Thermacut Ex-trafire 100sd User manual

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!

EX-TRAFIRE®100SD

Operator Manual, Revision T-52

SECTION 1: SAFETY ��5

!Caution! ��6

Plasma arc rays can burn eyes and skin��6

Noise can damage hearing ��6

Flying sparks (arc spray) can cause injury, ﬁre or explosion��6

Caution! Readoperator’smanual��6

Cutting 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 ��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

Claims��3-18

Box contents��3-18

Power supply location ��3-19

Mains power connection ��3-19

Connecting to an engine drive power generator��3-19

Grounding ��3-19

Mains power lead ��3-20

Three-phases mains power lead��3-20

Installation of three-phases mains power lead ��3-20

The mains power lead connection ��3-21

Torch installation step by step��3-21

Plasma gas supply ��3-24

INDEX

EX-TRAFIRE®100SD

Operator Manual, Revision T-5 3

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 industrial isolated module with an external power supply��3-28

The circle cutting guide installation

- for the FHT-EX®105RTXH/105TTH/45TTH��3-29

SECTION 4: OPERATION �� 4-32

Front view��4-33

Front control panel ��4-33

Rear view��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: MAINTENANCE�� 5-43

Routine maintenance ��5-44

Purging/draining the built-in ﬁlter��5-45

SECTION 6: ADITIONAL ORDERING INFORMATION �� 6-46

SECTION 7: TROUBLESHOOTING �� 7-47

SECTION 8: ACCESSORIES�� 8-52

Filter-EX Compressed Air Filter with replacement ﬁlter cartridge��8-52

Filter-EX Quick Connect Couplings��8-52

CNC interface��8-53

O-Ring lubricant��8-53

EX-TRAFIRE®100SD

Operator Manual, Revision T-54

Circle cutting guide kit 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

EX-TRAFIRE®100SD

Operator Manual, Revision T-5 5

SECTION 1�

SAFETY:

SECTION 1: SAFETY ��5

!Caution! ��6

Plasma arc rays can burn eyes and skin��6

Noise can damage hearing ��6

Flying sparks (arc spray) can cause injury, ﬁre or explosion��6

Caution! Read operator’s manual��6

Cutting 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 ��8

Plasma cutting can cause interference��8

Safety Sticker ��9

SECTION 1: SAFETY

EX-TRAFIRE®100SD

Operator Manual, Revision T-56

SAFETY

The symbol shown in this section means: !Caution! !Beware!

¡There are possible hazards with this procedure!

When you ﬁnd this symbol in the manual or on the system,

be cautious, and follow the related instructions to avoid the

hazard�

Follow the safety instructions to avoid danger�

Only qualiﬁed persons should install, operate, maintain and

repair the system�

Keep out of reach of children�

Prolonged exposure to noise from plasma cutting/gouging

can cause hearing damage�

• Use approved ear protection when operating the

plasma system�

• Warn others about the dangers of noise�

NOISE CAN DAMAGE HEARING

!CAUTION!

Arc rays from the cutting/gouging processes 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 ARC RAYS CAN BURN EYES AND SKIN

Flying sparks are created during the metal cutting/gouging

processes; the area around the cutting process should be kept

free from ﬂammables�

• Use face shield/safety glasses with side protection�

• Wear ﬂame resistant clothing, footwear and hand

protection�

• Use earplugs/defenders that are ﬂame resistant to

prevent sparks entering the ear and to reduce the

noise level�

FLYING SPARKS (ARC SPRAY) CAN

CAUSE INJURY, FIRE OR EXPLOSION

1

2

CAUTION!

READOPERATOR’SMANUAL

EX-TRAFIRE®100SD

Operator manual, Revision T-5 7

Touching electrical parts could cause a fatal shock or severe

burns�

• Do not touch live electrical components�

• Wear dry insulated gloves, shoes and protective clothing�

• Insulate yourself from the work and ground using dry

insulating material large enough for the work area�

• The working area should be clean and dry�

• Switch OFF the system for cleaning and maintenance

operations�

• Do not wrap cables around your body�

• Turn OFF the machine when not in use�

ELECTRIC SHOCK CAN KILL

• Periodically check the power supply cable, to insure

that the outer insulation is intact� Replace the power

supply cable immediately if damaged� DO NOT use

the system with bare or exposed wires, this is highly

dangerous�

• Before removing the cover or handling any of the

internal components of the system, wait 5 (FIVE)

minutes to ensure complete discharge of the

capacitors�

• Keep the system in good condition; repair or replace

damaged parts immediately� Maintain the system in

accordance with the manual�

Caution! After cutting, the workpiece will be HOT!

• Do not touch hot parts bare handed, wear suitable

hand protection�

• Allow cooling time before handling�

4

HOT PARTS CAN CAUSE SEVERE BURNS

FIRE PREVENTION

• 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 combustible

surfaces�

• Do not operate the system in areas with an atmosphere

containing high concentrations of dust, ﬂammable gases

or vapors�

• Do not use the system to cut pressurized containers that

have not been de-pressurized, vented and cleaned�

CUTTING CAN CAUSE FIRE

OR EXPLOSION

Flying sparks are created during the metal cutting/gouging

processes; the area should be kept free from ﬂammables�

• Use face shield/safety glasses with side protection�

• Wear ﬂame resistant clothing, footwear and hand

protection�

• Use earplugs/defenders that are ﬂame resistant to

prevent sparks entering the ear and to reduce the

noise level�

FLYING SPARKS (ARC SPRAY) CAN

CAUSE INJURY, FIRE OR EXPLOSION

3

The plasma arc is activated immediately after the torch trigger

is depressed�

• Turn off the power before changing the torch

consumables, the plasma arc can burn through skin and

gloves�

• Do not place your hand or hold the work piece near the

cutting path�

• Do not point the torch toward yourself or other persons�

PLASMA ARC CAN INJURE

5

EX-TRAFIRE®100SD

Operator Manual, Revision T-58

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�

6

7

EX-TRAFIRE®100SD

Operator manual, Revision T-5 9

Safety Sticker

+ = +

1

2

3

4

6

2.1

3.1 3.2 3.3

4.1 4.2 4.3

5.1 5.2 5.3

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

EX-TRAFIRE®100SD

Operator Manual, Revision T-52-10

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:

SECTION 2: SPECIFICATIONS

EX-TRAFIRE®100SD

Operator Manual, Revision T-5 2-11

SPECIFICATIONS

Dimensions and weight of the plasma arc power supply

* 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)�

EX-TRAFIRE®100SD

Operator Manual, Revision T-52-12

Speciﬁcations: plasma arc power supply

Open circuit voltage (U0)300 VDC

Output characteristic*

* Curve is deﬁned as the output voltage versus output current Drooping

Input voltage (U1) 3 x 400 VAC ± 15%

Rated output current (I2) 30 - 100 A

Standard rated output voltage (U2) U1= 400VAC±15%

170 V (Extra-Boost 220 V)

X 50% 100%

U2170 170

Cutting current at 50%/100% duty cycle (A) 3 x 400 VAC±15% 100 A 80 A

Maximum input power 3 x 400 VAC±15% 24�6 kVA

Duty cycle (X*) at 40º C at rated conditions (U1, I1, U2, I2)

*X=Ton/Tbase,

Ton = time, minutes

Tbase =10 minutes

U1rms X

400 VAC±15% 50%

Operating temperature −10º – +40º C

Rated AC phases (PH) and line frequency (Hz)

Model CE

PH Hz

3 50-60

Rated input voltage (U1), rated input current (I1) and

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 ingress foreign objects ≥ 12�5 mm

3 – No harmful ingress spraying water�

S – fan stationary during water test�

*WARNING: ! DO NOT OPERATE IN RAIN !

Toppling, tilting ( with or without Wheel kit) Up to 15º incline

Gas type Air Nitrogen

Gas quality speciﬁcation

Recommended Air quality:

ISO 8573-1 Class 1�2�2�

Purity ≥ 99�99%

Air max� particle size: 0�1 microns,

class 1 ref� to ISO 8573,

Air max� oil: 0�1 mg / m3,

class 2 ref�: ISO 8573,

Air max� dewpoint: +3° C,

class 4 ref� to ISO 8573

Gas quality Clean, moisture-free, without oil

Gas input pressure and ﬂow 10 bar / 145 psi 270 l/min

EX-TRAFIRE®100SD

Operator Manual, Revision T-5 2-13

PARAMETERS EX-TRAFIRE®100SD

Supply voltage (VAC) 3 x 400±15%

Frequency (Hz) 50/60

Maximum input current 80%-100% (A) 29�6

Maximum input power (KVA) 20�7

Open circuit voltage (VDC) 300

Rated output voltage (VDC) 170 (Extra-Boost 220V)

Cutting current at 100% duty cycle (A) 80

Recommended cutting capacity (mm) 35

Maximum 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 cut�

The following diagram represents a duty cycle of 50%�

It is recomended to unfold the cable, because of bigger heat generation if it‘s longer than 8 m�

EX-TRAFIRE®100SD

Operator Manual, Revision T-52-14

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

EX-TRAFIRE®100SD

Operator 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

EX-TRAFIRE®100SD

Operator Manual, Revision T-52-16

Symbols and marking

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 (OT) Gouging Mode

(TIP/TORCH) Missing or loose

nozzle/torch spare parts

(consumables) ON Power is ON

(GAS) Low inlet gas pressure alarm OFF Power is OFF

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 for

use in environments with danger of electrocution� 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�

EX-TRAFIRE®100SD

Operator Manual, Revision T-5 3-17

SECTION 3�

INSTALLATION:

SECTION 3: INSTALLATION

Upon receipt of goods��3-18

Claims��3-18

Box contents��3-18

Power supply location ��3-19

Mains power connection ��3-19

Connecting to an engine drive power generator��3-19

Grounding ��3-19

Mains power lead ��3-19

Three-phases mains power lead��3-20

Installation of three-phases 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 industrial isolated module with an external power supply��3-28

The circle cutting guide installation - for the FHT-EX®105RTXH/105TTH/45TTH��3-29

EX-TRAFIRE®100SD

Operator Manual, Revision T-53-18

INSTALLATION

Upon receipt of goods

1� Verify that all ordered items have been received, for short shipment or damage to equipment,

contact the Authorized Supplier�

2� If there is evidence of damage, see Claims, below�

3� All communication relating to this plasma arc system should include the model and serial

number located on the bottom of the plasma arc power supply�

4� Read the information in the SAFETY section of this manual before installing and operating the

system�

Claims

Claims for shipping damage; If the unit has been damaged in transit, contact 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 control procedure� If any of the parts are found to be defective or

missing, contact Authorized Supplier with the relevant information� For further assistance contact

Customer Services, details are listed at the back of this manual�

Box contents

Check the items that are shown in the illustration below� Packaging also includes an air line

connection DN7�2ES plug with male thread G1/4”�

OPERATOR

MANUAL

EX-TRAFIRE®100SD

Operator Manual, Revision T-5 3-19

Power supply location

Place the plasma arc power supply EX-TRAFIRE®100SD on a ﬂat even surface with a minimum

distance of 0�5 m of clear space all round to ensure good ventilation�

Mains power connection

The EX-TRAFIRE®100SD plasma arc power supply requires a 400 VAC ±15% three-phases mains

power source� Use a circuit breaker for power line input so that the operator can turn off the power

supply quickly in an emergency� Locate the switch so that it is easily accessible to the operator� The

interrupt level of the switch must be equal to or exceed the continuous rating of the fuses� Use slow

blow fuses with a suitable capacity in accordance with local and national electrical codes�

Connecting to an engine drive power generator

When using an engine drive generator to power 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, lighting systems or angle grinders�

Three-phases, 50/60 Hz, 400 VAC ±15%

Engine drive rating Current output EX-TRAFIRE 100SD Performance

25 kW 100 A Full arc stretch

22�5 kW 100 A Limited arc stretch

Grounding

To reduce electromagnetic interference (EMI) and to ensure personal safety and correct operation,

the EX-TRAFIRE®100SD must be properly grounded through the mains power lead in accordance

with local and national electrical codes of practice� The three-phases service must be of the 4-wire

type with a protective green-yellow wire for protective earth ground and must comply with national

and local electrical codes of practice�

EX-TRAFIRE®100SD

Operator Manual, Revision T-53-20

Mains power lead

EX-TRAFIRE®100SD is supplied with a 3 meter length of 4 core 4 mm2ﬂexo cable without plug�

Use of a mains power lead extension is at the discretion of the user� The extension of the mains

power lead shall comply with local and national codes of practice and should be installed by a

certiﬁed electrician� See 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 mm2mm2mm2mm2mm2

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 competent person should connect the mains

power lead to the plug�

Installation of three-phases mains power lead

Strip and prepare the mains power lead as show below:

Green-Yellow

Black

Grey

Brown

UNIT CE

L1 Black (U)

L2 Brown (V)

L3 Grey (W)

Earth Green-Yellow

THERMACUT EX-TRAFIRE 100SD User manual

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