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THERMACUT EX-TRAFIRE 100SD - User Manual

THERMACUT EX-TRAFIRE 100SD
60 pages
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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!

Table of Contents

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Summary

SECTION 1: SAFETY

General Safety Warnings

Key warnings including caution, reading manual, and immediate hazards.

Arc Ray and Noise Hazards

Risks from plasma arc rays and loud noise, with protective measures.

Flying Sparks and Explosion Risks

Hazards from flying sparks and potential for fire or explosion.

Cutting Fire and Electric Shock Risks

Hazards from cutting operations causing fire and electric shock dangers.

Arc Injury and Thermal Burns

Risks of plasma arc injury and severe burns from hot parts.

Smoke, Gases, and Cylinder Safety

Hazards from smoke, gases, and precautions around gas cylinders.

System Protection and Interference

Avoiding overheating, pacemaker interference, and electromagnetic interference.

Safety Sticker Overview

Explanation of the safety sticker and its visual instructions.

SECTION 2: SPECIFICATIONS

Dimensions and Weight

Physical dimensions and weight of the plasma arc power supply unit.

Detailed Specifications

Technical data including voltage, current, duty cycle, and IP code.

Duty Cycle Explanation

Definition and illustration of the duty cycle for plasma cutting operations.

Hand Torch Setup Guide

Diagram and instructions for setting up the hand torch.

Machine Torch Setup Guide

Diagram and instructions for setting up the machine torch.

Symbols and Markings Explained

Explanation of safety marks, certifications, and IEC symbols used on the equipment.

SECTION 3: INSTALLATION

Initial Setup and Verification

Procedures for verifying received goods, handling damages, and reporting claims.

Power Supply Installation and Grounding

Guidelines for placing the unit, connecting mains power, and proper electrical grounding.

Mains Power Lead Setup

Details on the supplied mains power lead and three-phase installation.

Power and Torch Connection

Connecting the mains power lead and the step-by-step torch installation.

Torch Connection Procedure

Detailed steps for connecting the torch TCS plug and latch mechanism.

Torch Connection Finalization

Completing the torch connection and ensuring proper seating of the TCS plug.

Gas Supply and Filtration

Specifications for compressed air supply, quality, and optional filtration.

Gas Supply Installation and Pressure Setting

Connecting the gas supply hose and setting the correct gas pressure.

System CNC Interface Connection

Connecting the system to CNC equipment via the interface connector.

External Coil Connections

Wiring diagrams for activating external DC and AC coils with power supplies.

Industrial Isolated Module Connection

Wiring diagram for connecting an industrial isolated module to the system.

Circle Cutting Guide Installation

Steps for installing the circle cutting guide onto the torch.

Circle Cutting Guide Operation

How to use the cutting guide with or without a radius bar for circular cuts.

Radius Bar Anchoring

Fasteners for anchoring the radius bar to the center of a circle.

SECTION 4: OPERATION

Front View and Control Panel

Identification of front panel components, display, and status indicators.

Rear View and Control Panel Details

Identification of rear panel connectors and switches for system access.

Powering On and LED Indicators

Procedures for turning on the unit and checking system status LEDs.

Hand Torch Operation and Safety

Guidelines for operating the hand torch, including safety trigger functionality.

Work Clamp Fitting and Edge Start Cutting

Proper fitting of the work clamp and techniques for edge start cutting.

Hand Torch Cutting Techniques

Best practices for manual cutting, including arc spray direction and consumables.

Piercing Operation

Technique for piercing metal with the plasma torch for initial cuts.

Gouging Operation and Parameters

How to perform gouging and recommended operating parameters for material removal.

Gouge Profile Modification

Adjusting parameters to modify the gouge profile, width, and depth.

Machine Torch Operation and Alignment

Operating the machine torch and ensuring proper alignment for automated cutting.

SECTION 5: MAINTENANCE

Routine Maintenance Schedule

Recommended maintenance tasks based on usage frequency (every usage, week, 3 months).

Built-in Filter Purging and Draining

Procedure for draining the built-in float type auto drain filter for air quality.

SECTION 6: ADDITIONAL ORDERING INFORMATION

SECTION 7: TROUBLESHOOTING

LED Fault Indicators

Troubleshooting based on LED status (LED3, LED2) and related faults.

Connection and Output Faults

Issues with pilot arc transfer, output stability, voltage, and control problems.

Cut Quality Issues

Diagnosing and resolving problems related to cut quality, current settings, and technique.

Error Code Reference

List and explanation of error codes (H01-H14) displayed by the system for fault identification.

SECTION 8: ACCESSORIES

Filter-EX Air Filter and Couplings

Details on Filter-EX compressed air filters, cartridges, and quick connect couplings.

CNC Interface and O-Ring Lubricant

Information on CNC interface kits and O-ring lubricant for maintenance.

Circle Cutting Guide Kit Details

Components included in the circle cutting guide kit for handheld cutting operations.

SECTION 9: POWER SUPPLY BLOCK DIAGRAM

SECTION 10: END OF LIFETIME PRODUCT DISPOSAL

Product Disposal and RoHS Statement

Guidelines for waste disposal, product recycling, and RoHS compliance.

SECTION 11: WARRANTY

Warranty Terms and Coverage

Details on warranty duration, claims process, and covered parts of the equipment.

ADDRESSES AND CONTACTS

Thermacut Headquarters and Sales

Contact information for the main production and sales departments of Thermacut.

Thermacut International Subsidiaries

Contact details for Thermacut's subsidiaries located in various countries.

Distributor and Trademark Information

Space for distributor details and acknowledgment of registered trademarks.

THERMACUT EX-TRAFIRE 100SD Specifications

General IconGeneral
BrandTHERMACUT
ModelEX-TRAFIRE 100SD
CategoryCutter
LanguageEnglish