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THERMACUT EX-TRAFIRE 55SD User Manual

THERMACUT EX-TRAFIRE 55SD
56 pages
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THERMACUT
®
EX-TRAFIRE
®
55SD
PLASMA CUTTING POWER SUPPLY
Operator Manual
Revision: T-3
English
2020
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-3-907-001
N-22160

Table of Contents

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THERMACUT EX-TRAFIRE 55SD Specifications

General IconGeneral
BrandTHERMACUT
ModelEX-TRAFIRE 55SD
CategoryWelding System
LanguageEnglish

Summary

SECTION 1: SAFETY

Safety Warnings and Precautions

!Caution!

Warning about potential hazards with procedures.

Caution! Read Operator's Manual

Instruction to follow safety instructions and only qualified persons should operate.

Plasma Arc Rays Can Burn Eyes and Skin

Hazards from arc rays and protective measures.

Noise Can Damage Hearing

Risks of prolonged exposure to noise from plasma cutting.

Flying Sparks (Arc Spray) Can Cause Injury, Fire or Explosion

Hazards from flying sparks and precautions.

Further Safety Precautions

Cutting Can Cause Fire or Explosion

Precautions against fire and explosion during cutting.

Electric Shock Can Kill

Dangers of electric shock and safety measures.

Plasma Arc Can Injure

Risks of injury from plasma arc and protective actions.

Hot Parts Can Cause Severe Burns

Warning about hot parts and necessary precautions.

Additional Safety Considerations

Smoke and Gases Can Be Hazardous

Health risks associated with fumes and smoke during operation.

Caution When Cutting Around Gas Cylinders

Safety measures for cutting near gas cylinders.

Do Not Exceed the Recommended Duty Cycle

Warning about exceeding duty cycle leading to overheating and damage.

Magnetic Field Can Affect Pacemakers

Precautions for individuals with pacemakers due to magnetic fields.

Plasma Cutting Can Cause Interference

Potential interference of plasma cutting with electronic equipment.

Safety Sticker Information

SECTION 2: SPECIFICATIONS

Dimensions and Weight of the Plasma Arc Power Supply

Specifications for 3 x 220 V Power Supply

Specifications for 3 x 400 V Power Supply

Product Parameters Summary

Hand Torch Setup

Machine Torch Setup

Symbols and Marking

SECTION 3: INSTALLATION

Installation - Initial Steps

Upon Receipt of Goods

Verification of received items and initial checks.

Claims

Procedures for reporting shipping damage or defective/missing goods.

Box Contents

List and illustration of items included in the package.

Installation - Power and Grounding

Power Supply Location

Guidelines for placing the plasma arc power supply for optimal ventilation.

Mains Power Connection

Requirements and safety for connecting the power supply to the mains.

Connecting to Engine Drive Generator

Instructions for powering the unit using an engine drive generator.

Grounding

Importance and procedure for proper grounding of the system.

Mains Power Lead Installation

Mains Power Lead

Information on supplied and extended mains power leads.

Three-Phases Mains Power Lead

Guidelines for using and connecting three-phase mains power leads.

Installation of Three-Phases Mains Power Lead

Step-by-step instructions for preparing and connecting the three-phase mains power lead.

Power Lead and Torch Connection

Mains Power Lead Connection

Instructions for a certified electrician to connect the mains power lead.

Torch Installation Step by Step

Sequential steps for connecting the torch to the power supply.

Torch Connection - TCS Plug

TCS Plug Latch with Key Position

Details on the position of the TCS plug latch with key.

Connecting TCS Latch to Socket

First step for connecting the TCS latch with key to the power supply socket.

Torch Connection - Finalizing Plug Insertion

Inserting TCS Plug into Socket

Second step for inserting the TCS plug into the socket.

Proper TCS Plug Position

Ensuring correct positioning of the TCS plug in the socket.

Gas Supply and Filtration

Plasma Gas Supply Requirements

Specifies the compressed air supply requirements for the plasma system.

Additional Gas Filtration

Explains when and how to use additional gas filtration systems.

Gas Supply Installation

System CNC Interface Connection

External Power Supply Activation

Activating External DC Coil

Wiring diagram for activating an external DC coil.

Activating External AC Coil

Wiring diagram for activating an external AC coil.

Activating Industrial Isolated Module

SECTION 4: OPERATION

Operation - Front View and Controls

Front View of the Unit

Overview of the plasma cutting unit's front panel layout.

Front Control Panel Explained

Detailed explanation of each control and indicator on the front panel.

Operation - Rear View and Controls

Rear View of the Unit

Overview of the plasma cutting unit's rear panel layout.

Rear Control Panel Details

Detailed explanation of controls and connectors on the rear panel.

Operation - Powering Up and Checks

Turning the Unit ON

Instructions for switching the plasma power supply on.

Checking LED Indicators

Verifying the status of LED indicators before cutting.

Hand Torch Operation

Operating the Hand Torch

General guidelines for using the hand torch.

Operating the Torch Safety Trigger

Step-by-step guide on using the torch safety trigger for ignition.

Cutting Techniques - Work Clamp and Edge Start

Fitting the Work Clamp

Proper procedure for attaching the work clamp to the workpiece.

Edge Start Cutting

Method for initiating a cut from the edge of the workpiece.

Hand Torch Cutting Techniques

General Cutting Technique

Advice on avoiding unnecessary firing and maintaining torch angle.

Shielded Consumables Usage

Guidelines for using shielded consumables and pull technique.

Gas Post Flow Explanation

Information on the gas post-flow period and its purpose.

Cutting Technique - Piercing

Machine Torch Operation and Alignment

Operating the Machine Torch

General instructions for operating the machine torch.

Alignment of the Machine Torch

Steps to ensure the machine torch is properly aligned for vertical cuts.

SECTION 5: MAINTENANCE

Routine Maintenance Schedule

Purging and Draining the Built-in Filter

SECTION 6: ADDITIONAL ORDERING INFORMATION

Troubleshooting - Power and Gas Issues

Main Switch ON, LED1 Off

Diagnosing issues when the main switch is on but LED1 is not illuminated.

LED2 Illuminates

Troubleshooting Over-Temperature (OT) and Over-Current (OC) faults indicated by LED2.

LED3 Illuminates

Diagnosing Gas Pressure faults or Pressure Switch faults indicated by LED3.

Troubleshooting - Arc and Gas Output Issues

LED3 Blinks - No Arc Output

Resolving issues with no arc output when trigger is depressed.

No Gas Output

Troubleshooting steps for when there is no gas output despite trigger activation.

No Arc Output Without Alarm

Diagnosing situations with no arc output and no alarm light.

Troubleshooting - Output and Arc Stability

No Transfer Between Pilot Arc and Workpiece

Diagnosing and fixing issues with pilot arc to workpiece transfer.

Unstable or Inadequate Output

Addressing problems with low, unstable, or inadequate output power.

Pilot Arc Ignition Difficulties

Troubleshooting issues with pilot arc ignition and cut continuity.

Restricted or Uncontrolled Output

Solutions for output that is restricted or cannot be controlled.

Troubleshooting - Cut Quality and Error Codes

Cut Quality Issues

Identifying causes and solutions for poor cut quality.

Error Codes Explained

List and explanation of common error codes displayed by the system.

SECTION 8: ACCESSORIES

Filter-EX Compressed Air Filter

Details on the Filter-EX air filter and its technical specifications.

Filter-EX Quick Connect Couplings

Information on quick connect couplings for air lines.

O-Ring Lubricant

SECTION 9: POWER SUPPLY BLOCK DIAGRAM

SECTION 10: END OF LIFETIME PRODUCT DISPOSAL

Use and Disposal of Waste

Guidelines for disposing of packaging materials and general waste.

End of Lifetime Product Disposal

Procedures for the disposal of electric and electronic equipment.

RoHS Statement

Confirmation of compliance with RoHS directive requirements for hazardous substances.

SECTION 11: WARRANTY

Warranty Terms and Conditions

Detailed terms and conditions of the product warranty.

Revision History

Addresses and Contacts

Thermacut Headquarters and Production

Contact information for Thermacut's main production facility.

Thermacut Sales Department

Contact details for the sales department.

Thermacut Subsidiaries

Contact information for various Thermacut subsidiaries worldwide.

Distributor Details

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