Plasma Cutting Products - Kjellberg Finsterwalde

Plasma Cutting Productsfor each Task the optimum SystemMade in GermanyPioneers in Plasma Cutting since 1959www.kjellberg.de

Plasma Cutting Technology made in GermanyKjellberg Finsterwalde – a company with longtradition – offers a wide range of products forCNC-guided and manual plasma cutting that fitdifferent demands and requirements.With products made in Germany users obtainnot only state-of-the-art equipment but also thelatest plasma cutting technology:2D plasma cutting3D plasma cutting• HiFocus neo series with Contour Cut technology• FineFocus series• 3D plasma cutting with robots• CutFire series• PA-S series• CUTi series• Additional EquipmentContour CutUnderwater plasmaMarkingManual plasma cuttingneo: new – efficient – originalContour Cut – Precision in Detailneo: high speed, best quality, long lifetime, low costsHigh cutting speed and best quality are nocontradiction with plasma cutting units fromKjellberg Finsterwalde.Further: neo offers long-living consumables,optimised technology and low gas consumptionas well as reduced cutting costs and increasedproductivity.new – efficient – original- 2 -Contour Cut stands for the precise cuttingof mild steel. When cutting small contours,narrow bars and small holes with a diameter tothickness ratio of 1:1 an outstanding cut qualityis achieved.Smooth cut surfaces and shar p cut edgesreduce time-consuming aftertreatment.Thus, productivity increases while costs arereduced.With Contour Cut Speed contours can becut at similar quality up to 50 % faster. Dueto the shorter processing time the costs percutting metre are reduced.

HiFocus neo – Precise and efficient Plasma CuttingHiFocus neo systems offer a higher level ofperformance. Users benefit from an excellentcutting and marking quality. Moreover, highcutting speeds improve productivity and lowerprocess costs.With cutting currents of maximum 600 A theHiFocus neo series covers a cutting range from0.5 mm to 160 mm.All HiFocus neo systems can be used in combinationwith all CNC-guiding and robot systemsin the market.In addition to straight, contour and bevel cutsup to 50°, the plasma cutting systemsHiFocus 130 neo, HiFocus 161i neo, HiFocus280i neo, HiFocus 360i neo, HiFocus 440i neoand HiFocus 600i neo can also be used formarking, notching and punching.HiFocus 280i neo, HiFocus 360i neo, HiFocus 440i neoFor frequently changing cutting tasks, likecutting different materials or a wide range ofmaterial thicknesses, HiFocus neo is the perfectsolution.Cutting Ranges HiFocusCuttingCurrentMaterial thickness in mm10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 16080 A130 A160 A280 A360 A440 A600 AHiFocus 80iHiFocus 130 neoHiFocus 161i neoHiFocus 280i neoHiFocus 360i neoMild steelStainless SteelHiFocus 440i neoHiFocus 600i neoRecommended cutting range (1) Max. cutting range (2) Piercing(1)These data are depending on the materials to be cut and their compositions.(2)Observe piercing capability.(1), (2)Technical Data HiFocusPower source HiFocus 80i HiFocus 130 neo HiFocus 161i neo HiFocus 280i neo HiFocus 360i neo HiFocus 440i neo HiFocus 600i neo (5)Mains voltage (3) 3x 400 V, 50 Hz 2x 3x 400 V, 50 HzFuse, slow 25 A 50 A 50 A 100 A 125 A 200 A 125 A + 134 AConnected load,max.Cutting current100 % duty cycle17 kVA 32 kVA 28 kVA 67 kVA 87 kVA 127 kVA 87 kVA + 93 kVA80 A 130 A 160 A 280 A 360 A 440 A 600 AMarking current - 16 A 5-25 A 5-50 A 5-50 A 5-50 A 5-50 ADimensions(L x W x H)970 x 510 x970 mm960 x 540 x1050 mm985 x 570 x1140 mm1030 x 680 x1450 mm1030 x 680 x1450 mm1030 x 680 x1450 mm2 x 1030 x 680 x1450 mmMass 161 kg 251 kg 206 kg 505 kg 517 kg 589 kg 517 kg + 510 kgPlasma gases O 2, N 2O 2, Ar, H 2, N 2O 2, Ar, H 2, N 2O 2, Ar, H 2, F5 (4) O 2, Ar, H 2, F5 (4) O 2, Ar, H 2, F5 (4) O 2, Ar, H 2, F5 (4)Marking gases - Ar Ar Ar Ar Ar ArSwirl gases O 2, N 2, Air, F5 (4) O 2, N 2, Air, F5 (4) O 2, N 2, Air, F5 (4) O 2, N 2, Air O 2, N 2, Air O 2, N 2, Air O 2, N 2, Air(3)Other voltages and frequencies on request(4)Forming gas F5 (95% N 2/5% H 2)(5)Consisting of HiFocus 360i neo and PowerModul HiFocus 600i neo- 3 -

Flow Control – Automatic Adjustment of Plasma and Swirl GasesThe settings for different materials and materialthicknesses can be accessed and used fromthe factory-adjusted cutting database. Specificor modified data can be saved in a specialcustomer database. The FlowControl can alsobe installed in existing guiding systemswithout database capabilities.Automatic Plasma Gas Unit FlowControl for HiFocusThe optimum gas mixture and the volume flowplay an essential role in order to achieve ahigh cut quality. Kjellberg Finsterwalde offersa flow-controlled plasma gas control unit forthe automatic adjustment of plasma and swirlgases.The settings for different materials and materialthicknesses can be accessed and used fromthe provided cutting database. Specific or modifieddata can be saved in a special customerdatabase. The FlowControl can also be installedin existing guiding systems without databasecapabilities.The FlowControl can be controlled by a serialinterface and can be used for HiFocus neosystems from HiFocus 130 neo to HiFocus 600ineo – also for marking.ATChanger – Automatic Torch Changing UnitATChanger changing a plasmatorchThe automatic torch changing unit ATChangerallows the automated change of plasma torchheads. Based on the quick-change systemused for Kjellberg plasma torches. ATChangeroffers the following advantages:• Almost fully automated controll of the cuttingsystem• Increase of productivity due to reduced downtimes• Equipping of system with up to eight torchheadswith consumables for constant ordifferent cutting tasks• Quick change between highest cutting outputand finest marking possibleATChanger offers space for up to eight plasmatorchesThe ATChanger can be installed in 2D and3D guiding systems. It can be used forHiFocus 280i neo, HiFocus 360i neo andHiFocus 440i neo – also as retrofit.- 4 -

FineFocus – For the upper Cutting RangeThe robust systems of the FineFocus series offerhigh performance even under extreme conditions.Good cut qualities can be achieved evenunder heavy load. Besides of technical gases,it is also possible to cut with air and achive highquality.The FineFocus 800 is the most powerful systemof the series. Two of them connected in parallelmake the FineFocus 1600 which achieveshighest cutting performance. Furthermore, boththe FineFocus 800 and the FineFocus 1600 canbe used for underwater plasma cutting.FineFocus 800, FineFocus 600, FineFocus 450Due to their attractive price-performance ratio,the FineFocus systems are ideally suited for allmetal-working industries, e.g. steel and metalconstruction, shipbuilding or metal servicecentres.HotWireThe FineFocus 800 can be modified quicklyand easily for applying the HotWire technologyfor cutting electrically conductive, non-conductive,combined and interrupted materials.HotWire: patented anduniqueQuality cutting ofgratingsCutting Ranges FineFocusCuttingCurrentMaterial thickness in mm20 40 60 80 100 120 160130 A200 AFineFocus 450FineFocus 600300 AFineFocus 800Recommended cutting range (1) Max. cutting range (2) Piercing(1)These data are depending on the materials to be cut and their compositions.(2)Observe piercing capability.(1), (2)Technical Data FineFocusPower source FineFocus 450 FineFocus 600 FineFocus 800Mains voltage (3)3x 400 V, 50 HzFuse, slow 50 A 100 A 125 AConnected load, max. 34 kVA 60 kVA 83 kVACutting current 100 % duty cycle 100 A (130 A at 75 % ED) 200 A 300 AMass 1025 x 711 x 970 mm 980 x 644 x 1320 mm 1370 x 870 x 1505 mmDimensions (L x W x H) 251 kg 370 kg 556 kgPlasma gases O 2, Air, Ar, H 2, N 2O 2, Air, Ar, H 2O 2, Air, Ar, H 2Swirl gases Air, N 2Air, N 2Air, N 2(3)Other voltages and frequencies on request- 5 -

Robot-Guided Plasma CuttingAll systems of the HiFocus neo series and theFineFocus 800 can be used in combination withall robotsystems in the market. Diverse types ofwork-pieces can be cut with robot systems:• Structural components for vehicles• Pipes and containers• Hollow profiles, open and closed profiles aswell as bulb flat profiles• Dished bottomsPlasma cutting of a pipeRobot-guided plasma cutting offers the followingadvantages:• Cost-efficient cutting• Simple programming• High cutting speeds• High cut quality, almost no rework required• High flexibility in applicationPlasma cutting of open profileTorches for Every TaskFor all plasma cutting systems, we offer plasmatorches that can be used in combination withrobots, partly different designs:• Straight version with 60° angled torch head• Straight version with 90° angled torch head• With quick-change headPlasma cutting of a closed profileKjellberg plasma torches can be usedfor bevel cutting up to 50°, with specialtorches up to 60°.- 6 -

PA-S – Plasma Cutting with Machine and Hand TorchesThe PA-S series is based on conventionalstep-switched power sources which are ideallysuited for automated cutting tasks with machinetorches in combination with 2D guiding systemsand 3D robots, but also for manual use withhand torches.We offer straight standard torches and specialtorches with short shafts as well as torches witha 60° or 90° angled torch head.Further advantages are:• Good quality of both cut surfaces• High lifetime of consumables due to directliquid coolingIt is possible to perform contour and straightcuts as well as bevel cuts up to 60° and interruptedcuts in all 2D and 3D positions.A wide range of accessories is available for thehand torches which make it easy to performmany diverse cutting tasks.PA-S70 W, PA-S45 WPlasma gougingBoth the machine and hand torches can bequickly converted for plasma gouging. Plasmagouging is ideal for eliminating welding defects,cracks, cavities and inclusions for preparing forbackwelding.Plasma gouging does not require after-treatment and producesless smoke compared to gouging with carbon electrodes.Cutting Ranges PA-SCuttingCurrentMaterial thickness in mm10 20 30 40 50 60 70130 APA-S45 W240 APA-S70 WRecommended cutting range (1) Max. cutting range (2) Piercing(1)These data are depending on the materials to be cut and their compositions.(2)Observe piercing capability.(1), (2)Technical Data PA-SPower source PA-S45 W PA-S70 WMains voltage (3)3 x 400 V, 50 HzFuse, slow 63 A 125 AConnected load, max. 38 kVA 76 kVACutting current45 A at 100 % d.c.85 A at 100 % d.c.130 A at 60 % d.c.80 A at 100 % d.c.160 A at 100 % d.c.240 A at 80 % d.c.Dimensions (L x W x H) 1025 x 711 x 970 mm 1380 x 870 x 1080 mmMass 240 kg 460 kg(3)Other voltages and frequencies on request- 7 -

CutFire – Starting Technique for Metal ConstructionFor simple automated cutting tasks KjellbergFinsterwalde offers the easy-to-use plasma cuttinginverters CutFire 100i and CutFire 65i withlow investment costs. They are preferable usedfor mild steel up to 20 mm.The inverters can be used in combination withCNC guiding systems and other automatic guidingsystems to perform straight and contour cuts.Typical fields of application are the metalworkingindustry and many other workshops,production plants and industrial enterprises.CutFire 100i, CutFire 65iThe CutFire inverters work cost-saving andsafe due to:• Using air as plasma gas• Low costs for consumables• Safe high-voltage ignition• Stepless adjustment of cutting currentCutting on guided system with CutFireThe CutFire 65i can be used for mechanisedas well as manual plasma cutting by simplychanging the torch.Cutting Ranges CutFireCuttingCurrentMaterial thickness in mm10 20 3065 A65i100 ACutFire 100iCutFireRecommended cutting range (1) Max. cutting range (2)(1), (2)Piercing(1)These data are depending on the materials to be cut and their compositions.(2)Observe piercing capability.Technical Data CutFirePower source CutFire 65i CutFire 100iMains voltage (3)3 x 400 V, 50 HzFuse, slow 16 A 25 AConnected load, max. 9.8 kVA 16.6 kVACutting current65 A at 35 % d.c.100 A at 100 % d.c.150A at 100 % d.c.Mass 470 x 180 x 270 mm 710 x 280 x 590 mmDimensions (L x W x H) 17 kg 50 kgPlasma gasesAir(3)Other voltages and frequencies on request- 8 -

FineMarker – Separate Plasma Marking UnitThe FineMarker is a separate unit for marking,notching and punching tasks on unalloyedsteels, stainless steels and semi-finished products,e.g. sheets, pipes, profiles, circuit boardsand others.The FineMarker makes it possible to mark componentswith simple annealing colours or deepnotches and punches.Penetration depth and line width are determinedby marking current, speed and the chosenmarking gas.FineMarkerPlasma markingTechnical Data FineMarkerPower sourceMains voltage (3)Fuse, slowConnected load, max.Cutting currentMassDimensions (L x W x H)Marking gas(3)Other voltages and frequencies on requestFineMarker3 x 400 V, 50 Hz10 A5.2 kVA25 A710 x 400 x 440 mm30 kgArThe FineMarker is well suited to supplementexisting oxy-fuel or plasma cuttingsystems and can be controlled from theguiding system via interface.Height Control Units Make the Cutting Process SafeIt is crucial for a safe cutting process and thequality of the cutting results to keep a constantdistance between torch and work-piece andto lift the torch during piercing.In addition to the simple, cost-efficient heightcontrol unit for simple cutting applications,Kjellberg Finsterwalde offers other database-supportedand bus-compatible, fullyautomated control units for highest demandsregarding automated cutting processes.It is possible to update existing cuttingmachines by retrofitting a height control unit.Height control KHC 4 Height control B 1000- 9 -

CUTi – Manual Plasma Cutting InvertersThe CUTi series offers powerful lightweightswith high reliability for the flexible and mobileuse at construction sites and in workshops.They are suitable for environments with increasedhazard of electric shock.The CUTi-inverters can be used for straight,profile an contour cutting in all positions.CUTi 35, CUTi 35C, CUTi 70, CUTi 90, CUTi 120The CUTi 35C takes a special position: It hasan internal compressor and can therefore beoperated without external compressed air supplyfor cutting a maximal material thickness of sixmm. With compressed air supply with materialthicknesses up to ten mm can be cut.CUTi series stands for mobility in practiceAccessoriesA large variety of accessories is availablefor the flexible use of the CUTi units.Cutting Ranges CUTiBevelling capLong consumablesCuttingcurrentMaterial thickness in mm10 20 30 40 5035 ACUTi 35C35 ACUTi 3570 ACUTi 7090 ACUTi 90120 ACUTi 120Circle cutting deviceTemplate cutsRecommended cutting range (1) Max. cutting range (1)(1)These data are depending on the materials to be cut and their compositions.Technical Data CUTiPower source CUTi 35C CUTi 35 CUTi 70 CUTi 90 CUTi 120Mains voltage 1 x 230 V 1 x 230 V 3 x 400 V 3 x 400 V 3 x 400 VFuse, slow 16 A 16 A 16 A 25 A 32 AConnected load, max. 3.3 [4,8 (2) ] kVA 3.7 kVA 11.1 kVA 15 kVA 16.7 kVACutting current 100 % d.c. 12–25 [35 (2) ] A 5–35 A 26–70 A 26–90 A 25–120 ADuty cycle25 % I 35 A35 % I 25 A100 % I 20 A40 % I 35 A60 % I 28 A100 % I 22 A35 % I 70 A60 % I 60 A100 % I 50 A40 % I 90 A60 % I 74 A100 % I 55 A35 % I 120 A60 % I 95 A100 % I 80 ADimensions (L x W x H) 550 x 150 x 245 mm 480 x 150 x 225 mm 470 x 180 x 250 mm 470 x 180 x 270 mm 610 x 230 x 410 mmMass 12.5 kg 10 kg 16.4 kg 17 kg 28.5 kgPlasma gasAir(2)With external compressed air supply- 10 -

Tradition determines Identity, Character and Profil of an Enterprise192219341936194119591962197019751986198819911995199820002004200620072008201020112013Foundation of Kjellberg Elektro-Maschinen GmbHFirst welding technique from FinsterwaldeKjellberg is Europe's biggest manufacturer of arcwelding techniqueKjellberg is the world's biggest manufacturer of arcwelding technique with 5,000 employeesYear of birth of Kjellberg Finsterwalde plasma technologyFirst use of an industrial plasma cutting systemwith 50 kW ready for series productionPatent for fine focus plasma cutting in cooperationwith the institute “Manfred von Ardenne” in DresdenFirst use of air as carrying gas for plasma cuttingKjellberg systems conquer the Japaneseshipbuilding industryBeginning of the underwater plasma cuttingtechnologyFirst primary-switched inverter – the plasma cuttingsystem PA-12 IInnovative new developments in the product rangeand a new distribution system are the basis for thecompany's reorganisationConsumables of the XL-Life system increase thelifetime for plasma cutting with oxygenIntroduction of the swirl gas technology for finefocus plasma cuttingHiFocus® – a new technology with laser-like cutquality – conquers the marketVery first flow-controlled automatic plasma gas supplyunit worldwide – a big step towards a new dimensionof quality and reproducibility of plasma cutsHiFocus 80i/160i/280i/360i make up the first completeseries with primary-switched inverter technologyIntroduction of new YellowXLife® generation ofconsumablesHigh flexibility with the new HiFocus 440i – at thepresent time the most powerful highprecisionplasma cutting system worldwideDevelopment of the new generation of plasmatorches PerCut 440/450 and PerCut 200/210 withnew consumablesIntroduction of the new plasma cutting technology-Contour Cut®Generation HiFocus neo and copper cathodesmake plasma cutting more efficient- 11 -

Plasma Cutting Technology made in GermanyFRMunichKjellberg Finsterwalde GroupWelding ElectrodesWelding EquipmentCutting EquipmentMechanical EngineeringKjellberg-plasma cutting units are CE-conform and correspond with the validguidelines and instructions of the European Union. They are developed andfabricated on basis of the standard EN 60974 (VDE 0544). The plasma cuttingunits are labelled with the S-sign and therefore applicable to environments withincreased hazard of electric shock. The fabrication takes place according to DINEN ISO 9001. The factory-owned quality assurance comprises piece and cuttingperformance tests, documented by test certificate.Our products represent a high level of quality and reliability. We reserve therights to change design and/or technical specification during the series fabrication.Claims of any kind cannot be derived from this brochure.Kjellberg Finsterwalde Plasma und Maschinen GmbHOscar-Kjellberg-Str. 20 | 03238 Finsterwalde | GermanyPhone: +49 3531 500-0 | Fax: +49 3531 500-8510plasma@kjellberg.de | www.kjellberg.de, , , YellowXLife, XL, HiFocus, PGC, PerCutCUTi und Contour Cut are trademarks of the Kjellberg Foundation/KjellbergFinsterwalde and may be registered in Germany and/or other countries.Copyright © 2013 Kjellberg Finsterwalde Plasma und Maschinen GmbH.All rights reserved.13-11-01