THERMACUT EX-TRAFIRE 65HD Bedienungsanleitung

Plasma Cutting System

Operating Instructions – EX-3-902-004/N21605 – CE

Revision 2, 23rd February, 2023

EN - 2

EX-TRAFIRE®65HD

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®105TTH and

FHT-EX®105TTM......................................................................... 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

6.6.5 Installing the cutting torch's gear rack..................................... EN-20

6.7 Installing consumables for the hand and machine

cutting torches............................................................................ EN-21

6.8 Aligning FHT-EX®105TTM machine cutting torch.................. EN-23

7 Operation of the power supply..............................EN-23

7.1 LCD description.......................................................................... EN-24

7.1.1 Setting the parameters.............................................................. EN-25

7.1.2 Selecting the cutting mode....................................................... EN-25

7.1.3 Connecting the work lead with the work lead clamp............ EN-26

7.2 Powering on the machine ......................................................... EN-26

7.3 Manual cutting process ............................................................. EN-26

7.4 Manual grid cutting, gouging, marking process.................... EN-27

7.5 Cutting......................................................................................... EN-27

7.6 Piercing........................................................................................ EN-28

EX-TRAFIRE®65HD

EN - 3

7.7 Gouging ...................................................................................... EN-29

7.7.1 Table for FHT-EX®105TT 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-37

12 Disposal ................................................................. EN-38

12.1 Disposal of materials.................................................................. EN-38

12.2 Disposal of consumables .......................................................... EN-38

12.3 Packaging .................................................................................... EN-38

13 Warranty ................................................................ EN-39

14 Block diagram........................................................ EN-40

15 Accessories ............................................................ EN-40

16 FHT-EX®105TTH hand cutting torch unit ............... EN-41

17 FHT-EX®105TTH consumables for

hand cutting torch ................................................. EN-42

17.1 FHT-EX®105TTH consumables for hand

cutting torch 45 – 65 A............................................................... EN-42

17.2 FHT-EX®105TTH consumables for SmoothLine hand

cutting torch................................................................................ EN-43

18 FHT-EX®105TTM machine cutting torch unit ......... EN-43

18.1 FHT-EX®105TTM machine cutting torch without gear rack... EN-43

18.2 FHT-EX®105TTSM short machine cutting torch .....................EN-44

19 FHT-EX®105TTM consumables for machine

cutting torch........................................................... EN-45

19.1 FHT-EX®105TTM consumables for standard machine

cutting torch 45 – 65 A............................................................... EN-45

19.2 FHT-EX®105TTM consumables for SmoothLine

machine cutting torch................................................................ EN-46

19.3 FHT-EX®105TTM consumables for marking machine

cutting torch................................................................................ EN-47

20 Ordering information on bulk packs and

starter kits.............................................................. EN-47

21 Cutting tables for mechanical cutting.................... EN-48

21.1 45 A cutting, shielded, with compressed air .......................... EN-49

21.2 55 A cutting, shielded, with compressed air .......................... EN-50

21.3 65 A cutting, shielded, with compressed air .......................... EN-51

21.4 40 – 45 A cutting, SmoothLine, shielded, with

compressed air........................................................................... EN-52

21.4.1 40 – 45 A cutting, SmoothLine, shielded, with

compressed air........................................................................... EN-53

EN - 4

EX-TRAFIRE®65HD

21.5 Tables for marking...................................................................... EN-54

21.5.1 Marking, shielded, with compressed air or argon ................. EN-54

EX-TRAFIRE®65HD 1 Identification

EN - 5

1 Identification

The EX-TRAFIRE®65HD is a portable plasma arc cutting power supply for

mechanized and manual plasma cutting, gouging, and marking. The

EX-TRAFIRE®65HD uses gas or nitrogen to cut almost all conductive

metals. The device may be operated only with original Thermacut®parts.

This documentation describes the EX-TRAFIRE®65HD cutting power

supply only.

When used in this documentation, the term “device” always refers to the

EX-TRAFIRE®65HD cutting power supply.

1.1 Marking

This product fulfills the requirements that apply to the market to which it

has been introduced. A corresponding marking has been affixed to the

product, if required.

1.2 Identification plate

The device is labeled by means of an identification plate on the housing

located under the machine.

For inquiries, please have at hand the device type and device number

per the identification plate.

1.3 Signs and symbols used

The following signs and symbols are used:

Fig. 1 EX-TRAFIRE®65HD 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.



EN - 6

2Safety EX-TRAFIRE®65HD

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:

2 Safety

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 device described in this document may be used only for the purpose

and manner described. The device 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 device to thaw pipes.

Do not use or store the device 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®65HD 2Safety

EN - 7

2.2 Obligations of the operator

Ensure that only qualified personnel are permitted to work on the

device or system.

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 device;

— 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 device’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 device can produce electromagnetic fields that could impact the

proper function of cardiac pacemakers and implanted defibrillators.

Do not use the device 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 device 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 device outdoors where it is wet.

Do not operate the device if the housing is open.

Read and observe the operating instructions.

EN - 8

2Safety EX-TRAFIRE®65HD

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 device 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 (OEL).

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®65HD 3 Scope of delivery

EN - 9

3 Scope of delivery

The following components are included in the scope of supply:

—1×EX-TRAFIRE

®65HD cutting power supply

—1×FHT-EX

®105TTH or FHT-EX®105TTM 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®65HD

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 device.

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 device status. A fault code is

displayed if an error occurs.

<POWER> switch (B) Used to switch the device 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

device to an optional CNC cutting table or

robot.

Multi-function button (I) For toggling between two menus and

setting the cutting parameters.

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