Kjellberg FineFocus 800 Instruction Manual
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Kjellberg FineFocus 800 Instruction Manual

Plasma cutting unit with swirl-gas torch for dry and under water cutting, suitable for cnc controlled cutting systems
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Instruction Manual
Plasma Cutting Unit
FineFocus 800
with swirl-gas torch for dry and under water cutting,
suitable for CNC controlled cutting systems
Article no.: .11.036.102 / .106 / .108

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Summary of Contents for Kjellberg FineFocus 800

  • Page 1 Instruction Manual Plasma Cutting Unit FineFocus 800 with swirl-gas torch for dry and under water cutting, suitable for CNC controlled cutting systems Article no.: .11.036.102 / .106 / .108...
  • Page 2 Please take absolute notice ! New Coolant “Kjellfrost” From today Kjellberg Finsterwalde is offering a new antifreezer with improved properties at the same price. The new antifreezer “Kjellfrost” contains anodic and cathodic acting inhibitors. These ingredients are protecting more effective all components of the cooling circuit against corrosion, even if compound members of steel, copper and copper alloys are in the circuit.
  • Page 3 Clean the eyes with much flowing water some und Arzt konsultieren minutes and call the doctor. - nach Hautkontakt - After skin-contact Sofort mit Wasser und Seife abwaschen und Quickly clean it with much water and soap. gut nachspülen 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 3 -...

  • Page 4: Table Of Contents

    5.2.4 Connection of the FineFocus 800 5.2.5 Connection of the plasma torches 5.2.5.1 Connection of the plasma torches to the FineFocus 800 5.2.5.2 Plasma torch connection to the plasma ignition box PZ-800 / plasma gas connection unit PGA 3-800 5.2.5.3 Plasma torch connection to the PBA-800 036_102...108_BA_engl.doc...
  • Page 5 Cooling system 7.1.5 Electrical revision Plasma torches Enclosure Scheme “piercing sequences during plasma cutting” Connection diagrams Cutting data FineFocus 800 Wiring diagram FineFocus 800 Spare parts lists PB-S77 W and PB-S75 WH-1 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 5 -...

  • Page 6: Safety Instruction

    • Place the torch on an insulated place • Keep environment and plasma equipment dry • Don´t use damaged cables and torches • Arrange regular electric inspections • Never shorten safety circuits (door contact, protective caps) 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 6 -...
  • Page 7 • Immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures. • Time of day that cutting has to be carried out 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 7 -...
  • Page 8 99 dB (A) under water cutting 250 A 40 mm 73 dB (A) 71 dB (A) Table 1 : noise level during plasma cutting Therefore wear approved ear protection when using the plasma system. 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 8 -...
  • Page 9 • The cutting machine after the cutting is placed outside the water table to avoid, that hydrogen or oxyhydrogen can penetrate hollow spaces (switch boards, etc). o Storing of plates on the cutting table for longer times is not allowed! 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 9 -...

  • Page 10: The Plasma Cutting Process

    A – coolant inlet C – plasma gas E – cutting direction without swirl gas with swirl gas B – coolant outlet D – swirl gas F – cutting edge 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 10 -...

  • Page 11: Dry Plasma Cutting

    Further advantages und features: • Cutting range (material depending) for the FineFocus 800: quality cut – 1.0 to 40 mm (dry cutting); severance – max. 80 mm; with 50 (60) kW cutting power • Steepless current adjustment from 80 to 300 A ensures optimum current adaptation to all cutting jobs •...

  • Page 12: Range Of Application

    The plasma hand torch PB-S75 WH-1 also is suitable without swirl gas for dry cutting and gouging. For the plasma hand torch various accessories, like circle attachment KSE 6, wheel guide RW2 and the tractor unit FE 1 are optional available. 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 12 -...

  • Page 13: Under Water Plasma Cutting

    Ar/H -mixture possible, can be avoided by adding N to the plasma gas (Ar/H -mixture) - plasma gas Ar/N / swirl gas N very sharp cutting edges and metallic clean surfaces 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 13 -...

  • Page 14: Technical Data

    Technical data Plasma rectifier FINEFOCUS 800 Primary side Input voltage U : .11.036.102 3~ 400V +5/-10%, 50Hz .11.036.106 3~ 500V +5/-10%, 50Hz .11.036.108 3~ 440V +5/-10%, 60Hz Fuse, slow 125A Cross section Cu 4 x 35mm Power factor cos ϕ...

  • Page 15: Plasma Hand Torch Pb-S75

    (99.999 %) Max. pressure: 0.6 MPa (6bar) 0.8 MPa (8bar) 0.6 MPa (6bar) Max. flow rate (torch connected): 2100 l/h 400 l/h 500 l/h Connector size: G1/4“ G3/8” links G1/4“ Table 6 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 15 -...

  • Page 16: Plasma Ignition Box Pz-800

    24 V AC, 50 / 60 Hz Dimensions (l x w x h): 450 x 185 x 240 mm Weight: 8.5 kg Connection to: FineFocus 800 with hose parcel extension PZL-800 Table 7 3.3.4 Plasma gas supply unit PGA 3-800 .11.825.245 Art.-no.:...

  • Page 17: Technical Description

    The power module of the FineFocus 800 consists of the main transformer, the 12-pulse rectifier, the choke coil, the pilot rectifier with pilot resistors and the power contactors.

  • Page 18: Plasma Components

    A tumbler switch on the PGE 1-800 starts the “gas purge” of the plasma gas, preselected with the selector switch on the FineFocus 800 and the activated swirl gas. The 25-pole control cable connects the PGE 1-800 with the socket X126, placed on the back panel of the FineFocus 800.

  • Page 19: Cable Set Pzl-800

    The PBA-800 contains the connectors for the water inlet, water return / cathode and the pilot current and furthermore the solenoids with the connectors for the plasma gases and the swirl gas. All components are accessible after opening the safety switch protected cover plate. 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 19 -...

  • Page 20: Cable Set Pbl-800

    Plasma counter PZE 1 The plasma counter PZE 1 records the number of ignitions, the arc stops and the effective cutting time. A 3-pole control cable connects the PZE 1 with FineFocus 800 (back side wall). 4.3.9 Tractor unit FE 1 The transportable tractor unit FE 1 mechanises the cutting process when using the hand torch PB-S75 WH-1.

  • Page 21: Commissioning

    After the installation is performed the direction of fan rotation has to be checked. The fan switch should close its contact. If not, change two phases on the mains cable on the terminal board. 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 21 -...

  • Page 22: Workpiece Connection / Current Return Line

    Depending on the system configuration the plasma torches of the PB-S77 W-1 series will be connected directly to the power source FineFocus 800 or to the plasma ignition box / plasma gas connection unit.

  • Page 23: Plasma Torch Connection To The Plasma Ignition Box Pz-800

    5.2.6 Connection of the plasma gas control unit PGE 1-800 A 25-pole control cable connects the PGE 1-800 with the FineFocus 800. The respective socket X126 is placed on the rear of the power source. The upper rear side of the PGE 1-800 contains the connectors for the plasma gas supply air (PG1) and oxygen (PG2), and the swirl gases nitrogen (WG1) and oxygen (WG2).

  • Page 24: Connection Of The Plasma Gas Controller Pge 2-800

    5.2.7 Connection of the plasma gas control unit PGE 2-800 The PGE 2 will be connected to the rear wall mounted socket X122 of the FineFocus 800 by a 4-pole cable. The supply connectors for the plasma gases argon (PG3), hydrogen (PG4) and nitrogen (PG 5) are placed on the top, whereas the outlet of the gases are located on the bottom side of rear of the PGE 2-800.

  • Page 25: Connection Of The Gas Hoses Between Pga 3-800 And Pba-800

    “PG1” of the PGE 1-800 • Open the valve and adjust the pressure so that under gas flow the pressure gauge on the PGE 1- 800 shows the value as given in the cutting chart 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 25 -...

  • Page 26: Swirl Gases (Oxygen, Nitrogen)

    PGE 1-800 are showing the values as given in the cutting chart Attention! All components coming in touch with oxygen have to be free of oil and grease! When using oxygen generally the pressure reducer has to be furnished with an explosion protection! 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 26 -...

  • Page 27: 5.2.13 Filling Up The Coolant

    7.1.4). 5.2.14 Connection to CNC-control The control cables for the combination of the control circuit of the plasma cutting unit FineFocus 800 with CNC-equipments have to be provided from the user. The connections X101, X103 and X102 are located at the rear wall of the power source. The contacts of the interface are calculated for 500 mA DC and an operation voltage of 24 V.
  • Page 28 The fault signals are activating retaining circuits. Resetting is possible by signal “RESET” from CNC or “RESET”-button “RESET” inside the plasma power source (open rear door on left side). Remark! If the remote control FB is connected torch ignition from CNC is not possible! 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 28 -...

  • Page 29: Operation

    Control and display elements The FineFocus 800 in any case can be operated directly by the control elements installed at the front panel. It furthermore is possible to replace front wall elements by CNC-signals to receive the desired switching functions.

  • Page 30: Service Elements Inside Of The Plasma Cutting Unit

    “torch ON” with FB 1 or CNC-signal to X102:A7-X102:A8 the plasma arc ignites positon 2: at signal “torch ON” from FB 1 or CNC-signal X102:A7-X102:A8 gas purge only is activated, for the ignition additionally a CNC-signal to X102:A7-X102:A8 is required (closing contact) 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 30 -...

  • Page 31: Cutting Operation

    7. Adjust step switch S8 (9) to desired current slope-up time 8. Press button S13 (7) “preset control” and adjust by potentiometer R7 (6) to the desired current value, indicated on the current display (2) 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 31 -...

  • Page 32: Machine Torch Operation

    • Move torch in cutting direction, if pilot arc contacts the workpiece cutting starts • Keep speed constant for good cut quality (fig. 6) • For materials above 50 mm use the wheel guide RW 2 instead of the guide bow 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 32 -...

  • Page 33: Plasma Gouging

    Switching OFF the plasma unit The plasma cutting unit FineFocus 800 will be switched OFF by turning the key switch S1 (4) to position “0”. All components of the unit are deactivated. When pressing the red push button S3 (3) “emergency stop”...

  • Page 34: Change Of Spare Parts On Plasma Torch Pb-S77 W

    1. Unscrew manually swirl gas cap (12) and protective cap (11) together with the swirl gas nozzle 2. Place insulating sleeve (13) for dry cutting to the torch and screw it on manually with the protective 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 34 -...
  • Page 35 Dry cut without Insulation sleeve swirl gas Protective cap tools Socket spanner cooling tube Socket spanner cathode Gas cap puller Socket spanner nozzle cap Hexagonal wrench 4 mm Test gauge cathode wear Table 21 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 35 -...

  • Page 36: Change Of Spare Parts On Plasma Torch Pb-S75 W/Wh

    6. Replace nozzle cap (7) by socket spanner (D) hand tight 7. Replace protective cap (8) manually (only hand torch) All O-rings (3 and 6) have to be replaced with care, avoid damages, twisting etc. 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 36 -...
  • Page 37 Socket spanner cooling tube Machine torch Socket spanner cathode Gas cap puller Machine torch Socket spanner nozzle cap Hexagonal wrench 4 mm Hand torch Test gauge cathode wear Gas guide puller Hand torch Table 22 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 37 -...

  • Page 38: Hints For Trouble Shooting And Protective Circuits

    No other parts can be removed from torch head. Use only spare parts of Kjellberg origin! Otherwise the machines guarantee becomes invalid. When starting the plasma unit after the change of spare parts again the following has to be obtained (see also chapter 6.2):...

  • Page 39: Maintenance

    Therefore the following gas pressure test has to be carried out weekly when using the plasma gases Ar/H -mixture or oxygen: • Disconnect the FineFocus 800 visibly from the mains • Open the outlet valves of the gas cylinders, adjust a pressure of 8 bar • Close outlet valves of the pressure reducers •...

  • Page 40: Electrical Revision

    Attention! Plasma torches have to be water tight at any time! Defective torches generally will be repaired by the Kjellberg Service Centre or at licensed repair shops! Attention! All components and parts coming in touch with oxygen have to be free of oil and grease! This refers specially to torch head and the consumables! 036_102...108_BA_engl.doc...

  • Page 41: Enclosure

    036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 41 -...

  • Page 42: Connection Diagrams

    036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 42 -...
  • Page 43 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 43 -...
  • Page 44 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 44 -...
  • Page 45 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 45 -...

  • Page 46: Cutting Data Finefocus 800

    Cutting data FineFocus 800 torch: PB-S77 W mild steel (4 up to 40 mm) valid from: 18.08.2003 plasma gas air with swirl gas air material: St37b-2 PG 1 PG 2 Material Current Nozzle Ignition gas Cutting gas Swirl gas Ignition...
  • Page 47 Cutting data FineFocus 800 (120 A) Torch: PB-S77 W mild steel (3 up to 15 mm) valid from: 18.08.2003 plasma gas O with swirl gas air Material: St37b-2 PG 1 PG 2 Material Current Nozzle Ignition gas Cutting gas Swirl gas...
  • Page 48 Cutting data FineFocus 800 (250 A) Torch: PB-S77 W mild steel (4 up to 70 mm) valid from: 18.08.2003 plasma gas O with swirl gas air Material: St37b-2 PG 1 PG 2 Material Current Nozzle Ignition gas Cutting gas Swirl gas...
  • Page 49 Cutting data FineFocus 800 (300 A) torch: PB-S77 W mild steel (25 up to 70 mm) plasma gas O with swirl gas air material: St37b-2 valid from: 18.08.2003 PG 1 PG 2 Material Current Nozzle Ignition gas Cutting gas Swirl gas...
  • Page 50 Cutting data FineFocus 800 (120-250 A) torch: PB-S77 W high-alloyed steel (6 up to 45 mm) valid from: 18.08.2003 plasma gas ArH with swirl gas N material: 1.4301 PG 3 PG 4 PG 5 Material Current Nozzle WGK Ignition gas...

  • Page 51: Wiring Diagram Finefocus 800

    Cutting data FineFocus 800 (200-250 A) torch: PB-S77 W aluminium (4 up to 60mm) valid from: 01.10.2003 plasma gas ArH with swirl gas N material: AlMg 3 PG 3 PG 4 PG 5 WG 1 Cutting material current nozzle Ignition gas...
  • Page 52 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 51 -...
  • Page 53 .11.828.700.000E Dear customer, you have purchased top-quality products of Kjellberg Finsterwalde Elektroden und Maschinen GmbH. When placing orders for spare parts please mention - The complete article no. of the plasma torch / machine - The designation and article no. of the spare part acc. to this list.
  • Page 54 NOZZLE L3 AIR/O2 120A 1.4mm 1.00 02.01.06 .12.40850 NOZZLE L2 AIR/O2 250A 2.5mm 1.00 02.01.06 .12.43050 NOZZLE L1 AIR/O2 160A 2.0mm 1.00 02.01.07 .10.505.923 O-RING 28 X 2.0 1.00 02.01.08 .12.37790 NOZZLE CAP PB-S75 1.00 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 53 -...
  • Page 55 1.00 20.07.00 .10.710.560 PIN SPANNER WITH HINGE FOR DIA. 4 1.00 30.00.00 .16.500.309 Hf-PROTECTION FOR HOSE P. PB-S76 W-2 1.00 30.00.01 .10.166.701 CABLE PROTECTION 1.00 30.00.02 .41.40581798 PLIERS FOR Hf-PROTECTION (TOOL) 1.00 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 54 -...
  • Page 56 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 55 -...
  • Page 57 1.00 02.01.06 .11.828.501.414 NOZZLE L3 AIR/O2 120A 1.4mm 1.00 02.01.06 .12.40850 NOZZLE L2 AIR/O2 250A 2.5mm 1.00 02.01.06 .12.43050 NOZZLE L1 AIR/O2 160A 2.0mm 1.00 02.01.07 .10.505.923 O-RING 28 X 2.0 1.00 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 56 -...
  • Page 58 1.00 20.07.00 .10.710.560 PIN SPANNER WITH HINGE FOR DIA. 4 1.00 30.00.00 .16.500.309 Hf-PROTECTION FOR HOSE P. PB-S76 W-2 1.00 30.00.01 .10.166.701 CABLE PROTECTION 1.00 30.00.02 .41.40581798 PLIERS FOR Hf-PROTECTION (TOOL) 1.00 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 57 -...
  • Page 59 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 58 -...
  • Page 60 CONTROL CABLE 4m 1.00 05.07.00 .11.828.701.745 PILOT CABLE 6m 1.00 05.08.00 .11.828.701.705 GASE HOSE L+AR/H2 2m 1.00 05.09.00 .11.828.701.742 CONTROL CABLE 6m 1.00 05.10.00 .10.575.040 COVER HOSE 32 x 1,5 mm 1.00 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 59 -...
  • Page 61 1.00 20.02.00 .12.48500 GAS GUIDE PULLER 1.00 20.03.00 .12.40320 CAP PULLER 1.00 20.04.00 .12.38190 SOCKET SPANNER FOR NOZZLE CAP 1.00 20.05.00 .10.712.536 HEXAGONAL WRENCH 4.0 mm 1.00 20.06.00 .12.38540 TEST GAUGE 1.00 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 60 -...
  • Page 62 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 61 -...
  • Page 63 • The operating personnel must have through knowledge of the Instruction Manual. • The Instruction Manual always must accompany the machine. For damages due to misuse or wrong service we will not take any responsibility. Kjellberg Finsterwalde Elektroden und Maschinen GmbH Germany D - 03238 Finsterwalde Leipziger Str.
  • Page 64 Änderungsnummer Änderungsdatum ab BON Geschrieben / geändert von ..11.036.102/.106/.108 14.10.2002 124192 Corinna Kloas / Peter Jagieniak .11.036.102/.106/.108 03.03.2003 124192 MR / Corinna Kloas .11.036.102/.106/.108 02.04.2003 124192 Peter Jagieniak / Corinna Kloas 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde - Seite 63 -...

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