manner
described. It is used only for the generation and control of the output
current required for plasma cutting, gouging, and marking. Any other use
is considered improper. Unauthorized modifications or changes to
enhance the performance are not permitted.
Do not exceed the maximum load data as defined by the document
supplied. Overloads lead to destruction.
Do not make any modifications or changes to this product.
Do not use the EX-TRAFIRE®125HD to thaw pipes.
Do not use or store the EX-TRAFIRE®125HD outdoors where it is wet.
DANGER
Describes an imminent threatening danger. If not avoided, it may cause
severe injury or death.
WARNING
Describes a potentially dangerous situation. If not avoided, this may
result in serious injury or death.
CAUTION
Describes a potentially harmful situation. If not avoided, this may result in
slight or minor injury.
NOTICE
Describes the risk of impairing work results or material damage and
indicates irreparable damage to the device or equipment.
EX-TRAFIRE®125HD 2Safety
EN - 7
2.2 Obligations of the operator
Ensure that only qualified personnel are permitted to work on the
EX-TRAFIRE®125HD.
Authorized personnel are:
— those who are familiar with the basic regulations on occupational
safety and accident prevention;
— those who have been instructed on how to handle the
EX-TRAFIRE®125HD;
— those who have read and understood these operating instructions;
— those who have been trained accordingly;
— those who are able to recognize possible risks because of their
special training, knowledge and experience.
Keep untrained persons out of the work area.
Each time the EX-TRAFIRE®125HD’s cover plates are opened, have
Thermacut®or another authorized specialist perform a safety inspection
in accordance with DIN IEC 60974 Part 4: “Periodic inspection and
testing”.
The EX-TRAFIRE®125HD can produce electromagnetic fields that could
impact the proper function of cardiac pacemakers and implanted
defibrillators.
Do not use the EX-TRAFIRE®125HD if you have a pacemaker or an
implanted defibrillator.
This Class A cutting device is not intended for use in residential areas with
a public low-voltage power supply system. It can potentially be difficult to
guarantee electromagnetic compatibility in these areas due to both
conducted and emitted interference.
The EX-TRAFIRE®125HD may be used only in industrial zones according
to DIN EN 61000-6-3.
2.3 Warning and notice signs
The following warning, notice and mandatory signs can be found on the
product:
These markings must always be legible. They may not be covered,
obscured, painted over, or removed.
2.4 Product-specific safety instructions
Do not use or store the EX-TRAFIRE®125HD outdoors where it is wet.
Do not operate the EX-TRAFIRE®125HD if the housing is open.
Read and observe the operating instructions.
EN - 8
2Safety EX-TRAFIRE®125HD
2.5 Safety instructions for the electrical power supply
Ensure that the input power cable is not damaged, for example, by
being driven over, crushed, or torn.
Check the input power cable for damage and wear at regular intervals.
If it is necessary to replace the input power cable, only models indicated
by the manufacturer may be used.
Only a qualified electrician should carry out work on the input power
cable and the input power plug.
Water protection and mechanical stability must be ensured when
replacing the input power plug of the input power cable.
2.6 Safety instructions for plasma cutting
Plasma cutting may cause damage to the eyes, skin, and hearing. Note
that other hazards may arise when the EX-TRAFIRE®125HD is used with
other cutting components. Therefore, always wear the prescribed
personal protective equipment as defined by local regulations.
All metal vapors, especially lead, cadmium, copper, and beryllium, are
harmful. Ensure sufficient ventilation or extraction. Do not exceed the
current occupational exposure limits (OELs).
To prevent the formation of phosgene gas, rinse workpieces that have
been degreased with chlorinated solvents using clean water. Do not
place degreasing baths containing chlorine in the vicinity of the cutting
area.
Adhere to the general fire protection regulations and remove
flammable materials from the vicinity of the cutting work area prior to
starting work. Provide appropriate fire extinguishing equipment in the
workplace.
2.7 Personal protective equipment
Wear your personal protective equipment (PPE).
Ensure that others in close proximity are also wearing personal
protective equipment.
Personal protective equipment consists of protective clothing, safety
goggles, face protection, ear protectors, protective gloves, and safety
shoes.
2.8 Emergency information
In the event of an emergency, immediately disconnect the following
supplies:
— Electrical power supply
— Gas supply
EX-TRAFIRE®125HD 3 Scope of delivery
EN - 9
3 Scope of delivery
The following components are included in the scope of supply:
—1×EX-TRAFIRE
®125HD cutting power supply
—1×FHT-EX
®125TTH or FHT-EX®125TTM cutting torch
— 1 × work lead incl. work lead clamp
— 1 × operating instructions
— 1 × “Safety Instructions” document
— 1 × “Warranty” document
— 1 × operating instructions for the cutting torch
— 1 × starter kit
Order the equipment parts and consumables separately.
The order data and ID numbers for the equipment parts and
consumables can be found in the product catalog.
For more information about points of contact, consultation, and orders,
visit
www.thermacut.com
.
Although the items delivered are carefully checked and packaged, it is not
possible to fully rule out the risk of transport damage.
Goods-in inspection
Check for order completeness by checking the delivery note.
Check the delivered goods for damage (visual inspection).
Claim process
If goods are damaged, notify the final carrier.
Keep the packaging for possible inspection by the carrier.
Returns
Use original packaging and packing material for returns.
If you have questions concerning the packaging or how to secure the
device, contact your supplier, carrier, or transport company.
EN - 10
4 Product description EX-TRAFIRE®125HD
4 Product description
4.1 Assembly and use
The control elements are located on the control panel. The connections are
on the front and rear of the EX-TRAFIRE®125HD.
Fig. 2 Control elements and connections
ADisplay
B<POWER> switch
COptional BUS interface
DG1/4" gas connection, plug
EOptional CNC interface
FPower cable
GWork lead connection
HTorch connection system (TCS)
IMulti-function button
Digital display (A) Displays the status of the
EX-TRAFIRE®125HD. A fault code is
displayed if an error occurs.
<POWER> switch (B) Used to switch the EX-TRAFIRE®125HD on
and off.
BUS interface (C) For connecting the optional CAN BUS or
RS485/422 BUS.
CNC interface
connection (E)
This optional interface is used to connect the
EX-TRAFIRE®125HD to an optional CNC
cutting table or robot.
Multi-function button (I) For toggling between two menus and
setting the cutting parameters.
D
I
CB
A
F
E
G
H
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