Plasma Cutting System

Operating Instructions – EX-5-902-007/N-23446 – CSA

Revision 4, 31st January, 2024

 EX-TRAFIRE®105HD

Table of contents

1 Identification ............................................................................ 5
1.1 Labeling..................................................................................................5
1.2 Identification plate ................................................................................5
1.3 Signs and symbols used.......................................................................6
1.4 Classification of the warnings ..............................................................6

2 Safety ....................................................................................... 7
2.1 Designated use......................................................................................7
2.2 Obligations of the operator .................................................................7
2.3 Warning and notice signs.....................................................................8
2.4 Product-specific safety instructions.....................................................8
2.5 Safety instructions for the electrical power supply ...........................8
2.6 Safety instructions for plasma cutting.................................................9
2.7 Personal protective equipment ...........................................................9
2.8 Emergency information ........................................................................9

3 Scope of delivery ...................................................................10

4 Product description ................................................................11

4.1 Assembly and use ...............................................................................11
4.2 Technical data ......................................................................................12
4.3 Technical data for cutting torches FHT-EX®105TTH and
FHT-EX®105TTM ..................................................................................14
4.3.1 Torch dimensions FHT-EX®105TTH...................................................16
4.3.2 Torch dimensions FHT-EX®105TTM ..................................................16
4.3.3 Torch dimensions FHT-EX®105TTSM ................................................16

5 Transport and positioning ......................................................17

6 Setting up the power supply..................................................18

6.1 Connecting to the gas supply............................................................18
6.2 Connecting the work lead..................................................................18
6.3 Connecting the power supply cable ................................................18
6.3.1 Connecting the single-phase machine.............................................18
6.3.2 Connecting the three-phase machine ..............................................19
6.4 Connecting the input power plug.....................................................19
6.4.1 Connection to a generator (optional)...............................................20
6.5 Connecting the cutting torch.............................................................21
6.5.1 Installing the cutting torch's gear rack .............................................22
6.6 Installing consumables for the hand and machine
cutting torches .....................................................................................23
6.7 Aligning FHT-EX®105TTM machine cutting torch ...........................25

7 Operation of the power supply..............................................25

7.1 LCD description...................................................................................26
7.1.1 Setting the parameters .......................................................................27
7.1.2 Selecting the cutting mode................................................................27
7.1.3 Connecting the work lead..................................................................28
7.2 Powering on the machine ..................................................................28
7.3 Manual cutting process ......................................................................29
7.4 Manual grid cutting and gouging process ......................................29
7.5 Cutting – Edge Start ............................................................................30

2
EX-TRAFIRE®105HD

7.6 Piercing ................................................................................................ 31

7.7 Gouging............................................................................................... 31
7.7.1 Table for FHT-EX®105TT material removal ..................................... 32
7.8 Stopping the cutting process............................................................ 33

8 Decommissioning .................................................................. 33

9 Maintenance and cleaning .................................................... 34

9.1 Maintenance and cleaning intervals ................................................ 35

10 Faults and troubleshooting.................................................... 37

11 Disassembly........................................................................... 42

12 Disposal ................................................................................. 43
12.1 Disposal of materials.......................................................................... 43
12.2 Disposal of consumables .................................................................. 43
12.3 Packaging ............................................................................................ 43

13 Warranty ................................................................................ 44

14 Block diagram........................................................................ 44

15 Accessories ............................................................................ 45

16 FHT-EX®105TTH hand cutting torch unit ............................... 46

17 FHT-EX®105TTH consumables for hand cutting torch ........... 47

17.1 FHT-EX®105TTH consumables for hand
cutting torch 45–85 A ......................................................................... 47
17.2 FHT-EX®105TTH consumables for hand
cutting torch 100–105 A..................................................................... 48
17.3 FHT-EX®105TTH consumables for SmoothLine hand
cutting torch ........................................................................................ 48

18 FHT-EX®105TTM machine cutting torch unit ......................... 49

18.1 FHT-EX®105TTM machine cutting torch without gear rack........... 49
18.2 FHT-EX®105TTSM short machine cutting torch .............................. 50

19 FHT-EX®105TTM consumables for machine

cutting torch........................................................................... 51
19.1 FHT-EX®105TTM consumables for standard machine
cutting torch 45–85 A ......................................................................... 51
19.2 FHT-EX®105TTM consumables for standard machine
cutting torch 100–105 A..................................................................... 52
19.3 FHT-EX®105TTM consumables for SmoothLine
machine cutting torch ........................................................................ 53
19.4 FHT-EX®105TTM consumables for marking machine
cutting torch ........................................................................................ 54

20 Cut charts for mechanized cutting......................................... 55

20.1 45 A cutting, shielded, with compressed air................................... 56
20.2 55 A cutting, shielded, with compressed air................................... 57
20.3 65 A cutting, shielded, with compressed air................................... 58

3
 EX-TRAFIRE®105HD

20.4 75 A cutting, shielded, with compressed air....................................59

20.5 85 A cutting, shielded, with compressed air....................................60
20.5.1 85 A cutting, shielded, with compressed air....................................61
20.6 100–105 A cutting, shielded, with compressed air .........................62
20.6.1 100–105 A cutting, shielded, with compressed air .........................63
20.7 40–45 A cutting, SmoothLine, shielded, with compressed air.......64
20.7.1 40–45 A cutting, SmoothLine, shielded, with compressed air.......65
20.8 Marking, shielded, with compressed air or argon ..........................66

21 Appendix................................................................................67
21.1 Connecting the optional CNC interface...........................................67
21.1.1 Setting the voltage divider DIP switches..........................................68
21.1.2 Enabling the external DC coil with an external power supply ......68
21.1.3 Enabling the external AC coil with an external power supply.......69
21.1.4 Enabling the industrially insulated module with
an external power supply...................................................................69

4
EX-TRAFIRE®105HD 1 Identification

1 Identification
The EX-TRAFIRE®105HD is a portable plasma arc cutting power supply for
mechanized and manual plasma cutting, gouging, and optional marking. It
uses compressed air or nitrogen to cut almost all electrically conductive
materials. The EX-TRAFIRE®105HD has to be operated only with original
Thermacut® consumables and maintenance parts.
This documentation describes the EX-TRAFIRE®105HD cutting power
supply.

1.1 Labeling
This product fulfills the requirements that apply to the market to which it
has been introduced. Corresponding labels have been affixed to the
product, if required.

1.2 Identification plate

Fig. 1 EX-TRAFIRE®105HD identification plate

The EX-TRAFIRE®105HD is labeled by means of an identification plate on

the housing located on the side and bottom of the machine.
 For inquiries, please have on hand the order and serial number of the
power supply as seen on the identification plate.

5
1 Identification EX-TRAFIRE®105HD

1.3 Signs and symbols used

The following signs and symbols are used:

 General instructions.
1 Action(s) to be carried out in succession.
Lists.
Cross-reference symbol refers to detailed, supplementary or further
information.
A Caption, item description.

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:

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.

6
EX-TRAFIRE®105HD 2 Safety

2 Safety
This chapter warns of potential 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.

2.1 Designated use

The power supply may be used only for the purpose and manner
described. The power supply 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 electrical load specifications as defined by
the document supplied. Overloads could lead to destruction.
 Do not make any modifications or changes to this product.
 Do not use the power supply to thaw pipes.
 Do not use or store the power supply in wet conditions or
environments.

2.2 Obligations of the operator

 Ensure that only qualified and trained personnel are permitted to work
on the power supply.
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 power supply;
— 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.

The EX-TRAFIRE®105HD can produce electromagnetic fields that could

impact the proper function of cardiac pacemakers and implanted
defibrillators.
 Do not use the EX-TRAFIRE®105HD if you have a pacemaker or an
implanted defibrillator.

7
2 Safety EX-TRAFIRE®105HD

2.3 Warning and notice signs

The following warning, notice, and mandatory signs can be found on top
of the product:

These markings must always be legible. They should not be covered,

obscured, painted over, or removed.

2.4 Product-specific safety instructions

 Do not use or store the power supply in wet conditions or
environments.
 Do not operate the power supply when the housing is open.

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 cables specified
in Table 9 Recommended cable extensions on page 19 must be used.
 Only a certified electrician or trained personnel 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.

8
EX-TRAFIRE®105HD 2 Safety

2.6 Safety instructions for plasma cutting

 Plasma cutting may cause damage to the eyes, skin, and hearing. Note
that other potential hazards may arise when the power supply is used
with other cutting components. Therefore, always wear the prescribed
personal protective equipment as defined by local regulations and
laws.
 All metal vapors, especially lead, cadmium, copper, and beryllium, are
harmful. Ensure sufficient ventilation or extraction. Do not exceed the
current occupational exposure limits (OELs).
 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 laws 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
welding glasses or goggles (see table below), face protection, ear
protectors, protective gloves, and safety shoes.
Table 1 Lens shade selector for plasma cutting per
AWS F2.2:2001 R2019
Cutting current Minimum shade
40 to 60 6
60 to 80 8
80 to 300 8 or 9

2.8 Emergency information

 In the event of an emergency, immediately disconnect the following
supplies:
— Electrical power supply
— Gas supply

9
3 Scope of delivery EX-TRAFIRE®105HD

3 Scope of delivery
The following components are included in the scope of supply:
— 1× EX-TRAFIRE®105HD cutting power supply
— 1× FHT-EX®105TTH or FHT-EX®105TTM cutting torch
— 1× work lead incl. work lead clamp
— 1× operating instructions
— 1× starter kit
The order data and ID numbers for the equipment parts and consumables
can be found in this manual.
 For more information about points of contact, consultation, and orders,
visit www.ex-trafire.us.
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 immediately.
 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
power supply, contact your supplier, carrier or transport company.

10
EX-TRAFIRE®105HD 4 Product description

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 power supply.
Fig. 2 Control elements and connections
A LCD Display F Power cable
B POWER switch G Work lead connection
C Optional BUS interface H Torch connection system (TCS)
D G 1/4" gas connection, plug I Multi-function button
E Optional CNC interface
A B C D

I E

LCD display (A) Displays the status of the power supply. A

fault code is displayed if an error occurs.
POWER switch (B) Used to switch the power supply on and off.
Optional BUS interface (C) For the connection of the optional CAN BUS
or RS485/422 BUS.
Optional CNC interface This optional interface is used to connect the
connection (E) power supply to an optional CNC cutting
table or robot.
Multi-function button (I) For toggling between two menus and
setting the cutting parameters.

11
4 Product description EX-TRAFIRE®105HD

4.2 Technical data

There are two EX-TRAFIRE®105HD systems:
— single-phase and
— three-phase
Table 2 Power supply specifications, single-phase
CSA
Rated open circuit voltage (U0) 290 V DC
Characteristic curve* Drooping
* The curve is defined as output
voltage versus output current
Input voltage (U1) 230 V AC ± 15 %
1 PH/50-60 Hz
Output arc current (I2) 20 – 85 A
Nominal output arc voltage (U2) 160 V DC
Maximum power input 23.8 k VA
Duty Cycle X is the percentage of 10 minutes that the system can cut
(Arc-On time) at nominal load (I2 and U2) without overheating at rated
input voltage.*
Duty Cycle X at 104 °F (40 °C) at 40 % at 85 A, U1 – 230 V AC
nominal conditions (U1, U2, I2) 60 % at 69 A, U1 – 230 V AC
100 % at 54 A, U1 – 230 V AC
Ambient temperature 14 °F (-10 °C) to 104 °F (+40 °C)
Rated input current (I1rms) and I1rms I1eff
effective input current (I1eff) at rated 70.1 A 44.3 A
output power Complies with standards
eff = effective
CSA C22.2 No. 60974-1:19
rms = root mean square
ANSI/NEMA/IEC60974-1-2019
Protection type IP23
Operating tilt angle Up to 15°
Dimensions (L × H × W) [in] 24 x 20 x 12
(613 × 515 × 302 mm)
Weight [lb] 96
(43.6 kg)

* Arc-On time (minutes) * 100

X= 10 (minutes)
= Duty Cycle [%]

When the Duty Cycle is exceeded, the system may overheat which would cause the power
supply to shut down. Wait for the power supply to cool down before returning to normal
operating conditions.

12
EX-TRAFIRE®105HD 4 Product description

Table 3 Power supply specifications, three-phase

CSA
Rated open circuit voltage (U0) 290 V DC
Characteristic curve* Drooping
* The curve is defined as output
voltage versus output current
Input voltage (U1) 208 - 460 - 575 V AC ± 15 %
3 PH/50-60 Hz
Output arc current (I2) 20 –105 A
Nominal output arc voltage (U2) 160 V DC
Maximum power input 23.8 k VA
Duty Cycle X is the percentage of 10 minutes that the system can cut
(Arc-On time) at nominal load (I2 and U2) without overheating at rated
input voltage.*
Duty Cycle X at 104 °F (40 °C) at 55 % at 105 A, U1 – 208 V AC
nominal conditions (U1, U2, I2) 60 % at 100 A, U1 – 208 V AC
100 % at 77 A, U1 – 208 V AC
80 % at 105 A, U1 – 460/575 V AC
100 % at 94 A, U1 – 460/575 V AC
Ambient temperature 14 °F (-10 °C) to 104 °F (+40 °C)
Rated input current (I1rms) and I1rms I1eff
effective input current (I1eff) at rated 208 V - 58.7 A 43.5 A
output power 460 V - 26.0 A 23.3 A
eff = effective
575 V - 23.8 A 21.3 A
rms = root mean square
Complies with standards
CSA C22.2 No. 60974-1:19
ANSI/NEMA/IEC60974-1-2019
Protection type IP23
Operating tilt angle Up to 15°
Dimensions (L × H × W) [in] 24 x 20 x 12
(613 × 515 × 302 mm)
Weight [lb] 96
(43.6 kg)

* Arc-On time (minutes) * 100

X= 10 (minutes)
= Duty Cycle [%]

When the Duty Cycle is exceeded, the system may overheat which would cause the power
supply to shut down. Wait for the power supply to cool down before returning to normal
operating conditions.

Table 4 Ambient conditions for transport and storage

Ambient temperature -4 °F (-20 °C) to 131 °F (+55 °C)
Relative humidity < 50 % at 104 °F (+40 °C)
< 90 % at 68 °F (+20 °C)

13
4 Product description EX-TRAFIRE®105HD

Table 5 Ambient conditions for operation

Ambient temperature 14 °F (-10 °C) to 104 °F (+40 °C)
Relative humidity < 50 % at 104 °F (+40 °C)
< 90 % at 68 °F (+20 °C)
Installation above sea level Max. 6 562 ft (2000 m)

Table 6 Gas data

Permissible gas Compressed air/nitrogen/argon*
Gas inlet pressure, cutting 90 to 145 psi (6.2 to 10 bar)
Recommended compressed air ISO 8573-1 class 1.2.2.
quality clean, and free from moisture and
oil
Recommended nitrogen/argon Purity: ≥ 99.99 %
quality
Needed flow rate 7.2 CFM (205 l/Min.) at
73 psi (5 bar)

* Nitrogen may be used for cutting stainless steel and Aluminum;

Argon may be used only in connection with the optional marking kit.

4.3 Technical data for cutting torches FHT-EX®105TTH and

FHT-EX®105TTM
FHT-EX® cutting torches are used for manual and mechanized 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 7 Technical data for FHT-EX®105TTH and FHT-EX®105TTM cutting
torches
FHT-EX®105TTH /
FHT-EX®105TTM
Recommended cutting capacity 13/8 in (35 mm)
Max. cutting capacity 2 in (50 mm)
Separating cut capacity 2 in (50 mm)
Piercing capacity 1 in (25 mm)
Permissible ambient temperature 14 °F (-10 °C) to 104 °F (+40 °C)
during operation
Permissible ambient temperature -13 °F (-25 °C) to 131 °F (+55 °C)
during transport and storage
Relative humidity < 90 % at + 68 °F (20 °C)
Sub-menu item Plasma cutting, gouging, optional
marking
Application type Manual and mechanized
Rated current and duty cycle 105 A/100 %

14
EX-TRAFIRE®105HD 4 Product description

Table 7 Technical data for FHT-EX®105TTH and FHT-EX®105TTM cutting

torches
FHT-EX®105TTH /
FHT-EX®105TTM
Permissible gas Compressed air/Nitrogen/Argon*
100 A/105 A approx. 5.5 CFM
(156 l/Min.) at 70 psi (4.8 bar)
75 A/85 A approx. 3.5 CFM
(101 l/Min.) at 75 psi (5.2 bar)
Flow rate
55 A /65 A approx. 3.0 CFM
(87 l/Min.) at 75 psi (5.2 bar)
45 A approx. 2.9 CFM (82 l /Min.)
at 75 psi (5.2 bar)
100 A/105 A approx. 7.2 CFM
(205 l/Min.) at 75 psi (5.2 bar)
Flow rate for gouging
65 - 85 A approx. 6.8 CFM
(195 l/Min.) at 75 psi (5.2 bar)
Maximum inlet pressure 145 psi (10 bar)
(Dynamic) operating pressure 75 psi (5.2 bar)
Gas post-flow period delay ≥ 25 seconds
Type of voltage DC
Protection type for IP3X (EN 60529)
EX-TRAFIRE®105HD
Connection type TCS (Torch Connection System) –
13 pin
Standard lengths (other lengths 16.5 ft (5 m) / 26 ft (8 m) /
available upon request) 50 ft (15 m) / 75 ft (23 m)

* Nitrogen may be used for cutting stainless steel and Aluminum;

Argon may be used only in connection with the optional marking kit.
Table 8 Cutting torch weights and cable lengths
Cutting torch Weight and cable lengths
FHT-EX®105TTH 16.5 ft (5 m) /5.5 lb (2.5 kg)
Standard hand cutting torch 26 ft (8 m) /7.3 lb (3.3 kg)
50 ft (15 m) /11 lb (5.0 kg)
75 ft (23 m) /17.4 lb (7.9 kg)
FHT-EX®105TTM STD-NR 16.5 ft (5 m) / 5.7 lb (2.6 kg)
Standard machine torch, 26 ft (8 m) / 7.5 lb (3.4 kg)
without rack 50 ft (15 m) /12.6 lb (5.7 kg)
75 ft (23 m) / 17.6 lb (8.0 kg)
FHT-EX®105TTSM 16.5 ft (5 m) / 5.7 lb (2.6 kg)
Short machine torch 26 ft (8 m) / 7.5 lb (3.4 kg)
50 ft (15 m) /12.6 lb (5.7 kg)
75 ft (23 m) / 17.6 lb (8.0 kg)

15
4 Product description EX-TRAFIRE®105HD

4.3.1 Torch dimensions FHT-EX®105TTH

Fig. 3 Torch dimensions FHT-EX®105TTH

4.3.2 Torch dimensions FHT-EX®105TTM

Fig. 4 Torch dimensions FHT-EX®105TTM

4.3.3 Torch dimensions FHT-EX®105TTSM

Fig. 5 Torch dimensions FHT-EX®105TTSM

16
EX-TRAFIRE®105HD 5 Transport and positioning

5 Transport and positioning

WARNING
Risk of injury due to improper transport and installation
Improper transport and installation can cause the power supply 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 power supply on a suitable surface (flat, solid, and dry) on
which it will not topple over, taking into account the max. operating tilt
angle of 15°.
 Note the weight of the power supply when lifting it. Lift with two
persons.
 4.2 Technical data on page 12
 Use an appropriate lifting tool with load handling equipment for
transporting and installing the power supply.
 Avoid abrupt lifting and setting down.
 Do not lift the power supply 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 power supply to tip or
fall over. This can result in material damage and irreparable damage.
 Protect the power supply against weather conditions, such as rain and
direct sunlight.
 Protect the power supply from spatter when cutting.
 Protect the power supply from direct exposure to sparks when
grinding.
 Use the power supply only in dry, clean, and well-ventilated rooms.
 Maintain a minimum distance of 3.3 ft (1 m) from the wall when
positioning the power supply to ensure that it has sufficient ventilation.

Fig. 6 Drain tube location

 When positioning the power supply,
make sure that the water separator's
drain opening (see circle) is not
covered.

17
6 Setting up the power supply EX-TRAFIRE®105HD

6 Setting up the power supply

6.1 Connecting to the gas supply

 Connect the gas hose with an inside
diameter of at least 3/8 in. (10 mm)
to the gas connection of the power
supply.

6.2 Connecting the work lead

 Connect the work lead to the work
lead connecting socket and secure it
by rotating clockwise.

6.3 Connecting the power supply cable

6.3.1 Connecting the single-phase machine

The power supply should be
connected by a certified electrician or
trained personnel.
L1 -> red
Red

Black
L2 -> black
White N -> white
en
Gre
Ground -> green

The green grounding wire is exclusively

for the grounding and must always be
connected!

18
EX-TRAFIRE®105HD 6 Setting up the power supply

6.3.2 Connecting the three-phase machine

The power supply should be
connected by a certified electrician or
trained personnel.
Red L1 -> red
Black
L2 -> black
White

Gre
en L3 -> white
Ground -> green

The green grounding wire is exclusively

for the grounding and must always be
connected!

Table 9 Recommended cable extensions

Input voltage Wire cross-sections Length
230 V AC 6 gauge/0.23 in2/ Up to 16.5 ft (5 m)
single-phase 50 ft (15 m) – 150 ft (45 m)
16 mm2
208 - 575 V AC/ Up to 16.5 ft (5 m)
three-phase 50 ft (15 m) – 150 ft (45 m)

Any extension cord must have wire sized for the cord length and system
voltage in accordance with local and national codes.

6.4 Connecting the input power plug

 Note the safety instructions.
 2.5 Safety instructions for the electrical power supply on page 8

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 power supply in a very humid environment
or on conductive material, install ground fault circuit breakers (GFCI) in
the power supply if according to electric code.
 Use slow-blow fuses and/or circuit breakers and GFCI that comply with
local regulations and electric codes.
 Ground the power supply according to the applicable regulations and
laws.
 Do not ground the power supply together with other devices or
machines.

19
6 Setting up the power supply EX-TRAFIRE®105HD

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 or
damage.
 Damaged, deformed or worn parts should only be replaced by a
certified electrician or trained personnel.

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.

For the input voltage and the fuse protection, please refer to:
 4.2 Technical data on page 12
 If necessary, have a certified electrician or trained personnel 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.

6.4.1 Connection to a generator (optional)

 Set the generator to three-phase alternating current.
 Plug the input power plug into the socket.
 Set the motor rating as shown in the following table.
Table 10 Connection to a generator
Generator rating Generator output Generator output voltage
current
≥ 30 kW, 3-phase 60 A at 208 V AC 208 V AC, 460 V AC or
30 A at 460 V AC 575 V AC (depending on
25 A at 575 V AC the specific power supply)

20
EX-TRAFIRE®105HD 6 Setting up the power supply

6.5 Connecting the cutting torch

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 EX-TRAFIRE®105HD. If used without, the EX-TRAFIRE®105HD will be
damaged. If the TCS Latch with Key Assembly is not used, the connectors
will be quickly damaged, as lead sets will detach from the power supply
damaging the connectors.
 Only use the EX-TRAFIRE®105HD with the TCS Latch with Key assembly
installed and properly secured.

1 Switch off the power supply.

2 Insert the TCS Latch with Key
Assembly into the TCS socket.

The TCS Latch with Key Assembly must

sit firmly in the TCS socket.

3 Insert the TCS plug into the

connector.
4 Push the plug while simultaneously
pressing down the Latch into locked
position.

21
6 Setting up the power supply EX-TRAFIRE®105HD

6.5.1 Installing the cutting torch's gear rack

Fig. 7 Cutting torch
A Mounting sleeve with torch body D Strain relief
B Reduction nut E Cable
C Mounting tube
A B C D E

1 Disconnect the machine cutting torch

from the cutting power supply.
2 Place on a flat surface.
3 Unscrew the strain relief so that it can
move freely along the torch cable.
4 Unscrew the mounting tube from the
reduction nut. Hold the reduction nut
and the mounting sleeve in order not
to damage the cables.
5 Carefully hold the reduction nut and
mounting sleeve with the torch body
to the side.

6 Push the gear rack into the groove of

the mounting tube.

7 Screw the mounting tube with gear

rack into the reduction nut. Hold the
reduction nut and the torch mounting
sleeve with torch body in order not to
damage the cables.
8 Tighten the mounting tube by hand.
9 Screw in the strain relief. Hold the
mounting tube tight to avoid
damaging the cables.
10Tighten the strain relief by hand.

22
EX-TRAFIRE®105HD 6 Setting up the power supply

6.6 Installing consumables for the hand and machine

cutting torches

WARNING
Electric shock due to live parts
Fatal electric shock can occur if components are live during maintenance
and cleaning work.
 Set the POWER switch to OFF before maintenance and cleaning work.
 Disconnect the input power supply from the wall.
 Observe the Lock-out/Tag-out procedures.

The procedure shown below applies to both the equipment of hand and
machine cutting torch.
Fig. 8 Torch consumables
A Shield D Electrode
B Retaining cap E Swirl ring
C Nozzle F Hand cutting torch/Machine cutting
torch
Hand cutting torch
A B C D E F

Machine cutting torch

A B C D E F

23
6 Setting up the power supply EX-TRAFIRE®105HD

1 Install nozzle into the retaining cap.

2 Insert the electrode into the retaining

cap and nozzle assembly.

3 Insert the swirl ring.

4 Screw the entire assembly onto the

hand cutting torch.
Do not overtighten.
The nozzle must be firmly in place and
must not move.

5 Install the shield.

Do not overtighten.

24
EX-TRAFIRE®105HD 7 Operation of the power supply

6.7 Aligning FHT-EX®105TTM machine cutting torch

For information on the cutting process see
 6 Setting up the power supply on page 18

1 Position the machine cutting torch

perpendicular to the workpiece.
2 Use an angle gauge to align the
machine cutting torch at 0° and 90°.

7 Operation of the power supply

WARNING
Risk of injury due to unexpected ignition of the plasma arc
Hand/Machine cutting torch:
Unexpected ignition may occur.
 Treat every torch as if it was ready to fire.

WARNING
Risk of injury when cutting
Plasma cutting can cause serious injury.
 Do not hold the workpiece in your hands.
 Keep your hands away from the cutting surface.
 Wear your personal protective equipment.

CAUTION
Risk of burns due to flying sparks when angling the cutting torch
When the cutting torch is angled during cutting or piercing, molten
metal (sparks) will escape in the direction in which the cutting torch is
pointed. This may result in burns.
 Do not point the cutting torch at yourself or other individuals when
angling it.
 Wear your personal protective equipment.

NOTICE
Material damage due to exceeding the maximum duty cycle
If the power supply is operated for longer than the maximum duty cycle,
it may be overloaded and irreparably damaged.
 Only operate the power supply up to the maximum permissible duty
cycle.
 4.2 Technical data on page 12
 Observe the maximum duty cycle for cutting components.

25
7 Operation of the power supply EX-TRAFIRE®105HD

NOTICE
Material damage caused by unplugging the input power plug
during operation
If the input power plug is unplugged during operation, the
EX-TRAFIRE®105HD may be irreparably damaged.
 Do not unplug the input power plug during operation and ensure a
constant power supply.

NOTICE
Material damage due to switching the output current strength
during operation
If the output current strength is switched during operation, the
power supply may be damaged.
 Set the output current strength before starting operation and do not
switch it during the cutting process.

7.1 LCD description

Fig. 9 LCD description
A Cutting voltage E Gouging/Marking I Air pressure
B Output arc current F Cutting J Transfer signal
C Torch type G Status K Indicates activation of
D Grid cutting H All cutting parameters the torch trigger or
set pins 3, 4 in the CNC
connection.
A B C

I H G F E D

26
EX-TRAFIRE®105HD 7 Operation of the power supply

7.1.1 Setting the parameters

The LCD menu is used to set the output current (amps), cutting modes, and
pressure in bar, or psi.

1 Press the multi-function button for

one second.
The adjustable values and the word
“Set” flash in red.
2 Press the multi-function button briefly
to switch between the values.
3 Turn the multi-function button to the
left or right to increase or decrease
the values.
4 Press the multi-function button briefly
to accept the set values.
Once all values are set, they are
displayed in white and the word
“Status” appears with a green and
white checkmark.

7.1.2 Selecting the cutting mode

Cutting
The current is 20–105 A.
The pressure of the cutting gas is
70 to 75 psi (4.8 to 5.2 bar).

Gouging
The current is 20 –105 A.
The pressure of the gas is 72 psi (5 bar).
Optional Marking
(uses same icon as gouging)
The current is 10*– 20 A.
The pressure of the gas is 35 psi
(2.4 bar).
The pressure is changed under
SETTINGS.
*Optional light marking

27
7 Operation of the power supply EX-TRAFIRE®105HD

Grid cutting
The current is 45–105 A.
The pressure of the cutting gas is
70 to 75 psi (4.8 to 5.2 bar).

7.1.3 Connecting the work lead

1 Remove contamination from the workpiece.
2 Connect the work lead clamp to the workpiece in order to allow
maximum electrical conduction.
3 Do not connect the work lead clamp to the material to be cut off.
4 Connect the work lead clamp as close as possible to the cutting area in
order to minimize electromagnetic fields.

7.2 Powering on the machine

 Set the POWER switch to ON.

The following is displayed immediately

after switching on:
— Type of power supply (105HD)
— Length of torch cable 16.5 ft, 26 ft,
50 ft, 75 ft (5, 8, 15, 23 m)
— Type of cutting torch (hand or
machine)
— Current firmware

28
EX-TRAFIRE®105HD 7 Operation of the power supply

7.3 Manual cutting process

1 Switch on the power supply.
2 Automatic gas test (five seconds).
3 Automatic system test (five seconds).
4 Press torch trigger.
5 Generate a pilot arc.
Once the workpiece is detected, the pilot arc switches to a cutting arc.
6 The cutting process starts.
7 Extinguish the arc by releasing the torch trigger.
Gas post-flow period is approx. 25 seconds depending on the output
current and is not adjustable.

7.4 Manual grid cutting and gouging process

1 Switch on the power supply.
2 Automatic gas test (five seconds).
3 Automatic system test (five seconds).
4 Select either grid cutting or gouging mode.
5 Press torch trigger.
6 Generate a pilot arc.
Once the workpiece is detected, the pilot arc switches to a cutting arc.
7 Grid cutting or gouging starts depending on the selected process.
8 Extinguish the arc by releasing the torch trigger.
Gas post-flow period is approx. 25 seconds depending on the output
current and is not adjustable.

29
7 Operation of the power supply EX-TRAFIRE®105HD

7.5 Cutting – Edge Start

1 Start the cutting process at the edge

of the workpiece.
2 Do not move the cutting torch until
the material has been cut through
completely.
3 Place the cutting torch upright on the
edge of the workpiece.
4 Pull the cutting torch in the cutting
direction. Sparks must emerge from
the underside of the workpiece.
5 Pay attention to the following when
cutting:
 Hold the cutting torch vertically and
observe the arc while cutting.
 Make light contact between the
shield and the workpiece and pull
the cutting torch in the cutting
direction at a constant speed.
 For cutting thin workpieces, reduce
output current strength to a
minimum to achieve the highest
cutting quality.
 For cutting straight lines/bevels, use
a straight edge as a guide.
 For cutting circles, use a template or
circle cutting device.
If sparks escape upwards during
cutting, the material has not yet been
completely severed. Proceed as
follows:
 Reduce the speed at which the
cutting torch is pulled.
 Check the setting for the output
current.
 Check the compressed air settings.
 Check consumables for wear/
damage.

30
EX-TRAFIRE®105HD 7 Operation of the power supply

7.6 Piercing

1 Hold the cutting torch at an angle to

the workpiece with a max. distance of
0.1 in (3 mm) from the nozzle to the
workpiece.
2 Press the torch trigger to ignite the
arc.

3 Turn the cutting torch slowly in a

vertical direction.
4 Hold the cutting torch until the arc
emerges from the underside of the
workpiece. This indicates the material
is completely pierced through.

5 Pull the cutting torch in the cutting

direction. Sparks must emerge from
the underside of the workpiece.

ti on
ec
g dir
u ttin
C

7.7 Gouging
Gouging can remove welding seams and achieve a controlled gouge
profile. The gouge profile can be influenced by the actions in the following
table:

Gouge profile Actions

Narrower and flatter  Reduce current or increase speed.
Narrower and  Reduce the distance between the torch and
deeper workpiece or hold the cutting torch at larger
angle to workpiece.
Wider and deeper  Increase current or reduce the speed.
Wider and shallower  Increase the distance between the cutting torch
and workpiece or hold the cutting torch at
flatter angle to the workpiece.

31
7 Operation of the power supply EX-TRAFIRE®105HD

1 Use gouging consumables suitable

to the cutting torch being used.
2 Hold the cutting torch at an angle of
30° to 35° inclined to the workpiece.
3 Hold the nozzle close enough to the
workpiece that it touches the
workpiece.
4 Press the torch trigger to ignite the
arc.
5 Continue to hold the cutting torch at
an angle of 30° to 35° to the
workpiece and move it in the
direction of the material to be
removed.

7.7.1 Table for FHT-EX®105TT material removal

Table 11 Table for FHT-EX®105TT material removal
Gouging parameters
(Dynamic) air pressure 75 psi (5.2 bar)
Distance between cutting As close as possible
torch and workpiece
Angle of cutting torch to 30° to 35°
workpiece
Speed 23 in/min. (0.6 m/min.)
Current 65 A 85 A 105 A
Removal rate for mild steel Approx. Approx. Approx.
11 lb/hr 17 lb/hr 20 lb/hr
(4.8 kg/h) (7.74 kg/h) (9.0 kg/h)
Width of gouge Approx. Approx. Approx.
0.21 in 0.22 in 0.24 in
(5.5 mm) (5.7 mm) (6.2 mm)
Depth of gouge Approx. Approx. Approx.
0.17 in 0.18 in 0.16 in
(4.5 mm) (4.8 mm) (4.1 mm)

32
EX-TRAFIRE®105HD 8 Decommissioning

7.8 Stopping the cutting process

CAUTION
Risk of injury due to hot parts
Parts may still be hot after the gas post-flow period ends. There is a risk of
burns.
 Wear your personal protective equipment.
 Allow the cutting torch to cool down for 5 to 10 minutes before
touching the parts.

 Release the torch trigger to end the cutting process.

After releasing the torch trigger, the gas continues to flow for up to
25 seconds in order to cool the cutting torch and the consumables.
 To end the gas post-flow period prematurely, briefly press and release
the torch trigger.
 Press the torch trigger again to ignite the pilot arc.

8 Decommissioning
1 Set the POWER switch to OFF.
2 Disconnect the EX-TRAFIRE®105HD from the input power supply.
3 Disconnect the EX-TRAFIRE®105HD from the gas supply.
4 Apply inward pressure to TCS plug when lifting latch for leads removal.

33
9 Maintenance and cleaning EX-TRAFIRE®105HD

9 Maintenance and cleaning

Scheduled maintenance and cleaning are prerequisites for a long service
life and trouble-free operation. The maintenance cycle is determined by
the work environment and the EX-TRAFIRE®105HD’s maintenance
intervals. If it is operated for more than eight hours a day, the maintenance
intervals should be changed as needed. When using plasma arc cutting
equipment, always observe the provisions of EN 60974-4 Inspection and
testing, as well as any local laws and regulations.

WARNING
Electric shock due to missing grounding
If the cover plates are improperly mounted, the grounding may not be
properly established. There is a risk of life-threatening electric shock.
 The cover plates may be disassembled and assembled only by a
certified electrician or trained personnel for maintenance and cleaning
work.
 Verify the grounding has been established correctly.

WARNING
Electric shock due to live parts
Fatal electric shock can occur if components are live during maintenance
and cleaning work.
 Set the POWER switch to OFF before maintenance and cleaning work.
 Disconnect the input power supply from the wall.
 Observe the Lock-out/Tag-out procedure.

WARNING
Electric shock due to 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
certified electrician or trained personnel.

CAUTION
Fire hazard due to contamination
Dust deposits inside the EX-TRAFIRE®105HD can lead to a reduction in
insulation. This can cause short circuits or fires.
 Clean the power supply annually with dried compressed air to remove
dust and cutting fume residue.

34
EX-TRAFIRE®105HD 9 Maintenance and cleaning

9.1 Maintenance and cleaning intervals

The specified intervals are standard values and refer to single-shift
operation. We recommend recording the inspections. The date of the
inspection, the detected defects and the name of the inspector should be
documented.
Table 12 Maintenance and cleaning intervals
 Check the gas settings.
 Check cables, connector hoses, and
Daily/every 6 hours connections for tight fit and damage, and
of cutting replace, if necessary.
 Check the work lead clamp for contamination.
 Check the cutting torch's consumables for wear.
Weekly  Check the cap sensor.
 Check the cutting torch for signs of cracks in the
torch body, and exposed wires.
 Check the gas hose, filter elements and
connections for leaks.
Every 3 months
 Open the EX-TRAFIRE®105HD body and have
the inside cleaned with a vacuum cleaner or dry,
clean compressed air by Thermacut® or trained
personnel.
Annually and after  Have a safety inspection performed by
each time the Thermacut® or trained personnel.
housing is opened

35
9 Maintenance and cleaning EX-TRAFIRE®105HD

Table 13 Parts inspection

Consumable Check for Action
Orifice is not round.  Replace the shield.
Spatter in the gap  Clean the shield and
Shield
between the shield and nozzle surface.
the nozzle.
Heat damage, cracks,  Replace the retaining
breaks, damaged cap.
Retaining cap
threaded connections,
clogged gas holes.
Nozzle Orifice is not round.  Replace the nozzle.
Outer surface is
damaged or dirty.
Electrode restriction due
 Clean or replace the
Swirl ring to dirt, debris, or damage
swirl ring.
on interior surfaces.
Clogged or damaged
gas holes.
Pit depth of hafnium is  Replace the
Electrode deeper than 0.6 in electrode.
(1.6 mm).
Fire or arc damage
inside.
Worn or damaged
threaded connections.  Replace the cutting
Burned or missing torch.
Cutting torch material.
Cutting torch is damaged
or dirty.
Damaged O-ring.  Replace the O-ring.
Dry O-ring.  Apply a thin layer of
silicone grease.

36
EX-TRAFIRE®105HD 10 Faults and troubleshooting

10 Faults and troubleshooting

Verify consumables selection according to:
 17 FHT-EX®105TTH consumables for hand cutting torch on page 47
 19 FHT-EX®105TTM consumables for machine cutting torch on page 51
 Contact your retailer or Thermacut® in the event of questions or
problems.

WARNING
Electric shock due to live parts
Fatal electric shock can occur if components are live during maintenance
and cleaning work.
 Set the POWER switch to OFF before maintenance and cleaning work.
 Disconnect the input power supply from the wall.
 Observe the Lock-out/Tag-out procedure.

Table 14 Fault messages in the display

Error code Cause Troubleshooting
H01 Input power voltage is  Check the input power
too low. voltage against the
specifications on the
identification plate.
H02 Input power voltage is  Check the input power
too high. voltage against the
specifications on the
identification plate.
H03 No arc or current when  Have the inverter,
the trigger is pressed. transformer, and FRD
checked by a certified
electrician or trained
personnel.
Missing nozzle or  Verify that the consumable
electrode. is installed correctly and, if
necessary, re-install it
correctly or replace it.
H04 Dirt or short circuit in the  Dismantle all consumables,
Arc does not cutting torch. clean the inside of the
ignite when cutting torch and install
torch trigger is correctly.
pressed or the Consumables are not  Use Thermacut® original
CNC start Thermacut® original consumables.
signal is on parts.
Consumable part is loose,  Verify that the consumables
incorrectly installed or are installed correctly and, if
defective. necessary, re-install
correctly or replace them.

37
10 Faults and troubleshooting EX-TRAFIRE®105HD

Table 14 Fault messages in the display

Error code Cause Troubleshooting
H05 The electrode is not  Check for free movement of
separated from the nozzle the electrode and clean or
during the pilot arc. replace parts, if necessary.
Fan is defective.  Ensure that the fan is
running freely.
 Replace fan or fan motor.
Duty cycle has been  Allow the power supply to
H06 exceeded. cool down.
Excess  Do not exceed the duty
temperature cycle.
Insufficient ventilation.  Verify sufficient space
around the power supply.
Components defective.  Contact service or your
retailer.
H07 Inverter overcurrent.  Have the output diodes,
Excess current main transformer, and IGBT
on the inverter board
checked by a certified
electrician or trained
personnel.
The cutting torch is  Verify the proper cutting
missing or not connected. torch is connected.
Consumables are loose,  Verify that the consumables
H08 incorrectly installed or are installed correctly and, if
Arc does not missing. necessary, re-install them
ignite when correctly or replace them.
trigger is Retaining cap is  Verify that the retaining cap
pressed or incorrectly installed or is correctly installed,
CNC start has been tightened too re-install correctly and
signal is on tightly. tighten, if needed.
Consumables used are  Use only Thermacut®
not Thermacut® original original consumables.
parts.
H11 Missing phase.  Have the issue checked by
a certified electrician or
trained personnel.
H14 Incorrect cutting torch.  Verify the proper cutting
torch is connected.

38
EX-TRAFIRE®105HD 10 Faults and troubleshooting

Table 14 Fault messages in the display

Error code Cause Troubleshooting
H15 No data communication  Check the cable.
at the BUS.  Replace the CAN and BUS
PCB.
 Have the control PCB
replaced by a certified
electrician or trained
personnel.
H16 Data recording failed.  Check the cable.
 Replace the CAN and BUS
PCB.
 Have the control PCB
replaced by a certified
electrician or trained
personnel.
Gas inlet pressure is  Check the inlet gas
below 72.5 psi (5 bar). pressure.
Insufficient plasma gas  Check the gas pressure and
flow. flow.
 Verify the gas settings are
correct.
H17 GAS
Defective torch cable.  Replace the torch cable.
Pressure sensor is  Have the pressure switch
defective. checked and, if necessary,
replaced by a certified
electrician or trained
personnel.
H18 Watchdog fault.  Have the control PCB
replaced by a certified
electrician or trained
personnel.
H19 Incorrect current setting.  Verify the cutting power
settings.
H20 Incorrect cutting mode.  Verify the cutting mode.
H21 Gas pressure fault.  Check the gas supply.
H22 The voltage of PFC is  Check if the PFC IGBT is
NO BUS_V incorrect. damaged.
H23 Torch trigger is pressed  Verify that the trigger is not
before starting or during pressed when the power
initialization. supply is switched on, and
during initialization.

39
10 Faults and troubleshooting EX-TRAFIRE®105HD

Table 15 General faults

Fault Description Cause Troubleshooting
Switch is set to ON, Power supply is  Check the input power
LCD does not insufficient. voltage.
illuminate. Power cable is not  Plug the input power plug
No/low input
connected. into the socket.
power voltage.
Switch is defective.  Switch must be replaced by
a certified electrician or
trained personnel.
Gas does not flow Gas valve Hose to gas valve  Connect hose to gas valve.
when the torch defective or gas loose or not
 Tighten correctly.
trigger is pressed hose loose. connected.
or the CNC start Gas valve is defective.  Contact your retailer.
signal is switched
on.
Arc does not ignite Incorrect cutting Cutting torch type is  Verify the proper cutting
and there is no torch type is incorrect. torch is connected.
fault code when connected.
torch trigger is
Incorrect gas Consumables are  Check consumables and
pressed or the
pressure. defective or replace, if necessary.
CNC start signal
switched is on. improperly installed.

No contact between  Remove contamination

work lead clamp and and/or oxidation from the
workpiece. workpiece and the work
lead clamp.
 .Attach the work lead
Poor contact clamp to the workpiece in
No transfer order to allow maximum
between work
between pilot arc electrical conduction.
lead clamp and
and workpiece.
workpiece. Standoff between  Decrease the standoff
cutting torch and between cutting torch and
workpiece is too workpiece.
great.
Work lead is  Replace the work lead.
defective.

40
EX-TRAFIRE®105HD 10 Faults and troubleshooting

Table 15 General faults

Fault Description Cause Troubleshooting
Connection fault in  Ensure that all cable
work lead or cutting connections are correctly
torch cable. installed.
No contact between  Remove contamination
work lead clamp and and/or oxidation from the
workpiece. workpiece and the work
Poor contact
lead clamp.
between work
 Attach the work lead clamp
lead clamp and
to the workpiece in order
Output current too workpiece. to allow maximum
low, cannot be
electrical conduction.
controlled.
Standoff between  Decrease the standoff
cutting torch and between cutting torch and
workpiece is too workpiece.
great.
Voltage fault. Faulty input voltage.  Verify the correct input
voltage according to the
identification plate.
 Check consumables and
replace, if necessary.
Pilot arc ignites Consumables Consumables are  Check consumables and
with difficulty and are defective. worn or damaged. replace, if necessary.
switches off. Faulty gas flow. Gas flow too high.  Check gas compressor.
Gas flow too low.  Check supply lines.
Output current Poor contact Connection fault.  Ensure that all cable
cannot be between work Faulty cable connections are properly
controlled. lead clamp and connections. secured.
workpiece.  Attach the work lead clamp
to the workpiece in order
to allow maximum
electrical conduction.

41
11 Disassembly EX-TRAFIRE®105HD

Table 15 General faults

Fault Description Cause Troubleshooting
Incorrect Output current (amps)  Adjust the output current
setting for too low/material too strength to the thickness of
output current. thick. the workpiece.
Consumables Consumables are  Inspect consumables in the
are defective. worn. cutting torch and replace, if
necessary.
 Adjust the output current
strength to the speed at
which the cutting torch is
pulled and the thickness of
Poor cutting Incorrect cutting the workpiece.
Insufficient cutting quality. technology.  Verify the standoff
quality. between cutting torch and
workpiece.
 7.5 Cutting – Edge Start on
page 30
 Remove contamination
and/or oxidation from the
Poor contact workpiece and the work
between work lead clamp.
Workpiece is dirty.
lead clamp and  Attach the work lead clamp
workpiece. to the workpiece in order
to allow maximum
electrical conduction.

11 Disassembly

WARNING
Electric shock due to live parts
Fatal electric shock can occur if components are live during maintenance
and cleaning work.
 Set the POWER switch to OFF before maintenance and cleaning work.
 Disconnect the power supply.

1 Disconnect the power supply.

2 Disconnect all supply connections.
3 Remove the work lead.
4 Disassemble the cutting torch cable assembly by applying inward
pressure to TCS plug while lifting TCS latch.

42
EX-TRAFIRE®105HD 12 Disposal

12 Disposal
Equipment marked with this symbol is covered by European
Directive 2012/19/EU on waste electrical and electronic
equipment (WEEE).
 Do not dispose of electrical and electronic equipment with
household waste.
 Disassemble electrical equipment prior to proper
disposal.
 11 Disassembly on page 42
 Collect electrical components separately and recycle in an
environmentally responsible manner.
 Observe local regulations, laws, provisions, standards and
guidelines.
 Please consult the responsible local authority for
information about collection and return of electrical
devices.

12.1 Disposal of materials

This product is mainly made of metallic materials that can be melted in
steel and iron works and are thus almost infinitely recyclable. The plastic
materials used are labeled in preparation for their sorting and separation
for later recycling.

12.2 Disposal of consumables

Oil, greases and cleaning agents must not contaminate the ground or
enter the sewage system. These substances must be stored, transported
and disposed of in suitable containers. Observe the relevant local
regulations and disposal instructions in the safety data sheets specified by
the manufacturer of the consumables. Contaminated cleaning tools
(brushes, rags, etc.) must also be disposed of in accordance with the
information provided by the consumables' manufacturer.
 Observe the relevant local regulations and disposal instructions in the
safety data sheets specified by the manufacturer of the consumables.

12.3 Packaging
Thermacut® has reduced the packaging to the necessary minimum. The
ability to recycle packaging materials is always considered during their
selection.

43
13 Warranty EX-TRAFIRE®105HD

13 Warranty
The goods delivered to buyer under contract with seller may be subject to
the terms, conditions, limitations, and restrictions of a warranty, if any, to
the extent set forth in seller’s standard terms and conditions of sale as of
the date of the contract between buyer and seller.
Buyer may access seller’s standard terms and conditions of sale on seller’s
website at www.ex-trafire.us or may obtain a copy by calling seller (see your
local contact information under ADDRESSES AND CONTACTS) and
requesting a copy of seller’s standard terms and conditions of sale.

14 Block diagram

44
EX-TRAFIRE®105HD 15 Accessories

15 Accessories
Table 16 Accessories
Accessories Part number Description
EX-0-802-001 DN 7.2 ES Quick-connect plug with
male thread G 1/4"
British standard straight thread

EX-0-802-002 DN 7.2 ES Quick-connect socket

with male thread G 1/4"
British standard straight thread

EX-0-803-001 CNC interface plug 14-pin kit,

incl. 7 pins

EX-0-803-003 CNC interface connection

cable 9.8 ft (3 m)
EX-0-803-004
CNC interface connection cable
19.6 ft (6 m)

EX-0-805-001 O-ring lubricant, silicone grease,

25 ml

For more information about accessories, visit our website:

www.ex-trafire.us.

45
16 FHT-EX®105TTH hand cutting torch unit EX-TRAFIRE®105HD

16 FHT-EX®105TTH hand cutting torch unit

Table 17 FHT-EX®105TTH hand cutting torch

Number Part number Description
®
EX-5-139-001 FHT-EX 105TTH hand cutting torch without
consumables with 16.5 ft (5 m) cable/TCS13
EX-5-139-002 FHT-EX®105TTH hand cutting torch without
consumables with 26 ft (8 m) cable/TCS13
A
EX-5-139-003 FHT-EX®105TTH hand cutting torch without
consumables with 50 ft (15 m) cable/TCS13
EX-5-139-004 FHT-EX®105TTH hand cutting torch without
consumables with 75 ft (23 m) cable/TCS13
B EX-0-321-003 Latch with Key Assembly

46
EX-TRAFIRE®105HD 17 FHT-EX®105TTH consumables for hand cutting torch

17 FHT-EX®105TTH consumables for hand cutting torch

17.1 FHT-EX®105TTH consumables for hand

cutting torch 45–85 A

Shielded

Gouging

Table 18 Consumables for hand cutting torch 45–85 A

Item Part number Description
A EX-5-404-051 Swirl ring 45–105 A
B EX-5-401-051 Electrode 45–105 A
C EX-5-410-051 Nozzle 45 A
D EX-5-410-053 Nozzle 55/65 A
E EX-5-410-030 Nozzle 75 A
F EX-5-410-055 Nozzle 85 A
G EX-5-415-050 Retaining cap 45–85 A
H EX-5-422-031 Shield 45–85 A
I EX-5-440-051 Nozzle, gouging 45–85 A
J EX-5-440-050 Shield, gouging

47
17 FHT-EX®105TTH consumables for hand cutting torch EX-TRAFIRE®105HD

17.2 FHT-EX®105TTH consumables for hand

cutting torch 100–105 A

Shielded

Gouging

Table 19 Consumables for hand cutting torch 100–105 A

Item Part number Description
A EX-5-404-051 Swirl ring 45–105 A
B EX-5-401-051 Electrode 45–105 A
C EX-5-410-056 Nozzle 100/105 A
D EX-5-415-051 Retaining cap 100/105 A
E EX-5-422-032 Shield 100/105 A
F EX-5-440-052 Nozzle, gouging 100/105 A
G EX-5-440-050 Shield, gouging

17.3 FHT-EX®105TTH consumables for SmoothLine hand

cutting torch
Shielded

E D C B A

Table 20 FHT-EX®105TTH consumables for SmoothLine hand cutting

torch
Item Part number Description
A EX-5-404-051 Swirl ring 45–105 A
B EX-5-401-051 Electrode 45–105 A
C EX-5-410-050 Nozzle, SmoothLine
D EX-5-415-050 Retaining cap 45/85 A
E EX-5-420-050 Shield 40/45 A

48
EX-TRAFIRE®105HD 18 FHT-EX®105TTM machine cutting torch unit

18 FHT-EX®105TTM machine cutting torch unit

18.1 FHT-EX®105TTM machine cutting torch without gear rack

Table 21 FFHT-EX®105TTM machine cutting torch without gear rack

Number Part number Description
EX-5-202-031 FHT-EX®105TTM machine torch without gear
rack, without consumables, with 16.5 ft (5 m)
cable/ TCS13
EX-5-204-031 FHT-EX®105TTM machine torch without gear
rack, without consumables, with 26 ft (8 m)
cable/ TCS13
A
EX-5-207-032 FHT-EX®105TTM machine torch without gear
rack, without consumables, with 50 ft (15 m)
cable/ TCS13
EX-5-210-034 FHT-EX®105TTM machine torch without gear
rack, without consumables, with 75 ft (23 m)
cable/ TCS13
B EX-0-321-003 Latch with Key Assembly

49
18 FHT-EX®105TTM machine cutting torch unit EX-TRAFIRE®105HD

18.2 FHT-EX®105TTSM short machine cutting torch

Table 22 FHT-EX®105TTSM short machine cutting torch

Number Part number Description
EX-5-242-021 FHT-EX®105TTSM short machine cutting torch,
without consumables, with 16.5 ft (5 m) cable/
TCS13
EX-5-244-021 FHT-EX®105TTSM short machine cutting torch,
without consumables, with 26 ft (8 m) cable/
TCS13
A
EX-5-247-021 FHT-EX®105TTSM short machine cutting torch,
without consumables, with 50 ft (15 m) cable/
TCS13
EX-5-250-021 FHT-EX®105TTSM short machine cutting torch,
without consumables, with 75 ft (23 m) cable/
TCS13
B EX-0-321-003 Latch with Key Assembly

50
EX-TRAFIRE®105HD 19 FHT-EX®105TTM consumables for machine cutting torch

19 FHT-EX®105TTM consumables for machine

cutting torch

19.1 FHT-EX®105TTM consumables for standard machine

cutting torch 45–85 A

Shielded

**Unshielded

Table 23 FHT-EX®105TTM consumables for standard machine cutting

torch 45–85 A
Item Part number Description
A EX-5-404-051 Swirl ring 45–105 A
B EX-5-401-051 Electrode 45–105 A
C EX-5-410-051 Nozzle 45 A
D EX-5-410-053 Nozzle 55/65 A
E EX-5-410-030 Nozzle 75 A
F EX-5-410-055 Nozzle 85 A
G EX-5-415-050 Retaining cap 45–85 A
H EX-5-415-052 Retaining cap 45–85 A with IHS tab
I EX-5-422-051 Shield 45–85 A, machine
J EX-5-423-001 Deflector

If a torch height controller is used, a retaining cap with IHS (initial height
sensing) must be used.

51
19 FHT-EX®105TTM consumables for machine cutting torch EX-TRAFIRE®105HD

19.2 FHT-EX®105TTM consumables for standard machine

cutting torch 100–105 A

Shielded

**Unshielded

Table 24 FHT-EX®105TTM consumables for standard machine cutting

torch 100–105A
Item Part number Description
A EX-5-404-051 Swirl ring 45–105 A
B EX-5-401-051 Electrode 45–105 A
C EX-5-410-056 Nozzle 100/105 A
D EX-5-415-051 Retaining cap 100/105 A
E EX-5-415-053 Retaining cap100/105 A with IHS tab
F EX-5-422-052 Shield 100/105 A, machine
G EX-5-423-001 Deflector

If a torch height controller is used, a retaining cap with IHS (initial height
sensing) must be used.

52
EX-TRAFIRE®105HD 19 FHT-EX®105TTM consumables for machine cutting torch

19.3 FHT-EX®105TTM consumables for SmoothLine

machine cutting torch

Shielded D

C B A
**Unshielded

Table 25 FHT-EX®105TTM consumables for SmoothLine machine cutting

torch
Item Part number Description
A EX-5-404-051 Swirl ring 45–105 A
B EX-5-401-051 Electrode 45–105 A
C EX-5-410-050 Nozzle, SmoothLine
D EX-5-415-050 Retaining cap 45–85 A
E EX-5-415-052 Retaining cap 45–85 A with IHS tab
F EX-5-422-050 Shield 40/45 A
G EX-5-423-001 Deflector

If a torch height controller is used, a retaining cap with IHS (initial height
sensing) must be used.

53
19 FHT-EX®105TTM consumables for machine cutting torch EX-TRAFIRE®105HD

19.4 FHT-EX®105TTM consumables for marking machine

cutting torch

Table 26 FHT-EX®105TTM consumables for marking machine cutting

torch
Item Part number Description
A EX-5-404-051 Swirl ring 45–105 A
B EX-5-401-051 Electrode 45–105 A
C EX-5-445-001 Nozzle, marking
D EX-5-415-050 Retaining cap 45–85 A
E EX-5-415-052 Retaining cap 45–85 A with IHS tab
F EX-5-445-002 Shield, marking

If a torch height controller is used, a retaining cap with IHS (initial height
sensing) must be used.

54
EX-TRAFIRE®105HD 20 Cut charts for mechanized cutting

20 Cut charts for mechanized cutting

Cut charts serve as a guideline for mechanized cutting. Individual systems
can be “fine tuned” to achieve optimum cutting quality.
Recommended speed:
Speeds adjusted for cutting capacity do not necessarily represent
maximum speeds. They are the speeds that must be achieved for the
specified material thickness.
Maximum speed:
The maximum cutting speeds are the result of in-depth laboratory testing.
Actual cutting speeds may vary due to different cutting applications.
Configuration without shield:
If consumables are used without a shield, either the torch must be manually
adjusted to the working height, or the arc voltage control (AVC) settings
must be selected to achieve the desired cutting quality.
Distance of torch to workpiece for configuration without shield = distance
of nozzle to workpiece 0.12 in (3 mm).

55
20 Cut charts for mechanized cutting EX-TRAFIRE®105HD

20.1 45 A cutting, shielded, with compressed air

Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf
thickness (shield to height delay time width
Settings for Standard quality
work cut (shield to
highest quality settings
height) workpiece
height) Cutting speed Voltage Cutting speed Voltage
[in] [in] [in] [Seconds] [ipm] [Volts] [ipm] [Volts] [in]
Mild steel
14 GA 0.138 0.1 220 113 261 107 0.055
12 GA 0.138 0.1 155 113 191 109 0.055
3/16 0.138 0.3 114 115 134 113 0.055
1/4 0.138 0.5 59 117 70 116 0.063
5/16 0.138 0.5 41 117 47 119 0.067
0.075
3/8 0.157 0.6 30 123 33 122 0.071
1/2 0.177 1 21 128 24 125 0.071
5/8 11 130 13 130 0.079
3/4 Edge start 7 139 8 136 0.087
1 4 146 6 142 0.087
Stainless steel
14 GA 0.138 0.1 209 112 299 112 0.039
12 GA 0.138 0.2 118 120 173 119 0.051
3/16 0.138 0.4 75 120 114 120 0.055
1/4 0.138 0.6 39 126 63 120 0.063
5/16 0.075 0.157 0.6 28 128 37 124 0.063
3/8 0.189 0.8 20 132 30 129 0.063
1/2 0.205 1.2 13 136 20 132 0.071
5/8 139 13 133 0.079
Edge start
3/4 140 8 138 0.079
Aluminum
1/16 0.138 0.1 309 116 374 115 0.043
1/8 0.138 0.2 189 121 279 118 0.059
3/16 0.138 0.4 142 121 220 120 0.059
1/4 0.138 0.5 79 128 120 125 0.059
0.075
5/16 0.138 0.6 51 128 71 125 0.063
3/8 0.157 0.7 34 132 40 130 0.067
1/2 24 134 29 133 0.067
Edge start
5/8 13 134 15 137 0.067

56
EX-TRAFIRE®105HD 20 Cut charts for mechanized cutting

20.2 55 A cutting, shielded, with compressed air

Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf
thickness (shield to height delay time width
Settings for Standard quality
work cut (shield to
highest quality settings
height) workpiece
height) Cutting speed Voltage Cutting speed Voltage
[in] [in] [in] [Seconds] [ipm] [Volts] [ipm] [Volts] [in]
Mild steel
14 GA 0.138 0.1 207 104 251 98 0.063
12 GA 0.138 0.1 167 106 191 106 0.063
3/16 0.138 0.3 137 107 153 106 0.063
1/4 0.138 0.5 70 109 97 107 0.067
5/16 0.138 0.8 57 109 65 107 0.067
0.075
3/8 0.157 1 35 115 44 114 0.075
1/2 0.157 1.2 29 117 32 115 0.079
5/8 0.177 1.5 20 128 23 124 0.087
3/4 12 128 15 127 0.087
Edge start
1 7 137 10 132 0.091
Stainless steel
14 GA 0.150 0.1 268 105 334 104 0.051
12 GA 0.150 0.2 217 105 274 104 0.051
3/16 0.150 0.5 167 105 204 108 0.051
1/4 0.150 0.8 78 109 90 108 0.067
5/16 0.075 0.150 1 47 115 58 110 0.067
3/8 0.197 1.2 30 119 40 115 0.079
1/2 0.276 1.3 23 121 29 118 0.079
5/8 16 122 18 121 0.079
Edge start
3/4 9 132 12 129 0.075
Aluminum
1/16 0.138 0.1 291 110 393+ 111 0.055
1/8 0.138 0.1 241 112 294 112 0.055
3/16 0.138 0.3 201 113 244 115 0.055
1/4 0.138 0.5 100 116 147 118 0.071
5/16 0.075 0.138 0.6 60 120 87 118 0.075
3/8 0.157 1 40 123 55 121 0.075
1/2 0.157 1 30 128 43 125 0.075
5/8 22 130 23 128 0.075
Edge start
3/4 13 136 18 141 0.067

57
20 Cut charts for mechanized cutting EX-TRAFIRE®105HD

20.3 65 A cutting, shielded, with compressed air

Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf
thickness (shield to height delay time width
Settings for Standard quality
work cut (shield to
highest quality settings
height) workpiece
height) Cutting speed Voltage Cutting speed Voltage
[in] [in] [in] [Seconds] [ipm] [Volts] [ipm] [Volts] [in]
Mild steel
14 GA 0.138 0.1 244 106 295 100 0.063
12 GA 0.138 0.1 197 108 224 108 0.063
3/16 0.138 0.3 161 109 181 108 0.063
1/4 0.138 0.5 83 111 114 109 0.067
5/16 0.138 0.5 67 111 77 109 0.067
0.075
3/8 0.157 0.8 41 117 51 116 0.075
1/2 0.157 1 34 119 38 117 0.079
5/8 0.177 1.3 24 130 27 126 0.087
3/4 15 130 17 129 0.087
Edge start
1 8 139 11 134 0.091
Stainless steel
14 GA 0.150 0.1 315 107 393 106 0.051
12 GA 0.150 0.2 256 107 323 106 0.051
3/16 0.150 0.5 197 107 240 110 0.051
1/4 0.150 0.5 92 111 106 110 0.067
5/16 0.075 0.150 0.8 55 117 69 112 0.067
3/8 0197 1 35 121 47 117 0.079
1/2 0.276 1.2 28 123 34 120 0.079
5/8 19 124 22 123 0.079
Edge start
3/4 11 134 15 131 0.075
Aluminum
1/16 0.138 0.1 342 112 393+ 113 0.055
1/8 0.138 0.1 283 114 346 114 0.055
3/16 0.138 0.3 236 115 287 117 0.055
1/4 0.138 0.4 118 118 173 120 0.071
5/16 0.075 0.138 0.5 71 122 102 120 0.075
3/8 0.157 0.8 47 125 65 123 0.075
1/2 0.157 1 35 130 51 127 0.075
5/8 26 132 28 130 0.075
Edge start
3/4 15 138 22 143 0.067

58
EX-TRAFIRE®105HD 20 Cut charts for mechanized cutting

20.4 75 A cutting, shielded, with compressed air

Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf
thickness (shield to height delay time width
Settings for Standard quality
work cut (shield to
highest quality settings
height) workpiece
height) Cutting speed Voltage Cutting speed Voltage
[in] [in] [in] [Seconds] [ipm] [Volts] [ipm] [Volts] [in]
Mild steel
12 GA 0.138 0.1 224 114 264 112 0.055
3/16 0.138 0.2 173 115 224 115 0.063
1/4 0.138 0.3 134 115 169 115 0.063
5/16 0.138 0.3 83 116 98 115 0.071
3/8 0.138 0.5 55 119 63 118 0.075
0.075
1/2 0.157 0.8 39 121 47 120 0.083
5/8 0.177 1.2 28 125 31 129 0.087
3/4 16 130 20 129 0.091
1 Edge start 10 137 13 135 0.091
1-1/8 6 143 8 140 0.098
Stainless steel
12 GA 0.138 0.2 268 106 354 104 0.059
3/16 0.138 0.3 216 112 283 107 0.059
1/4 0.138 0.5 118 112 150 114 0.063
5/16 0.138 0.5 87 117 94 114 0.071
3/8 0.075 0.157 0.8 55 119 67 114 0.071
1/2 0.170 1.2 33 128 47 122 0.079
5/8 0.170 1.5 24 130 27 129 0.079
3/4 15 139 20 129 0.079
Edge start
1 9 134 12 132 0.087
Aluminum
1/8 0.138 0.1 295 110 374 104 0.063
3/16 0.138 0.2 248 117 307 108 0.071
1/4 0.138 0.3 134 120 185 116 0.071
5/16 0.157 0.3 90 122 130 120 0.071
3/8 0.075 0.157 0.5 59 126 94 120 0.075
1/2 0.157 0.7 47 127 71 124 0.075
5/8 0.170 1 31 132 43 130 0.079
3/4 20 133 31 132 0.079
Edge start
1 12 142 19 135 0.083

59
20 Cut charts for mechanized cutting EX-TRAFIRE®105HD

20.5 85 A cutting, shielded, with compressed air

Recommended speed:
Speeds adjusted for cutting capacity do not necessarily represent
maximum speeds. They are the speeds that must be achieved for the
specified material thickness.
Maximum speed:
The maximum cutting speeds are the result of in-depth laboratory testing.
Actual cutting speeds may vary due to different cutting applications.
Configuration without shield:
If consumables are used without a shield, either the torch must be manually
adjusted to the working height, or the arc voltage control (AVC) settings
must be selected to achieve the desired cutting quality.
Distance of torch to workpiece for configuration without shield = distance
of nozzle to workpiece 0.10 in (+2.75 mm).

60
EX-TRAFIRE®105HD 20 Cut charts for mechanized cutting

20.5.1 85 A cutting, shielded, with compressed air

Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf
thickness (shield to height delay time width
Settings for Standard quality
work cut (shield to
highest quality settings
height) workpiece
height) Cutting speed Voltage Cutting speed Voltage
[in] [in] [in] [Seconds] [ipm] [Volts] [ipm] [Volts] [in]
Mild steel
12 GA 0.138 0.1 252 112 284 109 0.063
3/16 0.138 0.2 185 106 122 106 0.063
1/4 0.138 0.5 122 112 150 113 0.075
5/16 0.138 0.5 94 114 104 114 0.075
3/8 0.138 0.5 63 114 71 113 0.075
0.083
1/2 0.157 0.8 43 120 54 118 0.083
5/8 0.157 1 31 124 33 124 0.083
3/4 0.197 1.8 19 130 21 130 0.087
1 13 134 14 133 0.087
Edge start
1-1/8 6 141 8 138 0.102
Stainless steel
12 GA 0.138 0.2 291 107 362 103 0.055
3/16 0.138 0.5 240 109 295 105 0.055
1/4 0.138 0.5 142 112 181 111 0.059
5/16 0.138 0.5 90 113 110 114 0.063
3/8 0.083 0.157 0.8 59 116 75 116 0.075
1/2 0.197 1.2 39 121 51 120 0.071
5/8 0.197 1.4 28 125 30 126 0.079
3/4 19 129 22 127 0.083
Edge start
1 12 136 15 130 0.083
Aluminum
1/8 0.138 0.1 315 113 370 110 0.063
3/16 0.138 0.2 256 116 315 115 0.063
1/4 0.157 0.5 150 118 193 120 0.063
5/16 0.197 0.5 102 120 138 120 0.067
3/8 0.083 0.236 0.5 75 124 98 121 0.079
1/2 0.276 0.7 57 128 75 123 0.083
5/8 0.276 1 37 134 47 129 0.091
3/4 24 138 35 133 0.083
Edge start
1 15 141 21 138 0.083

61
20 Cut charts for mechanized cutting EX-TRAFIRE®105HD

20.6 100–105 A cutting, shielded, with compressed air

Recommended speed:
Speeds adjusted for cutting capacity do not necessarily represent
maximum speeds. They are the speeds that must be achieved for the
specified material thickness.
Maximum speed:
The maximum cutting speeds are the result of in-depth laboratory testing.
Actual cutting speeds may vary due to different cutting applications.
Configuration without shield:
If consumables are used without a shield, either the torch must be manually
adjusted to the working height, or the arc voltage control (AVC) settings
must be selected to achieve the desired cutting quality.
Distance of torch to workpiece for configuration without shield = distance
of nozzle to workpiece 0.18 in (+4.55 mm).

62
EX-TRAFIRE®105HD 20 Cut charts for mechanized cutting

20.6.1 100–105 A cutting, shielded, with compressed air

Material Cut height Pierce Pierce Recommended speed Maximum speed Kerf
thickness (shield to height delay time width
Settings for Standard quality
work cut (shield to
highest quality settings
height) workpiece
height) Cutting speed Voltage Cutting speed Voltage
[in] [in] [in] [Seconds] [ipm] [Volts] [ipm] [Volts] [in]
Mild steel
1/4 0.252 0.3 161 141 201 143 0.075
5/16 0.252 0.4 126 142 153 142 0.091
3/8 0.252 0.4 89 146 110 147 0.091
1/2 0.252 0.5 66 146 78 145 0.098
5/8 0.252 1 42 150 52 147 0.102
0.126
3/4 0.252 1 31 153 37 151 0.106
1 22 154 23 152 0.118
1-1/8 14 162 16 162 0.118
Edge start
1-1/4 11 162 13 162 0.118
1-1/2 8 170 8 172 0.118
Stainless steel
1/4 0.252 0.3 189 137 236 136 0.071
5/16 0.252 0.4 118 138 142 137 0.079
3/8 0.252 0.5 83 140 98 140 0.079
1/2 0.252 0.5 57 142 73 141 0.079
5/8 0.126 0.252 1 36 146 42 147 0.083
3/4 0.276 2 24 152 31 150 0.094
1 19 156 21 152 0.098
1-1/8 Edge start 12 161 14 160 0.098
1-1/4 11 161 12 159 0.098
Aluminum
1/4 0.252 0.3 235 143 279 145 0.079
5/16 0.252 0.4 164 139 198 147 0.079
3/8 0.252 0.4 104 150 129 145 0.087
1/2 0.252 0.5 75 149 96 149 0.091
5/8 0.126 0.252 0.5 51 154 65 150 0.091
3/4 0.295 1 40 158 47 150 0.087
1 26 163 31 161 0.091
1-1/8 Edge start 17 169 22 167 0.106
1-1/4 13 171 19 169 0.106

63
20 Cut charts for mechanized cutting EX-TRAFIRE®105HD

20.7 40–45 A cutting, SmoothLine, shielded, with compressed air

Recommended speed:
Speeds adjusted for cutting capacity do not necessarily represent
maximum speeds. They are the speeds that must be achieved for the
specified material thickness.
Maximum speed:
The maximum cutting speeds are the result of in-depth laboratory testing.
Actual cutting speeds may vary due to different cutting applications.
Configuration without shield:
If consumables are used without a shield, either the torch must be manually
adjusted to the working height, or the arc voltage control (AVC) settings
must be selected to achieve the desired cutting quality.
Distance of torch to workpiece for configuration without shield = distance
of nozzle to workpiece 0.08 in (+2.15 mm).

64
EX-TRAFIRE®105HD 20 Cut charts for mechanized cutting

20.7.1 40–45 A cutting, SmoothLine, shielded, with compressed air

EX-5-415-050

EX-5-422-050

EX-5-410-050 EX-5-401-051 EX-5-404-051

EX-5-415-052

EX-5-423-001

Material Cut height Pierce Pierce Recommended speed Kerf width Power supply
thickness (shield to height delay time Settings for highest
work cut (shield to
quality
height) workpiece
height) Cutting speed Voltage
[in] [in] [in] [Seconds] [ipm] [Volts] [in] [A]
Mild steel
26 GA 0.118 0 325 76 0.028
24 GA 0.118 0 325 76 0.028 40
22 GA 0.118 0.1 325 76 0.028
20 GA 0.118 0.2 325 76 0.028
0.079
16 GA 0.118 0.4 252 76 0.037
45
14 GA 0.118 0.4 189 80 0.039
12 GA 108 83 0.049
Edge start
3/16 75 85 0.053
Stainless steel
26 GA 0.118 0 325 70 0.026
24 GA 0.118 0 325 70 0.026 40
22 GA 0.118 0.1 325 70 0.026
20 GA 0.118 0.15 325 70 0.028
0.079
16 GA 0.118 0.4 242 75 0.028
14 GA 0.118 0.4 170 82 0.035 45
12 GA 82 94 0.043
Edge start
3/16 35 94 0.043

65
20 Cut charts for mechanized cutting EX-TRAFIRE®105HD

20.8 Marking, shielded, with compressed air or argon

With compressed air

Marking Power Cut height Initial Delay Marking Arc voltage Kerf Kerf
supply (shield to marking speed width depth
work cut height
height)
[Amps] [in] [in] [Seconds] [ipm] [Volts] [in] [in]
Mild steel
Low 10 0.252 0.252 0 100 127 0.055 <0.001
High 10 0.181 0.181 0 100 109 0.064 0.001
Stainless steel
Low 10 0.201 0.201 0 200 116 0.077 0.001
High 10 0.252 0.252 0 125 128 0.090 0.002
Aluminum
11 0.039 0.039 0 200 80 0.036 <0.001

With argon
Mild steel
Marking Power Cut height Initial Delay Marking Arc voltage Kerf Kerf
supply (shield to marking speed width depth
work cut height
height)
[Amps] [in] [in] [Seconds] [ipm.] [Volts] [in] [in]
Low 10 0.079 0.079 0 125 41 0.064 <0.001
High 15 0.059 0.059 0 125 41 0.047 <0.001
Stainless steel
Low 12 0.098 0.098 0 125 43 0.055 <0.001
High 15 0.098 0.098 0 100 43 0.059 <0.001
Aluminum
16 0.020 0.020 0 175 39 0.024 <0.001

66
EX-TRAFIRE®105HD 21 Appendix

21 Appendix

21.1 Connecting the optional CNC interface

The optional CNC interface plug installs onto the rear panel of the
EX-TRAFIRE®105HD. Control signals can be transmitted via the CNC
interface. For signal types see table 27. Control elements are located on
the control panel. Connections are on the front and rear of the power
supply.
 4.1 Assembly and use on page 11

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.
 Use Lock-out/Tag-out according to local regulations.

Fig. 10 Signal and pin assignment for CNC interface

3 5

6 4

14 12

13

Table 27 Signal and pin assignment

Signal START Arc Ground Voltage divider
Start plasma Start machine
cutting motion
Type Input Output Ground Output
Notice Open by default. Open by default. Reduced arc signal:
Requires potential- Potential-free with 20:1
free contact to max. capacity of: 21.1:1
close. 120 V AC/1 A 30:1
40:1
50:1
(supplies max. 18 V)
PIN 3, 4 12, 14 13 6 (+), 5 (−)
Internal cable color White, white Yellow, yellow Green 6 (red), 5 (black)

67
21 Appendix EX-TRAFIRE®105HD

21.1.1 Setting the voltage divider DIP switches

The voltage divider DIP switches are preset to 50:1.
 Turn off the EX-TRAFIRE®105HD and unplug the power supply prior to
opening the housing.
1 The housing must be opened only by a certified electrician or trained
personnel.
2 The voltage divider DIP switches must be set only by a certified
electrician or trained personnel.
Fig. 11 Voltage divider DIP switch settings

21.1.2 Enabling the external DC coil with an external power supply

 For 24 V DC, use a 1N4007 diode.
Fig. 12 Enable the external DC coil with an external power supply.

24 V DC
Use diode
1N4007 if the
voltage is
24 V DC.

68
EX-TRAFIRE®105HD 21 Appendix

21.1.3 Enabling the external AC coil with an external power supply

Fig. 13 Enable the external AC coil with an external power supply.

24 V AC
230 V AC

21.1.4 Enabling the industrially insulated module with

an external power supply
Industrial insulated user module with 24 V DC power supply.

1 Switch off the EX-TRAFIRE®105HD.

2 Remove the interface cover.
3 Connect the interface cable with the
cutting power supply.

Insulated
module

69
ADDRESSES AND CONTACTS
AMERICA

USA and Canada Mexico

THERMACUT, Inc. BINZEL MEXICO S.A. de C.V.
153 Charlestown Road C. Municipio de Tepezalá No. 109
Claremont, NH 03743 de Arteaga No. 102
Tel.: +1 (800) 932-8312 Valle de Ags., C.P. 20358
+1 (603) 543-0585 San Fco. de los Romo, Ags.
Fax: +1 (800) 972-6255 Tel.: +52 (449) 973-0116 Ext. 115
+1 (603) 542-2867 +52 (449) 220 6260
E-mail: sales@thermacut.us Fax: +52 (449) 9731388
www.thermacut.us E-mail: info@thermacut.com.mx
www.thermacut.com.mx

BRAZIL
BINZEL DO BRAZIL INDUSTRIAL Ltda
Estrada Uniao e Indústria,
Km 15,5 -Lt 17
Pedro do Rio,
Petrópolis – Rio de Janeiro,
CEP 25750-226
Tel.: +55 (24) 2222-9799
+55 (24) 2222-9789
+(24) 98134-2676
Fax: +55 (24) 2222-9789
E-mail: thermacut@thermacut.com.br
www.thermacut.com.br
Revision history
You can find the latest version of the operating manual on our website:
www.thermacut.us

Revision R1/10_2022
Revision 2/02_2023
— 4.2 „Technical data“ – Maximum input power changed to 23.8 kVA
Revision 3/2023
— 6.3.1 “Connecting the single-phase machine” – Connection
procedure clarified
— 6.3.2 “Connecting the three-phase machine” – Connection procedure
clarified
— Chapter “CNC connection” converted into appendix.

Revision 4/07_2023
— 1.2 “Identification plate” – Location changed
— 4.2 “Technical data - tables 2, 3, 5, and 6” – Content adjusted; new
layout; torch dimensions added
— 6.3 “Connecting the power supply cable” – Chapters 6.3.1 and 6.3.2
(Connections of the power supply), and 6.4.1. (Connection to a
generator) changed
— 6.4.1 “Connection to a generator” – Output current changed
 EX-5-902-007/N-23446 • 2024-01-31

© Copyright 2022 Thermacut Inc.,

Subject to change without a notice.
All Rights Reserved.