THERMACUT EX-TRAFIRE 45HD User manual

Plasma Cutting System
Operating Instructions – EX-2-902-002/N21603 – CE
Revision 2, 24th February, 2023

EN - 2
EX-TRAFIRE®45HD
Table of contents
1 Identification ............................................................... EN-4
1.1 Marking.............................................................................................. EN-4
1.2 Identification plate ........................................................................... EN-4
1.3 Signs and symbols used.................................................................. EN-4
1.4 Classification of the warnings......................................................... EN-5
2 Safety........................................................................... EN-5
2.1 Designated use................................................................................. EN-5
2.2 Obligations of the operator............................................................ EN-6
2.3 Warning and notice signs................................................................ EN-6
2.4 Product-specific safety instructions................................................ EN-6
2.5 Safety instructions for the electrical power supply ...................... EN-7
2.6 Safety instructions for plasma cutting............................................ EN-7
2.7 Personal protective equipment ...................................................... EN-7
2.8 Emergency information................................................................... EN-7
3 Scope of delivery......................................................... EN-8
4 Product description ..................................................... EN-9
4.1 Assembly and use ............................................................................ EN-9
4.2 Technical data................................................................................. EN-11
4.2.1 EX-TRAFIRE®45HD, Single-phase................................................. EN-11
4.2.2 EX-TRAFIRE®45HD, Three-phase.................................................. EN-12
4.3 Technical data for cutting torches FHT-EX®45TTH
and FHT-EX®45TTM ....................................................................... EN-13
5 Transport and positioning .........................................EN-15
6 Setting up the power supply .....................................EN-16
6.1 Connecting to the gas supply....................................................... EN-16
6.2 Connecting the work lead............................................................. EN-16
6.3 Connecting the power supply cable ........................................... EN-17
6.3.1 Connecting the single-phase machine........................................ EN-17
6.3.2 Connecting the three-phase machine......................................... EN-17
6.4 Connecting the input power plug................................................ EN-18
6.4.1 Connection to a generator (optional).......................................... EN-19
6.5 Connecting the cutting torch........................................................ EN-19
6.6 Connecting the CNC interface ..................................................... EN-20
6.6.1 Setting the DIP switches ................................................................ EN-21
6.6.2 Enabling the external DC coil with an external power supply . EN-21
6.6.3 Enabling the external AC coil with an external power supply.. EN-22
6.6.4 Enabling the industrially insulated module with an
external power supply................................................................... EN-22
6.7 Installing consumables for the hand and machine
cutting torches................................................................................ EN-23
6.8 Aligning FHT-EX®45TTM machine cutting torch ........................ EN-25
7 Operation of the power supply.................................EN-25
7.1 LCD description.............................................................................. EN-26
7.1.1 Setting the parameters.................................................................. EN-27
7.1.2 Selecting the cutting mode........................................................... EN-28
7.1.3 Connecting the work lead with the work lead clamp................ EN-28
7.2 Powering on the machine ............................................................. EN-29
7.3 Manual cutting process ................................................................. EN-29

EX-TRAFIRE®45HD
EN - 3
7.4 Manual grid cutting, gouging, marking process........................ EN-29
7.5 Cutting............................................................................................. EN-30
7.6 Piercing............................................................................................ EN-31
7.7 Gouging .......................................................................................... EN-31
7.7.1 Table for FHT-EX®45TT material removal ...................................EN-32
7.8 Stopping the cutting process .......................................................EN-33
8 Disconnecting the unit.............................................. EN-33
9 Maintenance and cleaning........................................ EN-34
9.1 Maintenance and cleaning intervals ............................................ EN-35
10 Faults and troubleshooting....................................... EN-36
11 Disassembly.............................................................. EN-40
12 Disposal .................................................................... EN-41
12.1 Disposal of materials...................................................................... EN-41
12.2 Disposal of consumables .............................................................. EN-41
12.3 Packaging........................................................................................ EN-41
13 Warranty ................................................................... EN-42
14 Block diagram........................................................... EN-43
15 Accessories ............................................................... EN-44
16 FHT-EX®45TTH hand cutting torch unit..................... EN-45
16.1 FHT-EX® 45TTH hand cutting torch unit components............... EN-45
16.2 FHT-EX®45TTH consumables for hand cutting torch................. EN-47
17 FHT-EX®45TTM machine cutting torch unit............... EN-48
17.1 FHT-EX®45TTM machine cutting torch components................. EN-48
17.2 FHT-EX®45TTM consumables for standard
machine cutting torch.................................................................... EN-50
17.3 FHT-EX®45TTM consumables for marking
machine cutting torch.................................................................... EN-51
18 Ordering information on bulk packs and starter kits EN-52
18.1 EX-TRAFIRE®45HD plasma power supply ...................................EN-52
18.2 EX-TRAFIRE®45HD manual plasma cutting systems .................. EN-52
18.3 EX-TRAFIRE®45HD mechanized plasma cutting systems.......... EN-53
18.4 Bulk packs for FHT-EX®45TTH and FHT-EX®45TTM................... EN-54
19 Cutting tables for mechanical cutting....................... EN-55
19.1 30 A cutting, shielded, with compressed air..............................EN-56
19.2 45 A cutting, shielded, with compressed air............................... EN-57
19.3 Tables for marking.......................................................................... EN-58
19.3.1Marking, shielded, with compressed air or Argon..................... EN-58

EN - 4
1 Identification EX-TRAFIRE®45HD
1 Identification
The EX-TRAFIRE®45HD is a portable cutting power supply for mechanized
and manual plasma cutting, gouging, and marking. The EX-TRAFIRE®45HD
uses gas, argon or nitrogen to cut almost all conductive metals. The device
may be operated only with original Thermacut®parts. This documentation
describes the EX-TRAFIRE®45HD cutting power supply only.
When used in this documentation, the term “device” always refers to the
EX-TRAFIRE®45HD 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®45HD 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

EX-TRAFIRE®45HD 2Safety
EN - 5
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 residual 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 in the 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.

EN - 6
2Safety EX-TRAFIRE®45HD
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.

EX-TRAFIRE®45HD 2Safety
EN - 7
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
—Gassupply

EN - 8
3 Scope of delivery EX-TRAFIRE®45HD
3 Scope of delivery
The following components are included in the scope of supply:
—1× EX-TRAFIRE®45HD cutting power supply
—1× FHT-EX®45TTH or FHT-EX®45TTM cutting torch
— 1× work lead incl. work lead clamp
— 1× operating instructions
— 1× “Safety Instructions” document
—1דWarranty”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.

EX-TRAFIRE®45HD 4 Product description
EN - 9
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, rear panel
AOn/Off switch
BOptional CNC interface
CG1/4" gas connection, plug
DOptional BUS interface
EInput power cable
Fig. 3 Control elements and connections, front panel
FWork lead connection
GTorch connection system (TCS)
HMulti-function button
IDisplay
A B
C
DE
Single-phase
CE
A
DB
Three-phase
F
G
H
I

EN - 10
4 Product description EX-TRAFIRE®45HD
ON/OFF switch (A) Used to switch the device on and off.
CNC interface
connection (B)
This optional interface is used to connect the
device to an optional CNC cutting table or
robot.
Gas connection (C) This interface is used to connect a
compressed air supply.
BUS interface (D) This optional interface is used to connect the
optional CAN BUS or RS485/422 BUS.
Multi-function button (H) For toggling between two menus and
setting the cutting parameters.
Digital display (I) Displays the device status. A fault code is
displayed if an error occurs.

EX-TRAFIRE®45HD 4 Product description
EN - 11
4.2 Technical data
4.2.1 EX-TRAFIRE®45HD, Single-phase
Table 1 Power supply specifications, single-phase
CE
Idle voltage (U0)292 V DC
Characteristic curve*
* The curve is defined as output voltage
versus output current
Drooping
Output current (I2)10 – 45 A
Nominal voltage (U2)145 V DC
Output current at 100% duty cycle (I2)16 A
Maximum power input 7.5 kVA
Duty cycle (X*) at 40°C under nominal
conditions (U1, I1, U2, I2)
*X = ton/tbase
ton = time, minutes
tbase =10 minutes
U1rms
40%
Ambient temperature -10° to +40°C
Input voltage (U1) 240 V AC ± 15%
Rated input current (I1rms) and effective
input current (I1eff) at rated output
voltage (U2) and rated output current
(I2) - only for cutting mode.
eff= effective
rms= root mean square
I1rms I1eff
16.5 A 14.8 A
Complies with standards IEC
60974-1,
IEC 60974-10
Insulation class F
Protection type IP23S
Tilt angle (with or without wheels) Up to15°
Dimensions(L×H×W)[mm]469.9 x 228.6 x 177.0
Weight (kg) 12.7

EN - 12
4 Product description EX-TRAFIRE®45HD
4.2.2 EX-TRAFIRE®45HD, Three-phase
Table 2 Power supply specifications, Three-phase
CE
Idle voltage (U0)308 V DC
Characteristic curve*
* The curve is defined as output voltage
versus output current
Drooping
Output current (I2)10 – 45 A
Nominal voltage (U2)145 V DC
Output current at 100% duty cycle (I2)45 A
Maximum power input 11.4 kVA
Duty cycle (X*) at 40°C under nominal
conditions (U1, I1, U2, I2)
*X = ton/tbase
ton = time, minutes
tbase =10 minutes
U1rms
80%
Ambient temperature -10° to +40° C
Input voltage (U1) 400 V AC ± 15%
3 PH/50 – 60 Hz
Rated input current (I1rms) and effective
input current (I1eff) at rated output
voltage (U2) and rated output current
(I2) - only for cutting mode.
eff= effective
rms= root mean square
I1rms I1eff
16.2 A 14.4 A
Complies with standards IEC
60974-1,
IEC 60974-10
Insulation class F
Protection type IP23S
Tilt angle (with or without wheels) Up to15°
Dimensions(L×H×W)[mm]469.9 x 228.6 x 177.0
Weight (kg) 12.7
Table 3 Ambient conditions for transport and storage
Ambient temperature -20 °C to +55 °C
Relative humidity <50%at+40C°
<90%at+20°C
Table 4 Ambient conditions for operation
Ambient temperature -10 °C to +40 °C
Relative humidity <50%at+40°C
<90%at+20°C
Installation above sea level max. 2000 m
Tilt angle Up to15°

EX-TRAFIRE®45HD 4 Product description
EN - 13
4.3 Technical data for cutting torches FHT-EX®45TTH
and FHT-EX®45TTM
FHT-EX®cutting torches are used for manual and mechanical cutting,
gouging, and marking. They use compressed air or nitrogen to cut mild
steels, stainless steels, aluminum, and other electrically conductive metals.
They are connected to the cutting power supply using the Torch
Connection System (TCS).
The values below refer to the torches!
Table 5 Gas data
Permissible gas Compressed air/nitrogen/argon
Max. gas inlet pressure 10 bar
Recommended compressed air
quality
ISO 8573-1 Class 1.2.2.
Purity: > 99,99%
clean, and free from moisture and
oil
Max. flow rate 120 l/min at 10 bar
Table 6 Technical data for FHT-EX®45TTH and FHT-EX®45TTM cutting
torches
FHT-EX®45TTH / FHT-EX®45TTM
Recommended cutting
capacity [mm]
12
Max. cutting capacity
[mm]
25
Piercing capacity [mm]10
Permissible ambient
temperature during
operation
-10° C to +40° C
Permissible ambient
temperature during
transport and storage
-25° C to +55° C
Relative humidity <90%at+20°C
Sub-menu item Plasma cutting, gouging, marking
Application type Manual and mechanical
Rated current and duty
cycle
45 A/100%
Permissible gas Compressed air/nitrogen
Flow rate 90 l/min. at 4.8 bar
Maximum pressure 10 bar
(Dynamic) operating
pressure
4.8 bar
Gas post-flow period
delay
>20 sec.
Type of voltage DC
Voltage rating 500 V peak value
Protection type for
device
IP3X (EN 60529)

EN - 14
4 Product description EX-TRAFIRE®45HD
Connection type TCS (Torch Connection System) - 13 Pin
Standard lengths
(other lengths available
upon request)
5m/8m/15m
Table 7 Cutting torch weights and cable lengths
Cutting torch Weight and cable lengths
FHT-EX®45TTH
Standard hand cutting torch
5m/1.5kg
8m/2.2kg
15 m/3.6 kg
FHT-EX®45TTM
Standard machine cutting torch
5m/1.5kg
8m/2.2kg
15 m / 3.6 kg
Table 6 Technical data for FHT-EX®45TTH and FHT-EX®45TTM cutting
torches
FHT-EX®45TTH / FHT-EX®45TTM

EX-TRAFIRE®45HD 5 Transport and positioning
EN - 15
5 Transport and positioning
WARNING
Risk of injury due to improper transport and installation
Improper transport and installation can cause the device to tip or fall
over. This may result in serious injury.
• Wear your personal protective equipment.
• Ensure that all supply lines and cables do not encroach into the area in
which employees are working.
• Place the device on a suitable surface (flat, solid, and dry) on which it
will not topple over, taking into account the max. tilt angle of 15°.
• Note the weight of the device when lifting it.
4.2 Technical data on page EN-11
• Use an appropriate lifting tool with load handling equipment for
transporting and installing the device.
• Avoid abrupt lifting and setting down.
• Do not lift the device over individuals or other devices.
• Use the attachment points provided.
NOTICE
Risk of material damage due to improper transport and installation
Improper transport or installation can cause the device to tip or fall over.
This can result in material damage and irreparable damage to the
device.
• Protect the device against weather conditions, such as rain and direct
sunlight.
• Protect the device from spatter when cutting.
• Protect the device from direct exposure to sparks when grinding.
• Use the device only in dry, clean, and well-ventilated rooms.
• Maintain a minimum distance of 0.5 m from the wall when positioning
the device to ensure that it has sufficient ventilation.
When positioning the device, make
sure that the water separator's drain
opening is not covered.

EN - 16
6 Setting up the power supply EX-TRAFIRE®45HD
6 Setting up the power supply
6.1 Connecting to the gas supply
6.2 Connecting the work lead
Connect the gas hose with an inside
diameter of at least 6 mm to the gas
connection of the device.
Single-phase
Three-phase
Connect the work lead to the work
lead connecting socket and secure it
by rotating clockwise.

EX-TRAFIRE®45HD 6 Setting up the power supply
EN - 17
6.3 Connecting the power supply cable
6.3.1 Connecting the single-phase machine
6.3.2 Connecting the three-phase machine
The power supply should be
connected by a qualified electrician.
L -> black (brown)
N -> blue
PE grounding -> green-yellow
Black(brown)
Green-yellow
Blue
Single -phase
The power supply should be
connected by a qualified electrician.
L1 -> black (U)
L2 -> brown (V)
L3 -> gray (W)
PE grounding -> green-yellow
Table 8 Recommended cable extensions
Input voltage Wire cross-sections Length
200 – 240 V AC/1 Phase
6mm
2Up to15 m
16 mm215 – 30 m
25 mm230 – 45 m
380 – 480 V AC/3 Phase 4mm
2Up to15 m
6mm
215 - 45 m
Black
Green-yellow
Gray
Brown
Three-phase

EN - 18
6 Setting up the power supply EX-TRAFIRE®45HD
6.4 Connecting the input power plug
Note the safety instructions.
2.5 Safety instructions for the electrical power supply on page EN-7
For the input voltage and the fuse protection, please refer to:
4.2 Technical data on page EN-11
If necessary, have a qualified electrician connect the input power cable
extension in accordance with local regulations.
Ensure that the power supply is adequately protected by a safety switch.
Insert the input power plug of the input power cable into the
corresponding socket.
WARNING
Electric shock due to improperly installed electrical power supply
If the electrical power supply and grounding are improperly installed,
fatal electric shock may occur.
• If you want to operate the device in a very humid environment or on
conductive material, install a ground fault circuit interrupter (GFCI) in
the power supply.
• Use a slow-blow GFCI fuse.
• Protect the power supply line to the device with suitable fuses that
comply with regulations.
• Ground the device according to the applicable regulations.
• Do not ground the device together with other devices or machines.
WARNING
Risk of electric shock due to improperly installed or defective cables
Damaged or improperly installed cables can lead to fatal electric shock.
• Check all live cables and connections for proper installation and
damage.
• Damaged, deformed or worn parts should only be replaced by a
qualified electrician.
WARNING
Risk of injury due to fire
Improper use or connection can result in fire. This may result in serious
injury.
Ensure that the operating voltage specified on the identification plate
is suitable for the input voltage.

EX-TRAFIRE®45HD 6 Setting up the power supply
EN - 19
6.4.1 Connection to a generator (optional)
Set the generator to single-phase or three-phase alternating current.
Plug the input power plug into the socket.
Set the motor rating as shown in the following table.
6.5 Connecting the cutting torch
Switch off the power supply.
Table 9 Connection to a generator
Generator motor rating Output current (I2)Arcvoltage
6kW 25 A U2= 200 V C
10 kW 45 A
10 kW 45 A
NOTICE
Risk of material damage if used without TCS Latch with Key
Assembly
The TCS Latch with Key Assembly is important for the proper working of
the machine. If used without, the connector pins may be damaged.
• Do not use the device without the TCS Latch with Key assembly
installed and properly secured.
1Insert the TCS Latch with Key
Assembly into the TCS socket.
The TCS Latch with Key Assembly
must sit firmly in the TCS socket.
2Push the cutting torch into the TCS
and ensure the Latch with Key
Assembly locks in place.

EN - 20
6 Setting up the power supply EX-TRAFIRE®45HD
6.6 Connecting the CNC interface
The CNC interface is on the rear of the device. Control signals can be
transmitted via the CNC interface. The signal types can be found in
table 10. The control elements are located on the control panel. The
connections are on the front and rear of the device.
4.1 Assembly and use on page EN-9
WARNING
Electric shock due to live parts
Live parts are exposed when the housing is open. This can result in fatal
electric shock.
• Set the <POWER> switch to <OFF> and disconnect the input power
plug before opening the housing.
Fig. 4 Pin assignment for CNC interface
Table 10 Pin assignment
Signal START
Start plasma
cutting
Arc
Start feeding
PE Voltage divider
Type Input Output PE Output
Notice Open by
default.
Requires
potential-free
contact to
close.
Open by
default.
Potential-free
with max.
capacity of:
120 V AC/1 A
Reduced arc
signal:
20:1
21.1:1
30:1
40:1
50:1
(supplies max.
10 V)
PIN 3, 4 12, 14 13 6 (+), 5 (-)
Internal
cable color
Yellow, yellow White, white Green/
yellow
6 (red), 5 (white)
4
12
6
14
35
13