Plasma Cutting Products - HyperthermHiFocus neo – Precise and efficient Plasma Cutting HiFocus neo...

www.kjellberg.de

Made in Germany

Plasma Cutting Products

Pioneers in Plasma Cutting since 1959

for each Task the optimum System

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3D plasma cutting2D plasma cutting

Contour Cut Underwater plasma

Marking Manual plasma cutting

Kjellberg Finsterwalde – a company with long tradition – offers a wide range of products for CNC-guided and manual plasma cutting that fit different demands and requirements.

With products made in Germany users obtain not only state-of-the-art equipment but also the latest plasma cutting technology:

• HiFocus neo series with Contour Cut technology• FineFocus series• 3D plasma cutting with robots• CutFire series• PA-S series• CUTi series• Additional Equipment

neo: high speed, best quality, long lifetime, low costs

Plasma Cutting Technology made in Germany

High cutting speed and best quality are no contradiction with plasma cutting units from Kjellberg Finsterwalde.

Further: neo offers long-living consumables, optimised technology and low gas consumption as well as reduced cutting costs and increased productivity.

neo: new – efficient – original Contour Cut – Precision in Detail

Contour Cut stands for the precise cuttingof mild steel. When cutting small contours,narrow bars and small holes with a diameter to thickness ratio of 1:1 an outstanding cut quality is 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.

new – efficient – original

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HiFocus 280i neo, HiFocus 360i neo, HiFocus 440i neo

For frequently changing cutting tasks, like cutting different materials or a wide range of material thicknesses, HiFocus neo is the perfect solution.

Cutting Ranges HiFocusCutting Current

Material thickness in mm

80 A

130 A

160 A

280 A

360 A

440 A

600 A

Mild steelStainless Steel

Recommended cutting range (1) Max. cutting range (2) Piercing (1), (2)

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

(1) These data are depending on the materials to be cut and their compositions. (2) Observe piercing capability.

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 Hz

Fuse, slow 25 A 50 A 50 A 100 A 125 A 200 A 125 A + 134 A

Connected load, max.

17 kVA 32 kVA 28 kVA 67 kVA 87 kVA 127 kVA 87 kVA + 93 kVA

Cutting current 100 % duty cycle

80 A 130 A 160 A 280 A 360 A 440 A 600 A

Marking current - 16 A 5-25 A 5-50 A 5-50 A 5-50 A 5-50 A

Dimensions (L x W x H)

970 x 510 x 970 mm

960 x 540 x 1050 mm

985 x 570 x 1140 mm

1030 x 680 x 1450 mm

1030 x 680 x 1450 mm

1030 x 680 x 1450 mm

2 x 1030 x 680 x 1450 mm

Mass 161 kg 251 kg 206 kg 505 kg 517 kg 589 kg 517 kg + 510 kg

Plasma gases O2, N2 O2, Ar, H2, N2 O2, Ar, H2, N2 O2, Ar, H2, F5 (4) O2, Ar, H2, F5 (4) O2, Ar, H2, F5 (4) O2, Ar, H2, F5 (4)

Marking gases - Ar Ar Ar Ar Ar Ar

Swirl gases O2, N2, Air, F5 (4) O2, N2, Air, F5 (4) O2, N2, Air, F5 (4) O2, N2, Air O2, N2, Air O2, N2, Air O2, N2, Air(3) Other voltages and frequencies on request (4) Forming gas F5 (95% N2/5% H2)

(5) Consisting of HiFocus 360i neo and PowerModul HiFocus 600i neo

HiFocus 600i neo

HiFocus 440i neo

HiFocus 360i neo

HiFocus 280i neo

HiFocus 161i neo

HiFocus 130 neo

HiFocus 80i

HiFocus neo – Precise and efficient Plasma Cutting

HiFocus neo systems offer a higher level of performance. Users benefit from an excel-lent cutting and marking quality. Moreover, high cutting speeds improve productivity and lower process costs.

With cutting currents of maximum 600 A the HiFocus neo series covers a cutting range from 0.5 mm to 160 mm.

All HiFocus neo systems can be used in combi-nation with all CNC-guiding and robot systems in the market.

In addition to straight, contour and bevel cuts up to 50°, the plasma cutting systems HiFocus 130 neo, HiFocus 161i neo, HiFocus 280i neo, HiFocus 360i neo, HiFocus 440i neo and HiFocus 600i neo can also be used for marking, notching and punching.

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The automatic torch changing unit ATChangerallows the automated change of plasma torchheads. Based on the quick-change systemused for Kjellberg plasma torches. ATChanger offers the following advantages:• Almost fully automated controll of the cutting

system• Increase of productivity due to reduced down-

times• Equipping of system with up to eight torch-

heads with consumables for constant or different cutting tasks

• Quick change between highest cutting output and finest marking possible

Flow Control – Automatic Adjustment of Plasma and Swirl Gases

ATChanger changing a plasmatorch

The optimum gas mixture and the volume flow play an essential role in order to achieve a high cut quality. Kjellberg Finsterwalde offers a flow-controlled plasma gas control unit for the automatic adjustment of plasma and swirl gases.

Automatic Plasma Gas Unit FlowControl for HiFocus

The settings for different materials and material thicknesses can be accessed and used from the factory-adjusted cutting database. Speci-fic or modified data can be saved in a special customer database. The FlowControl can also be installed in existing guiding systemswithout database capabilities.

The settings for different materials and material thicknesses can be accessed and used from the provided cutting database. Specific or mo-dified data can be saved in a special customer database. The FlowControl can also be instal-led in existing guiding systems without databa-se capabilities.

The FlowControl can be controlled by a serial interface and can be used for HiFocus neo systems from HiFocus 130 neo to HiFocus 600i neo – also for marking.

ATChanger offers space for up to eight plasmatorches

ATChanger – Automatic Torch Changing Unit

The ATChanger can be installed in 2D and 3D guiding systems. It can be used for HiFocus 280i neo, HiFocus 360i neo and HiFocus 440i neo – also as retrofit.

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FineFocus – For the upper Cutting Range

Cutting Current


130 A

200 A

300 A

20 40 60 80 100 120 160

FineFocus 450

FineFocus 600

FineFocus 800

Cutting Ranges FineFocus


Technical Data FineFocusPower source FineFocus 450 FineFocus 600 FineFocus 800

Mains voltage (3) 3x 400 V, 50 Hz

Fuse, slow 50 A 100 A 125 A

Connected load, max. 34 kVA 60 kVA 83 kVA

Cutting current 100 % duty cycle 100 A (130 A at 75 % ED) 200 A 300 A

Mass 1025 x 711 x 970 mm 980 x 644 x 1320 mm 1370 x 870 x 1505 mm

Dimensions (L x W x H) 251 kg 370 kg 556 kg

Plasma gases O2, Air, Ar, H2, N2 O2, Air, Ar, H2 O2, Air, Ar, H2

Swirl gases Air, N2 Air, N2 Air, N2

(3) Other voltages and frequencies on request

The FineFocus 800 can be modified quickly and easily for applying the HotWire technology for cutting electrically conductive, non-conducti-ve, combined and interrupted materials.

FineFocus 800, FineFocus 600, FineFocus 450

The robust systems of the FineFocus series offer high performance even under extreme condi-tions. Good cut qualities can be achieved even under heavy load. Besides of technical gases, it is also possible to cut with air and achive high quality.

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.

Due 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.

HotWire: patented and unique

HotWire

Quality cutting of gratings


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Robot-Guided Plasma Cutting

Plasma cutting of a pipe

Plasma cutting of open profile

Plasma cutting of a closed profile

All systems of the HiFocus neo series and the FineFocus 800 can be used in combination with all robotsystems in the market. Diverse types of work-pieces can be cut with robot systems:

• Structural components for vehicles• Pipes and containers• Hollow profiles, open and closed profiles as

well as bulb flat profiles• Dished bottoms

Robot-guided plasma cutting offers the follo-wing advantages:• Cost-efficient cutting• Simple programming• High cutting speeds• High cut quality, almost no rework required• High flexibility in application

Torches for Every TaskFor all plasma cutting systems, we offer plasma torches that can be used in combination with robots, partly different designs:• Straight version with 60° angled torch head• Straight version with 90° angled torch head• With quick-change head

Kjellberg plasma torches can be used for bevel cutting up to 50°, with special torches up to 60°.

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PA-S70 W, PA-S45 W

Plasma gouging

Plasma gouging does not require after-treatment and produces less smoke compared to gouging with carbon electrodes.

Cutting Ranges PA-SCutting Current


130 A

240 A

10 20 30 40 50 60 70

PA-S45 W

PA-S70 W

Power source PA-S45 W PA-S70 W

Mains voltage (3) 3 x 400 V, 50 Hz

Fuse, slow 63 A 125 A

Connected load, max. 38 kVA 76 kVA

Cutting current 45 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 mm

Mass 240 kg 460 kg

(3) Other voltages and frequencies on request

Technical Data PA-S

Both the machine and hand torches can be quickly converted for plasma gouging. Plasma gouging is ideal for eliminating welding defects, cracks, cavities and inclusions for preparing for backwelding.

PA-S – Plasma Cutting with Machine and Hand Torches

The PA-S series is based on conventional step-switched power sources which are ideally suited for automated cutting tasks with machine torches in combination with 2D guiding systems and 3D robots, but also for manual use with hand torches.

We offer straight standard torches and specialtorches with short shafts as well as torches with a 60° or 90° angled torch head.

Further advantages are:• Good quality of both cut surfaces• High lifetime of consumables due to direct

liquid cooling It is possible to perform contour and straight cuts as well as bevel cuts up to 60° and inter-rupted cuts 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.



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CutFire – Starting Technique for Metal Construction

Cutting on guided system with CutFire

For simple automated cutting tasks Kjellberg Finsterwalde offers the easy-to-use plasma cut-ting inverters CutFire 100i and CutFire 65i with low investment costs. They are preferable used for mild steel up to 20 mm.

The inverters can be used in combination with CNC guiding systems and other automatic guiding systems to perform straight and contour cuts.

Typical fields of application are the metalwor-king industry and many other workshops,production plants and industrial enterprises.

Cutting Ranges CutFireCutting Current


65 A

100 A

Recommended cutting range (1) Max. cutting range (2)

Piercing (1), (2)

CutFire 65i

CutFire 100i


Power source CutFire 65i CutFire 100i


Fuse, slow 16 A 25 A

Connected load, max. 9.8 kVA 16.6 kVA

Cutting current 65 A at 35 % d.c.150A at 100 % d.c.

100 A at 100 % d.c.

Mass 470 x 180 x 270 mm 710 x 280 x 590 mm

Dimensions (L x W x H) 17 kg 50 kg

Plasma gases Air(3) Other voltages and frequencies on request

Technical Data CutFire

CutFire 100i, CutFire 65i

The CutFire inverters work cost-saving and safe due to:• Using air as plasma gas• Low costs for consumables• Safe high-voltage ignition• Stepless adjustment of cutting current

The CutFire 65i can be used for mechanised as well as manual plasma cutting by simply changing the torch.

10 20 30

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FineMarker – Separate Plasma Marking Unit

The FineMarker is a separate unit for marking, notching and punching tasks on unalloyed steels, stainless steels and semi-finished pro-ducts, e.g. sheets, pipes, profiles, circuit boards and others.

The FineMarker makes it possible to mark com-ponents with simple annealing colours or deep notches and punches.

Penetration depth and line width are determined by marking current, speed and the chosen marking gas.

FineMarker

Plasma marking

Height Control Units Make the Cutting Process Safe

Power source FineMarker


Fuse, slow 10 A

Connected load, max. 5.2 kVA

Cutting current 25 A

Mass 710 x 400 x 440 mm

Dimensions (L x W x H) 30 kg

Marking gas Ar(3) Other voltages and frequencies on request

Technical Data FineMarker

The FineMarker is well suited to supple-ment existing oxy-fuel or plasma cutting systems and can be controlled from the guiding system via interface.

It is crucial for a safe cutting process and the quality of the cutting results to keep a constant distance between torch and work-piece and to lift the torch during piercing.

In addition to the simple, cost-efficient height control unit for simple cutting applications, Kjellberg Finsterwalde offers other data-base-supported and bus-compatible, fully automated control units for highest demands regarding automated cutting processes.

It is possible to update existing cutting machines by retrofitting a height control unit.

Height control KHC 4 Height control B 1000

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CUTi – Manual Plasma Cutting Inverters

The CUTi series offers powerful lightweights with high reliability for the flexible and mobile use at construction sites and in workshops. They are suitable for environments with increa-sed hazard of electric shock.

The CUTi-inverters can be used for straight, profile an contour cutting in all positions.

Cutting Ranges CUTiCutting current


35 A

35 A

70 A

90 A

120 A

10 20 30 40 50

CUTi 35C

CUTi 35

CUTi 70

CUTi 90

CUTi 120

Recommended cutting range (1) Max. cutting range (1)

Power source CUTi 35C CUTi 35 CUTi 70 CUTi 90 CUTi 120

Mains voltage 1 x 230 V 1 x 230 V 3 x 400 V 3 x 400 V 3 x 400 V

Fuse, slow 16 A 16 A 16 A 25 A 32 A

Connected load, max. 3.3 [4,8 (2)] kVA 3.7 kVA 11.1 kVA 15 kVA 16.7 kVA

Cutting current 100 % d.c. 12–25 [35 (2)] A 5–35 A 26–70 A 26–90 A 25–120 A

Duty cycle 25 % I 35 A35 % I 25 A

100 % I 20 A

40 % I 35 A60 % I 28 A

100 % I 22 A

35 % I 70 A60 % I 60 A

100 % I 50 A

40 % I 90 A60 % I 74 A

100 % I 55 A

35 % I 120 A60 % I 95 A

100 % I 80 A

Dimensions (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 mm

Mass 12.5 kg 10 kg 16.4 kg 17 kg 28.5 kg

Plasma gas Air

Technical Data CUTi

The CUTi 35C takes a special position: It has an internal compressor and can therefore be operated without external compressed air supply for cutting a maximal material thickness of six mm. With compressed air supply with material thicknesses up to ten mm can be cut.

Bevelling cap Long consumables

Circle cutting device Template cuts

Accessories

A large variety of accessories is available for the flexible use of the CUTi units.

CUTi series stands for mobility in practice

CUTi 35, CUTi 35C, CUTi 70, CUTi 90, CUTi 120

(1) These data are depending on the materials to be cut and their compositions.

(2) With external compressed air supply

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Tradition determines Identity, Character and Profil of an Enterprise

1922

1934

1936

1941

1959

1962

1970

1975

1986

1988

1991

1995

1998

2000

2004

2006

2007

2008

2010

2011

2013

Foundation of Kjellberg Elektro-Maschinen GmbH

First welding technique from Finsterwalde

Kjellberg is Europe's biggest manufacturer of arc welding technique

Kjellberg is the world's biggest manufacturer of arc welding technique with 5,000 employees

Year of birth of Kjellberg Finsterwalde plasma technology

First use of an industrial plasma cutting system with 50 kW ready for series production

Patent for fine focus plasma cutting in cooperation with the institute “Manfred von Ardenne” in Dresden

First use of air as carrying gas for plasma cutting

Kjellberg systems conquer the Japanese shipbuilding industry

Beginning of the underwater plasma cutting technology

First primary-switched inverter – the plasma cutting system PA-12 I

Innovative new developments in the product range and a new distribution system are the basis for the company's reorganisation

Consumables of the XL-Life system increase the lifetime for plasma cutting with oxygen

Introduction of the swirl gas technology for fine focus plasma cutting

HiFocus® – a new technology with laser-like cut quality – conquers the market

Very first flow-controlled automatic plasma gas sup-ply unit worldwide – a big step towards a new dimen-sion of quality and reproducibility of plasma cuts

HiFocus 80i/160i/280i/360i make up the first com-plete series with primary-switched inverter technology

Introduction of new YellowXLife® generation of consumables

High flexibility with the new HiFocus 440i – at the present time the most powerful highprecision plasma cutting system worldwide

Development of the new generation of plasma torches PerCut 440/450 and PerCut 200/210 with new consumables

Introduction of the new plasma cutting technology-Contour Cut®

Generation HiFocus neo and copper cathodes make plasma cutting more efficient

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Plasma Cutting Technology made in Germany

Munich

Kjellberg-plasma cutting units are CE-conform and correspond with the valid guidelines and instructions of the European Union. They are developed and fabricated on basis of the standard EN 60974 (VDE 0544). The plasma cutting units are labelled with the S-sign and therefore applicable to environments with increased hazard of electric shock. The fabrication takes place according to DIN EN ISO 9001. The factory-owned quality assurance comprises piece and cutting performance tests, documented by test certificate.

Our products represent a high level of quality and reliability. We reserve the rights to change design and/or technical specification during the series fabricati-on. Claims of any kind cannot be derived from this brochure.

, , , YellowXLife, XL, HiFocus, PGC, PerCut CUTi und Contour Cut are trademarks of the Kjellberg Foundation/Kjellberg Finsterwalde and may be registered in Germany and/or other countries.

Copyright © 2013 Kjellberg Finsterwalde Plasma und Maschinen GmbH. All rights reserved.

Kjellberg Finsterwalde Plasma und Maschinen GmbHOscar-Kjellberg-Str. 20 | 03238 Finsterwalde | GermanyPhone: +49 3531 500-0 | Fax: +49 3531 500-8510 [email protected] | www.kjellberg.de

Kjellberg Finsterwalde Group Welding Electrodes Welding EquipmentCutting Equipment Mechanical Engineering

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Plasma Cutting Products - HyperthermHiFocus neo – Precise and efficient Plasma Cutting HiFocus neo...

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