THERMACUT EX-TRAFIRE 40SD, Operator'S Manual

Page 1: ...0 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 MET...

Page 2: ...the system 8 Magnetic field can affect pacemakers 8 Plasma cutting can cause interference 8 Safety Sticker 9 SECTION 2 SPECIFICATIONS 2 11 Dimensions and weight of the plasma arc power supply 2 11 Sp...

Page 3: ...l 4 33 Torch consumables installation 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...

Page 4: ...ter EX Quick Connect Couplings 9 60 CNC interface 9 61 O Ring lubricant 9 61 Circle cutting guide kit for FHT EX 30 40H 9 61 SECTION 10 SYSTEM CIRCUIT DIAGRAM 10 62 Power supply block diagram 10 62 SE...

Page 5: ...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 hazar...

Page 6: ...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 res...

Page 7: ...ses 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 o...

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 t...

Page 9: ...ty instructions EX 0 904 003 N 21191 Machine Shield Deflector Hand Shield 1 Screw the electrode Use the electrode wrench EX 2 427 010 Do NOT overtighten electrode 2 Insert the swirl ring Must seated p...

Page 10: ...EX TRAFIRE 40SD Operator Manual Revision T 15 10 Blank page...

Page 11: ...supply 2 12 Specifications Torch FHT EX 40 2 13 Hand torch dimensions and configuration 2 14 Machine torch dimensions and configurations 2 14 Symbols and marking 2 15 SECTION 2 SPECIFICATIONS SPECIFIC...

Page 12: ...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...

Page 13: ...pe of voltage DC direct voltage Protection type of the machine side connections IP3X EN 60 529 Type of connection TCS torch connection system 13 pin Voltage rating 500V peak value Rated value of contr...

Page 14: ...l Revision T 15 2 14 Machine torch dimensions and configurations Shielded configuration using machine shield Unshielded configuration using deflector Hand torch dimensions and configuration Shielded c...

Page 15: ...k Mark This mark 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 Sy...

Page 16: ...mains power lead 3 19 The mains power lead connection 3 20 Torch installation step by step 3 20 Plasma gas supply 3 23 Additional gas filtration 3 23 Gas supply installation 3 24 Alignment of the mac...

Page 17: ...rier 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 Custome...

Page 18: ...r the EX TRAFIRE 40SD Engine drive operation 1 Set engine drive output to single phase AC 2 Plug the EX TRAFIRE 40SD mains power lead in to the power outlet 3 Hard wire connection No plug fitted shoul...

Page 19: ...wire cross section Length 100 130 VAC CE 1 phase 4 mm2 Up to 15 m 220 240 VAC CE C TICK 1 phase 2 5 mm2 Up to 40 m Note The system was tested with a 3 meter mains power lead for compliance with EMC st...

Page 20: ...etent 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 0 Turn OFF...

Page 21: ...ion torch location 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 lo...

Page 22: ...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 WARNING FHT EX 40 torches...

Page 23: ...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...

Page 24: ...h perpendicular to the material to be cut use a square to align the torch at 0 and 90 if torch alignment is not possible check the cutting table for level to obtain a true vertical cut 1 Air line hose...

Page 25: ...round Voltage divider 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 ca...

Page 26: ...rator Manual Revision T 15 3 26 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...

Page 27: ...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 inte...

Page 28: ...h 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 Work piece...

Page 29: ...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 wrenc...

Page 30: ...TRAFIRE 40SD Operator Manual Revision T 15 3 30 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 p...

Page 31: ...allation 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 techni...

Page 32: ...nob 3 Over Current OC Over Temperature OT alarm indicator 4 Multifunctional indicator TIP LED blinks when the consumables are loose improperly installed or missing this indication can be accompanied w...

Page 33: ...120 230V 7BAR MAX 101PSI MAX CNC INTERFACE ON OFF AIR 120 230V 7BAR MAX 101PSI MAX AIR 10BAR MAX 145PSI MAX Rear control panel detail Rear view Rear control panel 1 Power supply switch 2 Mains power l...

Page 34: ...hed off before changing consumables 1 Screw the electrode Use the electrode wrench EX 2 427 010 Do NOT overtighten electrode 4 Fit the nozzle on to the swirl ring 5 Screw on the nozzle retaining cap a...

Page 35: ...perator Manual Revision T 15 4 35 Turn ON Check the LED indicators Check that LED1 V is illuminated and LED2 LED3 and LED4 are not illuminated before cutting Switch ON I Note The cooling fan will only...

Page 36: ...sma 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 yo...

Page 37: ...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 el...

Page 38: ...ght contact between the shield and the work piece pull the torch at a steady travel speed Pulling the torch gives better control compared to pushing For cutting thin material reduce the amperage to th...

Page 39: ...that 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 work piece before firing Hold the torch at an angle to the work piece depres...

Page 40: ...X TRAFIRE 40SD Operator Manual Revision T 15 4 40 Mechanized Cutting Charts 30 A Mild steel Mechanized Cutting Shielded Configuration 4 41 40 A Mild steel Mechanized Cutting Shielded Configuration 4 4...

Page 41: ...ults of intensive laboratory testing Actual cutting speeds may vary based on different cutting applications Cut charts are a guide for mechanized cutting individual systems can be fine tuned to achiev...

Page 42: ...e the results of intensive laboratory testing Actual cutting speeds may vary based on different cutting applications Cut charts are a guide for mechanized cutting individual systems can be fine tuned...

Page 43: ...EX TRAFIRE 40SD Operator Manual Revision T 15 5 43 SECTION 5 MAINTENANCE Routine maintenance 5 44 Consumable parts inspection 5 45 Purging draining of the built in filter 5 46...

Page 44: ...rigger safety mechanism check for signs of cracking in the torch body or exposed wires Immediately replace the mains power lead plug if damaged Immediately replace the torch lead if damaged Check air...

Page 45: ...lace nozzle Retaining Cap Nozzle Out of round orifice indicates worn condition Replace nozzle Good orifice Worn orifice Swirl Ring Damage or contamination of external surface Replace swirl ring Intern...

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 pic...

Page 47: ...RTS FHT EX 40H Hand Torch Assembly 6 48 FHT EX 40H Hand Torch Components 6 49 FHT EX 40H Hand Torch Consumables 6 50 FHT EX 40M Machine Torch Assembly 6 51 FHT EX 40M Machine Torch Components 6 52 FHT...

Page 48: ...h Assembly TCS13 1 EX 2 130 001 FHT EX 40H Hand Torch Assembly w o consumables w 4m Lead TCS13 1 EX 2 101 003 FHT EX 40H Hand Torch Assembly w o consumables w 5m Lead TCS13 1 EX 2 131 005 FHT EX 40H H...

Page 49: ...5 010 Retaining Ring Outer circlip ring 7 EX 0 325 009 O Ring fitted in the TCS plug 8 EX 0 325 005 Male Crimp Pin for TCS Plug 9 EX 0 319 021 Insulating Teflon Tube 10 EX 2 304 020 Hand Torch PIP Pin...

Page 50: ...Electrode 2 EX 2 404 002 Swirl Ring 3 EX 2 409 003 Nozzle 30A 0 8mm 4 EX 2 409 001 Nozzle 40A 0 9mm 5 EX 2 415 004 Nozzle Retaining Cap Protection Cap 6 EX 5 419 005 Hand contact Shield 30A 7 EX 2 419...

Page 51: ...3 1 EX 2 235 001 FHT EX 40M Machine Torch Assembly w o consumables w 4m Lead TCS13 1 EX 2 202 003 FHT EX 40M Machine Torch Assembly w o consumables w 5m Lead TCS13 1 EX 2 236 005 FHT EX 40M Machine To...

Page 52: ...ne Torch Lead Replacement Kit 7 5m Lead TCS13 2 EX 2 357 008 Machine Torch Lead Replacement Kit 15m Lead TCS13 3 EX 5 318 001 TCS Plug Spring Stain Relief 4 EX 0 325 015 TCS Clam Shell Screw 5 EX 0 32...

Page 53: ...2 401 001 Electrode 2 EX 2 404 002 Swirl Ring 3 EX 2 409 003 Nozzle 30A 0 8mm 4 EX 2 409 001 Nozzle 40A 0 9mm 5 EX 2 415 004 Nozzle Retaining Cap Protection Cap 6 EX 2 421 006 Machine Shield 30A 7 EX...

Page 54: ...Torch Consumables Machine Torch Consumables Configuration 30 40A Item Part No DESCRIPTION 1 EX 2 401 001 Electrode 2 EX 2 404 002 Swirl Ring 3 EX 2 409 003 Nozzle 30A 0 8mm 4 EX 2 409 001 Nozzle 40A...

Page 55: ...m EX TRAFIRE 40SD Mechanized Plasma Cutting Systems Part No DESCRIPTION Length EX 2 011 001 EX TRAFIRE 40SD CE 1x100 240V Machine System FHT EX40M 4m M Starter Kit 4 m EX 2 011 002 EX TRAFIRE 40SD CE...

Page 56: ...is 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 no...

Page 57: ...stall the consumables and fit the retaining cap The retaining cap is not installed or tightened correctly Fit the retaining cap and correctly tighten Non original consumables Use original new consumab...

Page 58: ...rkpiece Work clamp connection fault Fluctuating connection between the clamp and work piece Clean the surface of the clamp and material No connection to work piece Incorrect distance between the torch...

Page 59: ...ection between the clamp and work piece Ensure that the work lead has a good connection to a clean and dry area of work piece Cut quality issues Incorrect current setting Poor quality Adjust the curre...

Page 60: ...all 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...

Page 61: ...Interface connection lead 6 m O Ring lubricant EX 0 805 001 Grease 25ml Circle cutting guide kit for FHT EX 30 40H EX 2 801 001 This Circle cutting guide kit for hand held cutting obtains Circle cutt...

Page 62: ...62 50 60HZ DC DC AC DC Rectifier Filter Inverter Transformer Rectifier Hall MCU DRIVE Initialization SG3525 Calculation Comparison Panel Logic test 85 265VAC AC L4981 DRIVE PFC Hall SECTION 10 POWER...

Page 63: ...ormation 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 y...

Page 64: ...e 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 o...

Page 65: ...EX TRAFIRE 40SD Operator Manual Revision T 15 12 65 Notes...

Page 66: ...EX TRAFIRE 40SD Operator Manual Revision T 15 12 66 Notes...

Page 67: ...EX TRAFIRE 40SD Operator Manual Revision T 15 12 67 Notes...

Page 68: ...EX TRAFIRE 40SD Operator Manual Revision T 15 12 68 Notes...

Page 69: ...7 2018 09 2018 a Page 6 45 FHT EX 40H Hand Torches Assembly new graphics and table b Page 6 46 New Part No of item 19 from EX 0 325 006 to EX 0 321 003 New item No 20 EX 0 323 001 TCS13 Plug Body c Pa...

Page 70: ...EX TRAFIRE 40SD Operator Manual Revision T 15 12 70 Revision history...

Page 71: ...hr THERMACUT HUNG RIA KFT Pet fi S ndor 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 tef nika 14 942...

Page 72: ...ovsk 574 Ma atice 686 01 Uhersk Hradi t 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 Rep...