Plasma Cutting Products for each Task the optimum System

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1 Plasma Cutting Products for each Task the optimum System Made in Germany Pioneers in Plasma Cutting since

2 Plasma Cutting Technology made in Germany 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: 2D plasma cutting 3D plasma cutting HiFocus neo series with Contour Cut technology FineFocus series 3D plasma cutting with robots CutFire series PA-S series CUTi series Additional Equipment Contour Cut Underwater plasma Marking Manual plasma cutting neo: new efficient original Contour Cut Precision in Detail neo: high speed, best quality, long lifetime, low costs 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. new efficient original Contour Cut stands for the precise cutting of 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 edges reduce time-consuming aftertreatment. Thus, productivity increases while costs are reduced. With Contour Cut Speed contours can be cut at similar quality up to 50 % faster. Due to the shorter processing time the costs per cutting metre are reduced.

3 HiFocus neo Precise and efficient Plasma Cutting HiFocus neo systems offer a higher level of performance. Users benefit from an excellent 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 combination 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. 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 HiFocus Cutting Current Material thickness in mm A 130 A 160 A 280 A 360 A 440 A 600 A HiFocus 80i HiFocus 130 neo HiFocus 161i neo HiFocus 280i neo HiFocus 360i neo Mild steel Stainless Steel HiFocus 440i neo HiFocus 600i neo Recommended 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 HiFocus Power 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 A Connected load, max. Cutting current 100 % duty cycle 17 kva 32 kva 28 kva 67 kva 87 kva 127 kva 87 kva + 93 kva 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 kg Plasma gases O 2 O 2, Ar, H 2 O 2, Ar, H 2 O 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 Ar Swirl gases O 2, Air, F5 (4) O 2, Air, F5 (4) O 2, Air, F5 (4) O 2, Air O 2, Air O 2, Air O 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 -

4 Flow Control Automatic Adjustment of Plasma and Swirl Gases The settings for different materials and material thicknesses can be accessed and used from the factory-adjusted cutting database. Specific or modified data can be saved in a special customer database. The FlowControl can also be installed in existing guiding systems without database capabilities. Automatic Plasma Gas Unit FlowControl for HiFocus 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. The settings for different materials and material thicknesses can be accessed and used from the provided cutting database. Specific or modified data can be saved in a special customer database. The FlowControl can also be installed in existing guiding systems without database 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 Automatic Torch Changing Unit ATChanger changing a plasmatorch The automatic torch changing unit ATChanger allows the automated change of plasma torch heads. Based on the quick-change system used for Kjellberg plasma torches. ATChanger offers the following advantages: Almost fully automated controll of the cutting system Increase of productivity due to reduced downtimes Equipping of system with up to eight torchheads with consumables for constant or different cutting tasks Quick change between highest cutting output and finest marking possible ATChanger offers space for up to eight plasmatorches 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

5 FineFocus For the upper Cutting Range The robust systems of the FineFocus series offer high performance even under extreme conditions. 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 system of the series. Two of them connected in parallel make the FineFocus 1600 which achieves highest cutting performance. Furthermore, both the FineFocus 800 and the FineFocus 1600 can be used for underwater plasma cutting. FineFocus 800, FineFocus 600, FineFocus 450 Due to their attractive price-performance ratio, the FineFocus systems are ideally suited for all metal-working industries, e.g. steel and metal construction, shipbuilding or metal service centres. HotWire The FineFocus 800 can be modified quickly and easily for applying the HotWire technology for cutting electrically conductive, non-conductive, combined and interrupted materials. HotWire: patented and unique Quality cutting of gratings Cutting Ranges FineFocus Cutting Current Material thickness in mm A 200 A FineFocus 450 FineFocus A FineFocus 800 Recommended 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 FineFocus Power 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 O 2, Air, Ar, H 2 O 2, Air, Ar, H 2 O 2, Air, Ar, H 2 Swirl gases Air Air Air (3) Other voltages and frequencies on request - 5 -

6 Robot-Guided Plasma Cutting 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 Plasma cutting of a pipe Robot-guided plasma cutting offers the following advantages: Cost-efficient cutting Simple programming High cutting speeds High cut quality, almost no rework required High flexibility in application Plasma cutting of open profile Torches for Every Task For 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 Plasma cutting of a closed profile Kjellberg plasma torches can be used for bevel cutting up to 50, with special torches up to

7 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 special torches 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 interrupted cuts in all 2D and 3D positions. A wide range of accessories is available for the hand torches which make it easy to perform many diverse cutting tasks. PA-S70 W, PA-S45 W Plasma gouging 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. Plasma gouging does not require after-treatment and produces less smoke compared to gouging with carbon electrodes. Cutting Ranges PA-S Cutting Current Material thickness in mm A PA-S45 W 240 A PA-S70 W Recommended 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-S 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 - 7 -

8 CutFire Starting Technique for Metal Construction For simple automated cutting tasks Kjellberg Finsterwalde offers the easy-to-use plasma cutting 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 metalworking industry and many other workshops, production plants and industrial enterprises. 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 Cutting on guided system with CutFire The CutFire 65i can be used for mechanised as well as manual plasma cutting by simply changing the torch. Cutting Ranges CutFire Cutting Current Material thickness in mm A CutFire 65i 100 A CutFire 100i Recommended 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 CutFire Power source CutFire 65i CutFire 100i Mains voltage (3) 3 x 400 V, 50 Hz Fuse, slow 16 A 25 A Connected load, max. 9.8 kva 16.6 kva Cutting current 65 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 mm Dimensions (L x W x H) 17 kg 50 kg Plasma gases Air (3) Other voltages and frequencies on request - 8 -

9 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 products, e.g. sheets, pipes, profiles, circuit boards and others. The FineMarker makes it possible to mark components 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 Technical Data FineMarker Power source Mains voltage (3) Fuse, slow Connected load, max. Cutting current Mass Dimensions (L x W x H) Marking gas (3) Other voltages and frequencies on request FineMarker 3 x 400 V, 50 Hz 10 A 5.2 kva 25 A 710 x 400 x 440 mm 30 kg Ar The FineMarker is well suited to supplement existing oxy-fuel or plasma cutting systems and can be controlled from the guiding system via interface. Height Control Units Make the Cutting Process Safe 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 database-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

10 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 increased hazard 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 120 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. CUTi series stands for mobility in practice Accessories A large variety of accessories is available for the flexible use of the CUTi units. Cutting Ranges CUTi Bevelling cap Long consumables Cutting current Material thickness in mm A CUTi 35C 35 A CUTi A CUTi A CUTi A CUTi 120 Circle cutting device Template cuts Recommended cutting range (1) Max. cutting range (1) (1) These data are depending on the materials to be cut and their compositions. Technical Data CUTi 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 [35 (2) ] A 5 35 A A A A Duty cycle 25 % I 35 A 35 % I 25 A 100 % I 20 A 40 % I 35 A 60 % I 28 A 100 % I 22 A 35 % I 70 A 60 % I 60 A 100 % I 50 A 40 % I 90 A 60 % I 74 A 100 % I 55 A 35 % I 120 A 60 % 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 (2) With external compressed air supply

11 Tradition determines Identity, Character and Profil of an Enterprise 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 supply unit worldwide a big step towards a new dimension of quality and reproducibility of plasma cuts HiFocus 80i/160i/280i/360i make up the first complete 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

12 Plasma Cutting Technology made in Germany FR Munich Kjellberg Finsterwalde Group Welding Electrodes Welding Equipment Cutting Equipment Mechanical Engineering 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 (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 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 fabrication. Claims of any kind cannot be derived from this brochure. Kjellberg Finsterwalde Plasma und Maschinen GmbH Oscar-Kjellberg-Str Finsterwalde Germany Phone: Fax: plasma@kjellberg.de 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

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