Kjellberg PerCut 200 Short Instruction Manual
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Kjellberg PerCut 200 Short Instruction Manual

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Short Instruction Manual
Short instruction manual HiFocus 161i with PGE 3-161
- Saftety
- Consumable change of the plasma torch
- Cutting charts
Art.-Nr.: .11.034.902.KBA

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Summary of Contents for Kjellberg PerCut 200

  • Page 1 Short Instruction Manual Short instruction manual HiFocus 161i with PGE 3-161 - Saftety - Consumable change of the plasma torch - Cutting charts Art.-Nr.: .11.034.902.KBA...
  • Page 2 Short instruction manual HiFocus 161i with PGE 3-161 P os: 1.1 /Überschriften/1/KBA/KBA HiFo 161i + PGE 3-161 @ 12\mod_1385361813652_19.doc @ 192112 @ 1 @ 1 1 Short instruction manual HiFocus 161i with PGE 3-161 hort instruction manual HiFocus 161i with PGE 3-161 os: 1.2 /Überschriften/1.1/Sicherheit_KBA @ 1\mod_1222090333431_19.doc @ 5425 @ 2 @ 1 1.1 Safety P os: 1.3 /Kurzbetriebsanleitung/KBA ordnungsgemäß...
  • Page 3 Short instruction manual HiFocus 161i with PGE 3-161 os: 1.12 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Umgang mit Gasflaschen 1 @ 1\mod_1222078509612_19.doc @ 5375 @ @ 1 WARNING Place the cylinders in an upright position and lock it against tilting over! Don't use damaged cylinders, pressure reducers and armatures! P os: 1.13 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Verschleißteile in Berührung mit Sauerstoff öl-und fettfrei (Explosionsschutzsicherung) @ 0\mod_1201005445751_19.doc @ 3177 @ @ 1 WARNING...
  • Page 4 P os: 1.21 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/Original-Kjellberg-Verschleißteile @ 0\mod_1202913276255_19.doc @ 3649 @ @ 1 You are only allowed to use ORIGINAL Kjellberg spare parts and consumables! The use of other manufacturer consumables leads to the loss of the warranty claim.
  • Page 5 PerCut 200 / 210A / 210M PerCut 201 / 211A / 211M P os: 1.26 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/Auf Vollständigkeit der Verschleißteile achten @ 0\mod_1200055848051_19.doc @ 2782 @ @ 1 Make sure that all wearing parts are complete and correct installed! Especially the cooling tube has to be inserted.
  • Page 6 1.2.1 Plasma machine torch PerCut 200 / 210A / 210M P os: 1.31 /Brenner/PerCut 200/210/Verschleißteilübersicht PerCut 210 @ 5\mod_1288873432771_19.doc @ 41237 @ @ 1 Dismounting of used consumables Manually unscrew the protective cap (xx.07) together with the swirl gas cap (xx.06).
  • Page 7 Short instruction manual HiFocus 161i with PGE 3-161 os: 1.33 /Überschriften/1.1.1/Plasma-Maschinenbrenner PerCut 201 / 211A / 211M @ 8\mod_1335434566622_19.doc @ 153764 @ 3 @ 1 1.2.2 Plasma machine torch PerCut 201 / 211A / 211M P os: 1.34 /Brenner/PerCut201/211/VT-Übersicht +Aus-u.Einbau @ 8\mod_1335432657792_19.doc @ 153656 @ @ 1 Dismounting of used consumables Before dismounting the consumables of the PerCut 211A please insert the change head in the “Station for the change heads”...
  • Page 8 Short instruction manual HiFocus 161i with PGE 3-161 os: 1.36 /Brenner/PerCut 440/450/Montagehinweis Düse @ 6\mod_1299572476000_19.doc @ 55454 @ @ 1 Fig. 1.: Insert the nozzle into the torch head Pos: 1.37 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...
  • Page 9 Short instruction manual HiFocus 161i with PGE 3-161 os: 1.38 /Überschriften/1.1/Bedien- und Anzeigeelemente der Stromquelle @ 2\mod_1236339818423_19.doc @ 9395 @ 2 @ 1 1.3 Operating and display elements of the power source P os: 1.39 /Stromquellen/HiFocus/HiFo161i/Bedien- und Anzeigeelemente @ 6\mod_1305094057624_19.doc @ 61750 @ @ 1 Fig.
  • Page 10 Short instruction manual HiFocus 161i with PGE 3-161 os: 1.41 /Stromquellen/HiFocus/HiFo161i/Reihenfolge der Bedienung @ 6\mod_1305116445455_19.doc @ 61848 @ @ 1 Operation sequences red mushroom button S3 “emergency stop" Unlock the button by turning it in one direction. Key switch S1 Turn the key switch to the position „I“.
  • Page 11 Short instruction manual HiFocus 161i with PGE 3-161  activate tumbler switch “down slope-time“ (7) and adjust the “down slope” - Potentiometer „Down slope“ (11) time with the potentiometer  look at the value shown at the current display (21) The display is in ms. selector switch (12) Adjust the selector switch to position 1 (preferred value) "up slope"...
  • Page 12 Short instruction manual HiFocus 161i with PGE 3-161 os: 1.43 /Überschriften/1.1/Bedien- und Anzeigeelemente der Gaskonsole @ 2\mod_1236339916893_19.doc @ 9400 @ 2 @ 1 1.4 Operating and display elements of the gas console P os: 1.44 /Gaskonsolen/PGE3-161/Bedien- und Anzeigeelemente PGE 3-161 @ 12\mod_1385112531591_19.doc @ 191814 @ @ 1 Fig.
  • Page 13 Short instruction manual HiFocus 161i with PGE 3-161 os: 1.46 /Überschriften/1.1/Hinweise zur Fehlersuche @ 0\mod_1197633890412_19.doc @ 1844 @ 2 @ 1 1.5 Information for trouble shooting P os: 1.47 /Stromquellen/HiFocus/HiFo161i/Tabelle Hinweise Fehlersuche @ 6\mod_1305193803146_19.doc @ 61942 @ @ 1 error reason / solution ...
  • Page 14 Short instruction manual HiFocus 161i with PGE 3-161 os: 1.50 /Stromquellen/HiFocus/HiFo161i/Fehlerliste @ 6\mod_1305107521701_19.doc @ 61792 @ @ 1 error chart / error codes - of the power source current- relevance LED-display cause end or fault clearance display ER 1 gas-coolant- “Cumulative temperature error“(18)
  • Page 15 Short instruction manual HiFocus 161i with PGE 3-161 current- relevance LED-display cause end or fault clearance display ER 3 Torch defect LED signal lamp current flow during yellow “Cumulative gas preflow switch OFF unit, check torch error“(18) ER30 and consumables short circuit at the torch ER31...
  • Page 16 Short instruction manual HiFocus 161i with PGE 3-161 Kjellberg Finsterwalde Plasma und Maschinen GmbH Germany • D - 03238 Finsterwalde • Oscar-Kjellberg-Str. 20 phone: +49 3531 500-0 • Fax: +49 3531 500-227 e-mail: plasma@kjellberg.de Internet: www.kjellberg.de os: 2 /Überschriften/Sicherheitshinweise_Produktname @ 1\mod_1222148646980_19.doc @ 5440 @ @ 1 - Saftety Pos: 3 /Überschriften/Verschleißteilwechsel_Produktname @ 1\mod_1222148651251_19.doc @ 5445 @ @ 1...
  • Page 17 Instruction Manual - Power source HiFocus 161i neo - Plasma gas control unit PGE 3-161 - Plasma machine torch PerCut 200 / 210 … - Plasma machine torch PerCut 201 / 211 … - Plasma torch connection unit PBA-161 Art.-Nr.: .11.034.902.BA...
  • Page 18 All rights reserved in the event of the grant of a patent, utility model or design. Subject to alterations .  Kjellberg Finsterwalde Plasma und Maschinen GmbH, 2013 Kjellberg Finsterwalde Plasma und Maschinen GmbH Oscar-Kjellberg-Straße 20 DE - 03238 Finsterwalde Tel.:...

  • Page 19: Table Of Contents

    General information Contents General information ..........................7 Warranty claim ..........................7 Standards and Directives ......................... 7 Information to the instruction manual - target groups ..............8 Plasma cutting as procedure......................9 Safety instructions ..........................11 Explanation of the safety symbols....................11 Endangerment by high contact voltage..................17 Working in environments with increased electric endangerment...........
  • Page 20 Connection of the gas supply......................85 7.6.1 Plasma gases ..........................86 7.6.2 Swirl gases..........................88 Plasma machine torch PerCut 200 / 210 …..................91 Technical data ..........................92 Technical description........................93 Connection of the plasma torch to the plasma torch connection unit PBA ........94...
  • Page 21 General information Consumables and their exchange....................95 8.4.1 Plasma machine torch PerCut 200 / 210A / 210M ..............98 8.4.2 Replacement of the current socket and current plug in the torch shaft ........100 8.4.3 Operation of the torch after consumable change ..............100 Information for using of the change heads...................
  • Page 22 General information 12.4 Spare parts list PerCut 210M ....................... 153 12.5 Spare parts list PerCut 201 ......................156 12.6 Spare parts list PerCut 211A......................158 12.7 Spare parts list PerCut 211M ....................... 162 12.8 Spare parts list PBA-161 ......................165 List of Abbreviations..........................167 Index ..............................168 Pos: 2 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 23: General Information

    Pos: 3.3 /Allgemeines/Gewährleistungsanspruch @ 0\mod_1197458588902_19.doc @ 1520 @ @ 1 We point out explicitly that only spare parts and consumables of Kjellberg original have to be used! Otherwise a warranty claim does not exist. Kjellberg Finsterwalde as manufacturer of the equipment can not make any guarantees for the safety of the equipment according to the valid regulations.

  • Page 24: Information To The Instruction Manual - Target Groups

    General information Pos: 3.7 /Überschriften/1.1/Hinweise zur Bertiebsanleitung - Zielgruppen @ 0\mod_1197551942124_19.doc @ 1656 @ 2 @ 1 1.3 Information to the instruction manual - target groups Pos: 3.8 /Allgemeines/Hinweise zur Betriebsanleitung @ 0\mod_1198075112816_19.doc @ 2238 @ @ 1 Our products are of first-rate quality and high reliability and are in operational condition at any time. You fully will enjoy all these benefits, as long as you carefully observe these instructions for operation, maintenance and handling.

  • Page 25: Plasma Cutting As Procedure

    General information Pos: 5.1 /Überschriften/1.1/Plasmaschneiden als Verfahren @ 0\mod_1197554221573_19.doc @ 1704 @ 2 @ 1 Plasma cutting as procedure Pos: 5.2 /Allgemeines/Plasmaschneidverfahren, Beschreibung @ 0\mod_1198075619387_19.doc @ 2248 @ @ 1 The plasma is defined as a gas having atoms and molecules which are partly split into ions and electrons and having therefore a high electrically conductivity.
  • Page 26 General information Pos: 5.5 /Allgemeines/Plasmaschneidverfahren,Tabelle @ 2\mod_1238069850087_19.doc @ 9805 @ @ 1 Plasma cutting process Dry-plasma cutting Under water-plasma cutting without swirl gas with swirl gas with swirl gas A Coolant circuit B Plasma gas C Swirl gas In plasma cutting without Plasma torches with swirl gas The under water plasma cutting process swirl gas the plasma arc hits...

  • Page 27: Safety Instructions

    Safety instructions Pos: 7.1 /Überschriften/1/Sicherheit @ 0\mod_1197388764940_19.doc @ 1439 @ 1 @ 1 2 Safety instructions Pos: 7.2 /Überschriften/1.1/Erläuterung der Sicherheitssymbole @ 0\mod_1197465551735_19.doc @ 1537 @ 2 @ 1 Explanation of the safety symbols Pos: 7.3 /Sicherheit/Erläuterung der Symbole @ 0\mod_1197465063600_19.doc @ 1533 @ @ 1 DANGER, WARNING and CAUTION are signal words, which describes a degree of exposure.
  • Page 28 Safety instructions Warning symbols (choice): A black graphic symbol within a yellow triangle with a black edge defines a safety sign, which describes an endangerment. Warning of general hazard area Warning of dangerous electrical voltage! Warning of flammable substances Warning of explosive substances Warning of poisonous substances Warning of optical radiation Warning of electromagnetic radiation...
  • Page 29 Safety instructions Mandatory sign (choice): A white graphic symbol within a blue circle defines a safety sign, which indicates that an action shall be carried out, in order to prevent an endangerment. General mandatory sign Use eye shield Use ear protection Use inhalation protection Use foot guard Use hand guard...
  • Page 30 Safety instructions Prohibition sign (choice): A black graphic symbol within a red circle with a red diagonal bar defines a safety sign, which indicates that an action shall be stopped or not be carried out. Smoking is forbidden Fire, open light and smoking are forbidden Contact is forbidden Meal and drinking are forbidden Do not use in housing areas...
  • Page 31 Safety instructions Pos: 7.5 /Sicherheit/Warnschild, Text @ 0\mod_1199715950375_19.doc @ 2404 @ @ 1 Warning label The warning label is visibly attached on the power source. The operator and the maintenance personnel must familiarize themselves with the meaning of the symbols before working at the unit.
  • Page 32 Safety instructions Pos: 7.8 /Sicherheit/Weitere Hinweise und Warnungen @ 0\mod_1199797455150_19.doc @ 2420 @ @ 1 Further information and warning:  to ensure stableness of the plasma unit, an inclination of 10° may not be exceeded  connect the power source only with properly fitted protective conductor ...

  • Page 33: Endangerment By High Contact Voltage

    Safety instructions Pos: 7.10 /Überschriften/1.1/Gefährdung durch hohe Berührungsspannung @ 0\mod_1197552041125_19.doc @ 1660 @ 2 @ 1 2.2 Endangerment by high contact voltage Pos: 7.11 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Warnung Öffnen des Gerätes @ 0\mod_1199714392778_19.doc @ 2391 @ @ 1 WARNING Warning of dangerous electric voltage Electric shock can be deadly.

  • Page 34: Endangerment By High Voltage Ignition

    Safety instructions Pos: 7.19 /Überschriften/1.1/Gefährdung durch Hochspannungszündung @ 0\mod_1197552347357_19.doc @ 1668 @ 2 @ 1 2.4 Endangerment by high voltage ignition Pos: 7.20 /Sicherheit/Gefährdung durch Hochspannungszündung @ 0\mod_1199798211923_19.doc @ 2428 @ @ 1 For igniting the pilot arc a high voltage igniter is installed in the power source. When pressing the ON-button the high voltage is applied to the cathode and nozzle.

  • Page 35: Endangerment By Electromagnetic Fields

    Safety instructions Pos: 7.24 /Überschriften/1.1/Gefährdung durch elektromagnetische Störungen @ 0\mod_1197552428045_19.doc @ 1672 @ 2 @ 1 2.5 Endangerment by electromagnetic fields Pos: 7.25 /Sicherheit/Gefährdung durch elektromagnetische Störungen-Teil1 @ 0\mod_1199798656080_19.doc @ 2436 @ @ 1 The plasma cutting installation complies with the instructions of the EN 60974-10 (VDE 0544, part 10) "Arc Welding Equipment –...
  • Page 36 Safety instructions Pos: 7.30 /Sicherheit/Gefährdung durch elektromagnetische Störungen-Teil3 @ 0\mod_1199798845546_19.doc @ 2444 @ @ 1 Recommendations for assessment of the area (EN 60974-10) Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area, and shall take the following into account: ...

  • Page 37: Endangerment By Heat And Light Radiation

    Safety instructions Pos: 7.36 /Überschriften/1.1/Gefährdung durch Wärme- und Lichtstrahlung @ 0\mod_1197552537506_19.doc @ 1676 @ 2 @ 1 Endangerment by heat and light radiation Pos: 7.37 /Sicherheit/Gefährdung durch Wärme-und Lichtstrahlung @ 0\mod_1199799546328_19.doc @ 2452 @ @ 1 The radiation of the plasma arc can lead to eye injuries and skin burns. Eyes and skin have to be protected from the radiation of the plasma arc therefore.

  • Page 38: Endangerment By Gases, Smoke And Types Of Dust

    Safety instructions Pos: 7.40 /Überschriften/1.1/Gefährdung durch Gase, Rauche und Stäube @ 0\mod_1197552640467_19.doc @ 1680 @ 2 @ 1 Endangerment by gases, smoke and types of dust Pos: 7.41 /Sicherheit/Gefährdung durch Gase, Rauche und Stäube @ 0\mod_1199799715379_19.doc @ 2456 @ @ 1 Due to the plasma process itself hazardous substances may be produced.

  • Page 39: Prevention Of Formation Of Oxyhydrogen

    Safety instructions Pos: 7.46 /Überschriften/1.1/Vermeidung von Knallgasbildung @ 0\mod_1197552737646_19.doc @ 1684 @ 2 @ 1 2.8 Prevention of formation of oxyhydrogen Pos: 7.47 /Sicherheit/Vermeidung von Knallgasbildung-Teil1 @ 0\mod_1199799928396_19.doc @ 2460 @ @ 1 (Does only apply for plasma cutting of aluminium in any combination with water) The molten aluminium which is blown out of the cutting kerf forms in water an aluminium granule which is oxidizing in water very fast because of its large surface.

  • Page 40: Endangerment By Noise

    Safety instructions Pos: 7.52 /Überschriften/1.1/Gefährdung durch Lärm @ 0\mod_1197552995672_19.doc @ 1688 @ 2 @ 1 2.9 Endangerment by noise Pos: 7.53 /Sicherheit/Gefährdung durch Lärm-Teil1 @ 0\mod_1199800350921_19.doc @ 2473 @ @ 1 Be aware that during the plasma cutting a high noise level is produced. Depending on the technological process and the cutting parameters the following sound level is reached: Pos: 7.54 /Sicherheit/Schallpegelmessung @ 0\mod_1200574914423_19.doc @ 2912 @ @ 1 Process: Dry plasma cutting...

  • Page 41: Endangerment By Spatter

    Safety instructions Pos: 7.58 /Überschriften/1.1/Gefährdung durch Spritzer @ 0\mod_1197553139562_19.doc @ 1692 @ 2 @ 1 2.10 Endangerment by spatter Pos: 7.59 /Sicherheit/Gefährdung durch Schneidspritzer @ 0\mod_1199800700797_19.doc @ 2481 @ @ 1 During plasma cutting and hole piercing sparks, slag and hot metal are produced. The risk of burns and fire exists! To avoid endangerments the following has to be arranged: ...

  • Page 42: Handling Of The Coolant "Kjellfrost

    (only valid for units with liquid cooled torches) Pos: 7.67 /Sicherheit/Umgang mit dem Kühlmittel "Kjellfrost" @ 0\mod_1199800926774_19.doc @ 2489 @ @ 1 For all liquid- cooled plasma torches Kjellberg Finsterwalde is using the coolant „Kjellfrost”, suitable as anti-freezer as well.
  • Page 43 Safety instructions Pos: 7.71 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Ethandiol-Brand-1-Verdunstung @ 1\mod_1227086496483_19.doc @ 6150 @ @ 1 WARNING Leaked or slopped coolant "Kjellfrost" and evaporation of water portions can cause an increasing concentration of the component ethanediol. If there is a sufficient energy-rich ignition source, it can cause an inflammation and combustion of the ethanediol-debris.

  • Page 44: Maintenance

    Maintenance Pos: 9.1 /Überschriften/1/Wartung @ 0\mod_1197550754735_19.doc @ 1640 @ 1 @ 1 3 Maintenance Pos: 9.2 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Warnung Öffnen des Gerätes @ 0\mod_1199714392778_19.doc @ 2391 @ @ 1 WARNING Warning of dangerous electric voltage Electric shock can be deadly.

  • Page 45: Cleaning

    Maintenance Pos: 9.7 /Überschriften/1.1.1/Reinigung @ 0\mod_1197630016183_19.doc @ 1764 @ 3 @ 1 3.1.2 Cleaning Pos: 9.8 /Überschriften/1.1.1.1/Reinigung der Stromquelle @ 0\mod_1216713725288_19.doc @ 4955 @ 4 @ 1 3.1.2.1 Cleaning of the power source Pos: 9.9 /Wartung/Reinigung der Stromquelle @ 0\mod_1197990338325_19.doc @ 2134 @ @ 1 From the power source all dust and dirt which has collected inside by the fan have to be removed in intervals of 4 to 6 months.

  • Page 46: Electrical Revision

    Maintenance Pos: 9.13 /Überschriften/1.1.1/elektrische Revision @ 0\mod_1197630324394_19.doc @ 1768 @ 3 @ 1 3.1.3 Electrical revision Pos: 9.14 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/elektrische Revision durch Elektrofachkraft @ 0\mod_1215496817737_19.doc @ 4470 @ @ 1 The electrical revision of the plasma cutting system and the disposal of the noticed defects have to be carried out according to the statutory provisions via electrical specialist! Pos: 9.15 /Wartung/Elektrische Revision @ 0\mod_1197990462046_19.doc @ 2138 @ @ 1 According to existing regulation an electrical revision of the plasma cutting system has to be arranged:...

  • Page 47: Plasma Torch

    This refers specially to the torch head and the consumables. Pos: 9.21 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/Original-Kjellberg-Verschleißteile @ 0\mod_1202913276255_19.doc @ 3649 @ @ 1 You are only allowed to use ORIGINAL Kjellberg spare parts and consumables! The use of other manufacturer consumables leads to the loss of the warranty claim.

  • Page 48: Maintenance Special

    Maintenance Pos: 11.1 /Überschriften/1.1/Wartung speziell @ 0\mod_1197630595186_19.doc @ 1780 @ 2 @ 1 3.2 Maintenance special Pos: 11.2 /Überschriften/1.1.1/Gasdruckprobe @ 0\mod_1197630517542_19.doc @ 1776 @ 3 @ 1 3.2.1 Gas pressure test Pos: 11.3 /Wartung/Gasdruckprobe- allgemein @ 0\mod_1199886312473_19.doc @ 2540 @ @ 1 When using oxygen, hydrogen or inflammable gas mixtures the check of the gas supply system is particularly important.
  • Page 49 Maintenance Pos: 11.9 /Wartung/Protokoll-GasdruckprobeTeil 1 @ 0\mod_1215593985203_19.doc @ 4555 @ @ 1 Year Month carried out gas pressure test Date Name Signature Oxygen Hydrogen June July Sept June July Sept Pos: 11.10 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...
  • Page 50 Maintenance Pos: 11.11 /Wartung/Protokoll-GasdruckprobeTeil 2 @ 0\mod_1201187237057_19.doc @ 3194 @ @ 1 Year Month carried out gas pressure test Date Name Signature forming gas June July Sept June July Sept Pos: 11.12 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 51: Coolant System

    Maintenance Pos: 11.13 /Überschriften/1.1.1/Kühlmittelsystem @ 0\mod_1197630747611_19.doc @ 1784 @ 3 @ 1 3.2.2 Coolant system Pos: 11.14 /Wartung/HiFo 80i,130,160i/Kühlmittelsystem-Teil1 @ 1\mod_1232545626022_19.doc @ 8007 @ @ 1 Losses of coolant during the change of consumables have to be replaced. Therefore weekly the filing level has to be checked.

  • Page 52: Preventive Periodic Maintenance - Component Change Plan

    Maintenance Pos: 11.18 /Überschriften/1.1.1/Vorbeugende periodische Instandhaltung @ 0\mod_1206446876457_19.doc @ 3754 @ 3 @ 1 3.2.3 Preventive periodic maintenance - component change plan Pos: 11.19 /Wartung/HiFo 80i,130,160i/HiFo161i/vorbeugende Periodische Instandhaltung @ 6\mod_1305275524855_19.doc @ 62003 @ @ 1 To guarantee a high availability of the unit, the strict adherence of the stated maintenance measures is necessary.
  • Page 53 Maintenance 5 years or after coolant (-15°C or -25°C) .12.62330 or .12.62350 unit depending 5000 cutting hours ignition unit contactor .10.161.710.24 nozzle-workpiece contactor .10.161.722.24 .10.535.611 6 years or after coolant (-15°C or -25°C) .12.62330 or .12.62350 unit depending 6000 cutting hours ignition unit contactor .10.161.710.24 nozzle-workpiece contactor...

  • Page 54: Customer Information On Repair Processing

    Customer information on repair processing Pos: 13.1 /Überschriften/1/Reparaturen, Kundeninformationen zu @ 8\mod_1336998620141_19.doc @ 154157 @ 1 @ 1 4 Customer information on repair processing Pos: 13.2 /Reparaturinformationen/Einleitung @ 8\mod_1336997520792_19.doc @ 154101 @ @ 1 To ensure effective processing of repair orders, please take note of the following: Pos: 13.3 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Hinweise (schwarz)/Reparaturinfo-1-ohne Zubehör @ 8\mod_1336994716980_19.doc @ 154023 @ @ 1 Information Ship without accessories where possible...

  • Page 55: Disposal

    Pos: 15.5 /Entsorgung/Entsorgung der Geräte @ 0\mod_1214904040990_19.doc @ 4389 @ @ 1 The units of the company Kjellberg Finsterwalde are products which can properly be recycled or disposed after placing out of operation on the basis of regional applicable regulations by a waste management company.

  • Page 56: Power Source Hifocus 161I Neo

    Power source HiFocus 161i neo Pos: 17.1 /Stromquellen/HiFocus/HiFo161i/neo/Foto @ 11\mod_1383571113418_0.doc @ 189581 @ @ 1 Pos: 17.2 /Überschriften/1/HiFo 161i neo @ 11\mod_1383571364983_19.doc @ 189600 @ 1 @ 1 6 Power source HiFocus 161i neo - Power source HiFocus 161i neo Pos: 17.3 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 57: Technical Data

    Power source HiFocus 161i neo Pos: 17.4 /Überschriften/1.1/Technische Daten/t.d.der Stromquelle @ 3\mod_1246276866745_19.doc @ 15365 @ 2 @ 1 6.1 Technical data Pos: 17.5 /Stromquellen/HiFocus/HiFo161i/neo/technische Daten-161i-neo @ 11\mod_1382433506634_19.doc @ 187584 @ @ 1 primary side: 3x 400V ±10%, 50Hz mains voltage U 28 kVA (100% ED) max.

  • Page 58: Technical Description

    Pos: 17.7 /Überschriften/1.1/Technische Beschreibung/Stromquelle @ 3\mod_1246362076809_19.doc @ 15633 @ 2 @ 1 6.2 Technical description Pos: 17.8 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/Sicherheitstechnische Einheit/Plasmabrenner PerCut 200/210 nur für HiFocus80i-161ii, Stromquelle @ 5\mod_1288864093807_19.doc @ 41182 @ @ 1 Only plasma torches of the types PerCut 200/210A/210M of Kjellberg Finsterwalde are determined for use with power sources HiFocus 80i, HiFocus 130, HiFocus 160i and HiFocus 161i by EN 60974-1.

  • Page 59: Hifocus- Technology

    Power source HiFocus 161i neo Pos: 17.12 /Überschriften/1.1.1/HiFocus-Technologie @ 2\mod_1236062718305_19.doc @ 9241 @ 3 @ 1 6.2.2 HiFocus- technology Pos: 17.13 /Stromquellen/Allgemeines/Hifocus-Technologie @ 2\mod_1236062266877_19.doc @ 9229 @ @ 1 By the application of the Plasma Fine-Focus-Principle acc. to Professor Manfred von Ardenne with its extreme constriction of the plasma arc extraordinarily energy densities will be achieved, which will be PLUS additionally increased in the HiFocus range with HiFocus...

  • Page 60: Special Parameters Of The Power Source

    Power source HiFocus 161i neo Pos: 17.17 /Überschriften/1.1.1/spezielle Parameter der Stromquelle @ 2\mod_1236062862244_19.doc @ 9249 @ 3 @ 1 6.2.4 Special parameters of the power source Pos: 17.18 /Stromquellen/HiFocus/HiFocus 80i/130/160i/HiFocus 160i/spezielle Parameter @ 2\mod_1236844437913_19.doc @ 9445 @ @ 1  stepless adjustable cutting current from 10 – 160 A (100 % ED) ...

  • Page 61: Cutting Technology

    In the cutting data manual you will find for your plasma cutting machine the available cutting technologies and the associated parameters under point "Technology overview". Pos: 17.22 /Stromquellen/HiFocus/HiFocus 80i/130/160i/HiFocus 160i/Anwendungsbereiche PerCut PerCut 200/210 @ 1\mod_1231914931153_19.doc @ 7225 @ @ 1 HiFocus CC –technology (HiFocus Contour Cut)
  • Page 62 Power source HiFocus 161i neo HiFocus CCS –technology (HiFocus Contour Cut Speed) mild steel stainless steel aluminium Optimized plasma cutting technology for fast cutting of outer contours.  cutting of small inner contours is possible  high cutting performance due to much higher cutting speeds ...
  • Page 63 Power source HiFocus 161i neo HiFocus- technology mild steel stainless steel aluminium Basic technology with highest cutting quality  cutting of inner contours is possible  direct corner cutting is possible  Double-Straight-Effect (both cut surfaces are applicable for technology) ...
  • Page 64 Power source HiFocus 161i neo HiFocusF-technology mild steel stainless steel aluminium Plasma cutting technology for flying cutting  Double-Straight-Effect (both cut surfaces are applicable for technology)  dross-free plasma cutting in a larger range of parameters  no time-consuming rework required ...

  • Page 65: Plasma Marking

    Power source HiFocus 161i neo Pos: 17.25 /Überschriften/1.1/Plasmamarkieren @ 1\mod_1234347483310_19.doc @ 8320 @ 2 @ 1 6.4 Plasma marking Pos: 17.26.1 /Stromquellen/HiFocus/HiFocus 80i/130/160i/Markieren/Markieren, Kerben, Körnen - HiFocus 160i ... @ 1\mod_1231926760881_19.doc @ 7294 @ @ 1 (does only apply for power sources and gas consoles, which support plasma marking) By application of the “Plasma FineFocus-Principle”...

  • Page 66: Putting Into Operation

    Power source HiFocus 161i neo Pos: 17.28 /Überschriften/1.1/Inbetriebnahme @ 0\mod_1197632842339_19.doc @ 1808 @ 2 @ 1 6.5 Putting into operation Pos: 17.29 /Überschriften/1.1.1/Überprüfung, Aufstellung und Transport @ 2\mod_1237368815504_19.doc @ 9640 @ 3 @ 1 6.5.1 Check, placement and transport Pos: 17.30 /Stromquellen/Allgemeines/Überprüfung @ 0\mod_1201525234482_19.doc @ 3250 @ @ 1 ...
  • Page 67 Power source HiFocus 161i neo Pos: 17.33 /Stromquellen/Allgemeines/Transport, Verladen mittels Gabelstapler @ 0\mod_1216372983708_19.doc @ 4710 @ @ 1 It is possible to load the unit by forklift. Pos: 17.34 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Warnung, Kippgefahr bei Gabelstaplerverladung, PA @ 0\mod_1199976872772_19.doc @ 2648 @ @ 1 WARNING Danger of tilting at the loading by the fork truck! Further personal and material damages can result, please note the rules of conduct when...

  • Page 68: Installation

    Power source HiFocus 161i neo Pos: 17.39 /Überschriften/1.1.1/Installation @ 0\mod_1197634429825_19.doc @ 1870 @ 3 @ 1 6.5.2 Installation Pos: 17.40 /Überschriften/1.1.1.1/Netzanschluss @ 0\mod_1197634515572_19.doc @ 1874 @ 4 @ 1 6.5.2.1 Mains connection Pos: 17.41 /Stromquellen/HiFocus/HiFo161i/Netzanschluss @ 6\mod_1305030297662_19.doc @ 61672 @ @ 1 The plasma cutting machine is delivered by default for the connection to the mains cable (4x16 mm², 5 m long) and mains plug (CEE-63 A) .
  • Page 69 Power source HiFocus 161i neo Pos: 17.46.1 /Überschriften/unterstrichene Überschrift/Allgemeine Hinweise @ 3\mod_1246962614380_19.doc @ 15827 @ @ 1 General information Pos: 17.46.2 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/geltende nationale und lokale Vorschriften @ 0\mod_1199802901541_19.doc @ 2505 @ @ 1 The operator has to follow national and local regulations (for example Employer’s Liability Insurance Association)! Pos: 17.46.3 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/guter elektrischer Kontakt zw.
  • Page 70 Power source HiFocus 161i neo Pos: 17.46.8 /Stromquellen/Allgemeines/Erdung HiFocus 80i-440i, Teil 3, Bild @ 3\mod_1246970494965_19.doc @ 15942 @ @ 1 Fig. 5.: Potential equalisation and protective conductor guidance, example Pos: 17.46.9 /Stromquellen/Allgemeines/Erdung HiFocus 80i-440i, Teil 4, Legende @ 3\mod_1246970867195_19.doc @ 15949 @ @ 1 Footnote/Term Explanation Note...

  • Page 71: Connections At The Rear Panel Of The Power Source

    Power source HiFocus 161i neo Pos: 17.48 /Überschriften/1.1.1.1/Rückwand der Stromquelle @ 0\mod_1197634723247_19.doc @ 1886 @ 4 @ 1 6.5.2.3 Connections at the rear panel of the power source Pos: 17.49 /Stromquellen/HiFocus/HiFo161i/Text Rückwand @ 6\mod_1305030499711_19.doc @ 61686 @ @ 1 All connecting and control cables will be placed to the rear panel of the power source. Voltage-carrying parts and the fuses are accessible only after opening the cover plate, which is protected by a safety contact.
  • Page 72 Power source HiFocus 161i neo Pos: 17.52 /Stromquellen/HiFocus/HiFo161i/neo/Rückseitige Anschlüsse der HiFo 161i-neo, Beschreibung @ 11\mod_1382450976936_19.doc @ 187644 @ @ 1 Connector ocs (ohmic contact sensor) X138 8-pol. socket Connector guiding system (ON / OFF for Plasma unit, X106 7-pol. socket emergency stop) Connector remote control (FB) X132...

  • Page 73: Remote Control Fb

    Power source HiFocus 161i neo Pos: 17.55 /Stromquellen/HiFocus/HiFo161i/externe Katodenleitung @ 6\mod_1305189623403_19.doc @ 61870 @ @ 1 Fig. 7.: Connector external cathode cables 2 x 16 mm²: cable lugs placed against each other (18) Pos: 17.56 /Überschriften/1.1/Fernbediensatz @ 0\mod_1197633349787_19.doc @ 1820 @ 2 @ 1 6.6 Remote control FB Pos: 17.57 /Stromquellen/Allgemeines/Fernbediensatz @ 0\mod_1201786336258_19.doc @ 3384 @ @ 1 With the remote control FB the cutting process with the plasma machine torch (ignition of pilot arc) can be...

  • Page 74: Operating And Display Elements

    Power source HiFocus 161i neo Pos: 17.63 /Überschriften/1.1/Bedien- und Anzeigeelemente @ 0\mod_1197632890017_19.doc @ 1812 @ 2 @ 1 6.8 Operating and display elements Pos: 17.64 /Stromquellen/HiFocus/HiFo161i/Bedien- und Anzeigeelemente @ 6\mod_1305094057624_19.doc @ 61750 @ @ 1 Fig. 8.: Control- and display elements Pos: 17.65 /Stromquellen/HiFocus/HiFo161i/Bedien- und Anzeigeelmente beschr.
  • Page 75 Power source HiFocus 161i neo Tumbler switch „Gas pressure test" Upper switch position: Plasma cutting machine ready for gas pressure test::  LED signal lamp yellow “cumulative error” (18) and “Process error” (19) are ON  solenoid valves are closed ...
  • Page 76 Power source HiFocus 161i neo LED signal lamp green “Temperature power source o.k." LED is ON, when the temperature of the power source is within the acceptable range. LED signal lamp white “Current flows" LED is ON, when the pilot arc is ON. LED signal lamp white “Main arc”...
  • Page 77 Power source HiFocus 161i neo Pos: 17.67 /Stromquellen/HiFocus/HiFo161i/Anzeige im Display @ 6\mod_1305100445292_19.doc @ 61778 @ @ 1 information at the Meaning Remark display voltage current serial connections between plasma unit and display only during cutting breaks guiding system activated remote control (FB) is connected display only during cutting breaks gas test active gas flows...
  • Page 78 Power source HiFocus 161i neo actual value cutting voltage (example: 112 V) display during cutting and marking actual value current (example: 25 A) plasma unit is waiting for an OFF- signal from disturbance end guiding unit (CNC) or remote control (FB) ER ≙...

  • Page 79: Cutting Operation

    Power source HiFocus 161i neo Pos: 17.69 /Überschriften/1.1/Schneidbetrieb @ 0\mod_1197633041208_19.doc @ 1816 @ 2 @ 1 6.9 Cutting operation Pos: 17.70 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Plasmaanlage nicht mit geöffnetem Gehäuse betreiben @ 0\mod_1201864736354_19.doc @ 3502 @ @ 1 WARNING It is not allowed to operate the unit with any of the housing cover plates not in place! It is hazardous to the operator and other people in the area, and prevents the equipment from...
  • Page 80 Power source HiFocus 161i neo Pos: 17.74 /Stromquellen/HiFocus/HiFo161i/Reihenfolge der Bedienung @ 6\mod_1305116445455_19.doc @ 61848 @ @ 1 Operation sequences red mushroom button S3 “emergency stop" Unlock the button by turning it in one direction. Key switch S1 Turn the key switch to the position „I“. “Mains ON"...
  • Page 81 Power source HiFocus 161i neo Potentiometer „Down  activate tumbler switch “down slope-time“ (7) and adjust the “down slope” - slope“ (11) time with the potentiometer  look at the value shown at the current display (21) The display is in ms. selector switch (12) Adjust the selector switch to position 1 (preferred value) "up slope"...
  • Page 82 Power source HiFocus 161i neo Pos: 17.76 /Stromquellen/HiFocus/HiFocus 80i/130/160i/HiFocus 160i/Ein- und Ausschalten des Plasmabrenners @ 1\mod_1231859156090_19.doc @ 7205 @ @ 1 Switch ON and OFF of the plasma torch The pilot arc will be established by the ON-signal from the guiding system (X102:B2-B3) or when pressing the ON-button of the remote control FB after the gas preflow.
  • Page 83 Power source HiFocus 161i neo Pos: 17.82 /Stromquellen/HiFocus/HiFocus 80i/130/160i/Abbildung-Abstandsregelung @ 1\mod_1227619198247_19.doc @ 6530 @ @ 1 Fig. 10.: schematic diagram of a cutting process with height control system Pos: 17.83 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...
  • Page 84 Power source HiFocus 161i neo Pos: 17.84 /Stromquellen/HiFocus/HiFocus 80i/130/160i/Beschreibung Abstandsregelung @ 1\mod_1227619205263_19.doc @ 6535 @ @ 1 Sequence steps of height control process ON / setting plasma torch to ignition height torch ON / gas pre-flow / waiting for pilot arc ON keep torch to ignition height / waiting for current ON, main arc ON hole piercing, lifting up to pierce height temporary (at larger material thickness) lowering torch to cutting height, delay time for height control...

  • Page 85: Combination Of The Hifocus With Cnc-Controls Of The Guiding Systems And Robots

    25 pole socket (system Wieland), placed in the back wall of the power source. The respective cable the user has to prepare himself. The necessary materials can be supplied on request from Kjellberg Finsterwalde. The potential-free contacts are dimensioned for a current load of max. 500 mA DC at a control voltage of 24 V.
  • Page 86 Power source HiFocus 161i neo Information If the Remote Control FB is connected no ignition of the plasma torch from the CNC control is possible. Pos: 17.93 /Stromquellen/HiFocus/HiFocus 280i/360i/440i/X104, Signale vom Strom-und Spannungs-Istwert @ 0\mod_1201788359570_19.doc @ 3411 @ @ 1 X104 signal remark...
  • Page 87 According to existing safety standards it must not be possible to start the unit external (through CNC) and from the power source as well. The On/Off- function should be practicable only from one place! Kjellberg Finsterwalde clearly pointes out that in case the switching On is carried out from the CNC the user has to realize the safety function (e.g.

  • Page 88: Multiple Machine Operation

    Power source HiFocus 161i neo Pos: 17.101 /Überschriften/1.1/Mehrmaschinenbetrieb @ 0\mod_1197633679745_19.doc @ 1832 @ 2 @ 1 6.11 Multiple machine operation Pos: 17.102 /Stromquellen/HiFocus/HiFocus 280i/360i/440i/Mehrmaschinenbetrieb @ 0\mod_1201789354296_19.doc @ 3423 @ @ 1 For a multiple machine operation each plasma unit has to be provided with a separate machine number. Therefore the PCB Sequence control (LP 067101) is furnished with the Jumpers J7 and J8 (see following chart).

  • Page 89: Switching Regime Of The Power Source

    Power source HiFocus 161i neo Pos: 17.105 /Überschriften/1.1/Einschaltregime Stromquelle @ 0\mod_1197633736767_19.doc @ 1836 @ 2 @ 1 6.12 Switching regime of the power source Pos: 17.106 /Überschriften/1.1.1/Einschaltung über Fernbediensatz @ 0\mod_1197634911857_19.doc @ 1894 @ 3 @ 1 6.12.1 Start by remote control FB (at commissioning) Pos: 17.107 /Stromquellen/HiFocus/HiFocus 280i/360i/440i/Einschalten über Fernbediensatz @ 0\mod_1201791128240_19.doc @ 3451 @ @ 1 Connection to socket X132 X132...

  • Page 90: Start From Cnc With Special Function "Separate Ignition Signal

    Power source HiFocus 161i neo Pos: 17.111 /Überschriften/1.1.1/Einschalten von CNC mit Sonderfunktion "Separates Zündsignal" @ 0\mod_1197635129112_19.doc @ 1902 @ 3 @ 1 6.12.3 Start from CNC with special function "separate ignition signal" Pos: 17.112 /Stromquellen/HiFocus/HiFocus 280i/360i/440i/Einschalten von CNC mit Sonderfunktion "Separates Zündsignal" @ 0\mod_1201791389476_19.doc @ 3459 @ @ 1 Connection to socket X102 (process start signal) and X132 (ignition signal) X132 Function...

  • Page 91: Protective Facilities

    Power source HiFocus 161i neo Pos: 17.116 /Überschriften/1.1/Schutzeinrichtungen @ 0\mod_1197633842718_19.doc @ 1840 @ 2 @ 1 6.13 Protective facilities Pos: 17.117 /Stromquellen/HiFocus/HiFo161i/Schutzeinrichtung @ 6\mod_1305192437628_19.doc @ 61928 @ @ 1 The plasma cutting machine is ready for operation, when after actuating the key switch S1 "mains on" (2) and the green illuminated push button S2 "readiness for operation"...

  • Page 92: Information For Trouble Shooting

    Power source HiFocus 161i neo Pos: 17.119 /Überschriften/1.1/Hinweise zur Fehlersuche @ 0\mod_1197633890412_19.doc @ 1844 @ 2 @ 1 6.14 Information for trouble shooting Pos: 17.120 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Warnung Öffnen des Gerätes @ 0\mod_1199714392778_19.doc @ 2391 @ @ 1 WARNING Warning of dangerous electric voltage Electric shock can be deadly.
  • Page 93 Power source HiFocus 161i neo Pos: 17.125 /Stromquellen/HiFocus/HiFo161i/Fehlerliste @ 6\mod_1305107521701_19.doc @ 61792 @ @ 1 error chart / error codes - of the power source current- relevance LED-display cause end or fault clearance display ER 1 “Cumulative gas-coolant- error“(18) temperature settle disturbances see disturbance Gas,...
  • Page 94 Power source HiFocus 161i neo current- relevance LED-display cause end or fault clearance display ER 3 LED signal lamp current flow during Torch defect yellow “Cumulative gas preflow switch OFF unit, check torch error“(18) and consumables ER30 short circuit at the torch ER31 LED signal lamp...

  • Page 95: Plasma Gas Control Unit Pge 3-161

    Plasma gas control unit PGE 3-161 Pos: 19.1 /Gaskonsolen/PGE3-161/Foto @ 12\mod_1385114023339_0.doc @ 191834 @ @ 1 Pos: 19.2 /Überschriften/1/Komponenten/PGE3-161 @ 12\mod_1385114289972_19.doc @ 191853 @ 1 @ 1 7 Plasma gas control unit PGE 3-161 - Plasma gas control unit PGE 3-161 Pos: 19.3 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 96: Technical Data

    Plasma gas control unit PGE 3-161 Pos: 19.4 /Überschriften/1.1/Technische Daten/t.d.fürPlasmagaskonsole @ 3\mod_1246276961407_19.doc @ 15381 @ 2 @ 1 7.1 Technical data Pos: 19.5 /Gaskonsolen/PGE3-161/Technische Daten der PGE 3-161 @ 12\mod_1385112525521_19.doc @ 191754 @ @ 1 PGE 3-161 - art.-no.: .11.825.104 Operating voltage Solenoid valves: 24 V AC, 50 / 60 Hz...

  • Page 97: Technical Description

    Plasma gas control unit PGE 3-161 Pos: 19.7 /Überschriften/1.1/Technische Beschreibung/plasmagaskonsole @ 3\mod_1246362137469_19.doc @ 15639 @ 2 @ 1 7.2 Technical description Pos: 19.8 /Gaskonsolen/PGE 3-HM/Technische Beschreibung PGE 3-HM @ 1\mod_1232025814375_19.doc @ 7451 @ @ 1 The plasma gas console is needed when adjusting and dosing the plasma and swirl gases according to operation.
  • Page 98 Plasma gas control unit PGE 3-161 Fig. 18.: Dimension diagram PGE 3-161 Pos: 19.10 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 99: Connection Of The Plasma Gas Control Unit

    Plasma gas control unit PGE 3-161 Pos: 19.11 /Überschriften/1.1/Anschluss der Plasmagaseinstelleinheit @ 1\mod_1221565600674_19.doc @ 5268 @ 2 @ 1 7.3 Connection of the Plasma Gas Control Unit PGE Pos: 19.12 /Gaskonsolen/PGE3-161/Anschluss der PGE 3-161 @ 12\mod_1385112527421_19.doc @ 191774 @ @ 1 The PGE 3-161 is connected to the X110 socket situated at the rear of the plasma machine via a 25-pole control line.

  • Page 100: Operating And Display Elements

    Plasma gas control unit PGE 3-161 Pos: 19.16 /Überschriften/1.1/Bedien- und Anzeigeelemente @ 0\mod_1197632890017_19.doc @ 1812 @ 2 @ 1 7.4 Operating and display elements Pos: 19.17 /Gaskonsolen/PGE3-161/Bedien- und Anzeigeelemente PGE 3-161 @ 12\mod_1385112531591_19.doc @ 191814 @ @ 1 Fig. 20.: Operating and display elements of the PGE 3-161 tumbler switch S5 “gas test”...

  • Page 101: Connection Of The Gas Hoses Between Plasma Gas Console And Pba

    Plasma gas control unit PGE 3-161 Pos: 19.19 /Überschriften/1.1/Anschluss der Gasschläuche zwischen Plasmagaskonsole und PBA @ 0\mod_1197636176586_19.doc @ 1934 @ 2 @ 1 7.5 Connection of the gas hoses between plasma gas console and PBA Pos: 19.20 /Gaskonsolen/PGE 3-HM/Anschluss der Gasschläuche zwischen Plasmagaskonsole und PBA @ 1\mod_1232025808359_19.doc @ 7411 @ @ 1 The length of the gas hoses for the connection of the components of the Plasma Cutting Complex have to arranged according to the system configuration.

  • Page 102: Plasma Gases

    Plasma gas control unit PGE 3-161 Pos: 19.29 /Überschriften/1.1.1/Plasmagase @ 1\mod_1226057517942_19.doc @ 5832 @ 3 @ 1 7.6.1 Plasma gases Pos: 19.30 /Gaskonsolen/PGE 3-HM/Gasversorgung Plasmagas @ 1\mod_1232025813391_19.doc @ 7441 @ @ 1 For the gas supply the following hoses have to be used: Plasma gas Colour of the gas hose Marking...
  • Page 103 Plasma gas control unit PGE 3-161 Pos: 19.39 /Überschriften/unterstrichene Überschrift/Sauerstoff @ 1\mod_1231339546871_19.doc @ 6940 @ @ 1 Oxygen Pos: 19.40 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Verschleißteile in Berührung mit Sauerstoff öl-und fettfrei (Explosionsschutzsicherung) @ 0\mod_1201005445751_19.doc @ 3177 @ @ 1 WARNING All parts that come into contact with oxygen must be kept oil and grease free! When using oxygen, the explosion protection for oxygen must be connected to the pressure-reducer...

  • Page 104: Swirl Gases

    Plasma gas control unit PGE 3-161 Pos: 19.48 /Überschriften/1.1.1/Wirbelgase @ 1\mod_1226057544925_19.doc @ 5836 @ 3 @ 1 7.6.2 Swirl gases Pos: 19.49 /Gaskonsolen/Allgemein/Anschluss der Gasversorgung-Teil1 @ 0\mod_1200925831915_19.doc @ 3136 @ @ 1 The connections for the plasma gas supply hoses can be found at the rear of the plasma gas console (see upper Fig.).
  • Page 105 Plasma gas control unit PGE 3-161 Pos: 19.56 /Überschriften/unterstrichene Überschrift/Luft @ 1\mod_1232633158925_19.doc @ 8060 @ @ 1 Pos: 19.57 /Gaskonsolen/Allgemein/Anforderungen an die Luftqualität @ 1\mod_1221556931523_19.doc @ 5230 @ @ 1 Air quality specifications  max. particle size 0,1 m Class 1 according to ISO 8573 ...
  • Page 106 Plasma gas control unit PGE 3-161 Pos: 19.62 /Überschriften/unterstrichene Überschrift/Formiergas @ 1\mod_1232030449267_19.doc @ 7547 @ @ 1 Forming gas Pos: 19.63 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Anschluss Formiergas @ 1\mod_1232030910695_19.doc @ 7560 @ @ 1 WARNING Before attaching the backing gas the oxygen hose has to be removed from the inlet “swirl gas WG1”! Pos: 19.64 /Gaskonsolen/PGE 3-HM/Gasversorgung Formiergas @ 1\mod_1232030535799_19.doc @ 7551 @ @ 1 ...

  • Page 107: Plasma Machine Torch Percut 200 / 210

    Plasma machine torch PerCut 200 / 210 … Pos: 21.1 /Brenner/PerCut 200/210/Foto @ 6\mod_1296648334557_0.doc @ 54299 @ @ 1 Pos: 21.2 /Überschriften/1/Brenner/Plasmamaschinenbrenner PerCut 210 @ 5\mod_1288881607497_19.doc @ 41336 @ 1 @ 1 8 Plasma machine torch PerCut 200 / 210 …...

  • Page 108: Technical Data

    Plasma machine torch PerCut 200 / 210 … Pos: 21.4 /Überschriften/1.1/Technische Daten/t.d.fürBrenner @ 3\mod_1246277225034_19.doc @ 15393 @ 2 @ 1 8.1 Technical data Pos: 21.5 /Brenner/PerCut 200/210/Technische Daten PerCut 200/210 @ 5\mod_1288856450227_19.doc @ 41161 @ @ 1 PerCut 200 PerCut 210A PerCut 210M (.11.850.021)

  • Page 109: Technical Description

    8.2 Technical description Pos: 21.8 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/Sicherheitstechnische Einheit/Plasmabrenner PerCut 200/210M nur für HiFocus130- 161i, Brenner @ 5\mod_1288864100761_19.doc @ 41193 @ @ 1 The plasma torches PerCut 200 / 210A / 210M and PerCut 201 / 211A / 211M of Kjellberg Finsterwalde are determined for use with power sources HiFocus 130, HiFocus 160i and HiFocus 161i by EN 60974-1.

  • Page 110: Connection Of The Plasma Torch To The Plasma Torch Connection Unit Pba

    Plasma machine torch PerCut 200 / 210 … Pos: 21.13 /Überschriften/1.1/Anschluss der Plasmabrenner an die PBA @ 0\mod_1197635424876_19.doc @ 1910 @ 2 @ 1 8.3 Connection of the plasma torch to the plasma torch connection unit PBA Pos: 21.14 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Plasmaanlage vom Netz trennen @ 0\mod_1200055330844_19.doc @ 2770 @ @ 1...

  • Page 111: Consumables And Their Exchange

    Plasma machine torch PerCut 200 / 210 … Pos: 21.17 /Überschriften/1.1/Verschleißteile und deren Austausch @ 0\mod_1197635517862_19.doc @ 1914 @ 2 @ 1 8.4 Consumables and their exchange Pos: 21.18 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Verschleißteilwechsel am Plasmabrenner -Plasmaanlage von Netz trennen @ 0\mod_1200055457147_19.doc @ 2774 @ @ 1...
  • Page 112 Plasma machine torch PerCut 200 / 210 … Pos: 21.24 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Ethandiol-Brand-2.1-Verdampfung, Katodenabbrand @ 1\mod_1228291972637_19.doc @ 6570 @ @ 1 WARNING If an above the wear limits driven cathode produce a damage of the plasma torch, leaking coolant can impact glowing dross.
  • Page 113 Plasma machine torch PerCut 200 / 210 … Pos: 21.27 /Brenner/Allgemein/Abbildung Katodenverschleißprüfung @ 0\mod_1200047767954_19.doc @ 2704 @ @ 1 Control with flat meter feeler Control with sharp meter feeler .16.004.810.8 .16.004.810.2 Reset only with unused cathode Fig. 26.: Ascertaining of the cathode wear with the cathode dial indicator Art.-Nr. .36.000.015 Pos: 21.28 /Brenner/Allgemein/Verschleißteile-Teil2 @ 0\mod_1200048713900_19.doc @ 2708 @ @ 1...

  • Page 114: Plasma Machine Torch Percut 200 / 210A / 210M

    8.4.1 Plasma machine torch PerCut 200 / 210A / 210M Pos: 21.34 /Brenner/PerCut 200/210/Verschleißteilübersicht PerCut 210 @ 5\mod_1288873432771_19.doc @ 41237 @ @ 1 Dismounting of used consumables Manually unscrew the protective cap (xx.07) together with the swirl gas cap (xx.06).
  • Page 115 Plasma machine torch PerCut 200 / 210 … Pos: 21.36 /Brenner/PerCut 440/450/Montagehinweis Düse @ 6\mod_1299572476000_19.doc @ 55454 @ @ 1 Fig. 27.: Insert the nozzle into the torch head Pos: 21.37 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 116: Replacement Of The Current Socket And Current Plug In The Torch Shaft

    Plasma machine torch PerCut 200 / 210 … Pos: 21.38 /Überschriften/1.1.1/strombuchse oder -stecker auswechseln @ 3\mod_1254217082621_19.doc @ 22106 @ 3 @ 1 8.4.2 Replacement of the current socket and current plug in the torch shaft Pos: 21.39 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Vorsicht (gelb)/Arbeiten an Strombuchse und Stecker @ 3\mod_1254206443668_19.doc @ 21992 @ @ 1...

  • Page 117: Information For Using Of The Change Heads

    Pos: 21.43 /Überschriften/1.1/Wartung und Pflege der Wechselköpfe @ 0\mod_1197635679856_19.doc @ 1918 @ 2 @ 1 8.5 Information for using of the change heads Pos: 21.44 /Brenner/PerCut 200/210/PerCut 210A+PerCut 210M @ 5\mod_1288881315833_19.doc @ 41281 @ @ 1 PerCut 210A and PerCut 210M Pos: 21.45 /Überschriften/1.1.1/Abbau des Wechselkopfes @ 0\mod_1197636750077_19.doc @ 1962 @ 3 @ 1...
  • Page 118 Plasma machine torch PerCut 200 / 210 … Pos: 21.51 /Brenner/PerCut 200/210/Parkstation @ 5\mod_1288881538464_19.doc @ 41325 @ @ 1 Please use for dismantling of the change head PerCut 210M the “Station for change head PerCut 450M” Fig. 29.: Station for change head PerCut 450M...

  • Page 119: Maintenance Of The Change Head

    Plasma machine torch PerCut 200 / 210 … Pos: 21.53 /Überschriften/1.1.1/Wartung der Wechselköpfe @ 0\mod_1197636969017_19.doc @ 1970 @ 3 @ 1 8.5.2 Maintenance of the change head Pos: 21.54 /Brenner/PerCut 200/210/Tabelle-ETL-Zeichnung 210A/M @ 5\mod_1288877128111_19.doc @ 41248 @ @ 1 Plasma torch: PerCut 210A PerCut 210M Drawing of the spare parts lists: .11.850..221.E0...

  • Page 120: Control Of The Location Pin

    Plasma machine torch PerCut 200 / 210 … Pos: 21.62 /Brenner/PerCut 440/450/Abb. innere + äußere O-Ringe @ 7\mod_1314782932449_19.doc @ 132753 @ @ 1 Fig. 30.: Inner and outer o-rings of the quick-change head Pos: 21.63 /Überschriften/1.1.1.1/Kontrolle des Pilotstifts @ 3\mod_1254404885145_19.doc @ 22204 @ 4 @ 1 8.5.2.2...

  • Page 121: Percut 210M

    Pos: 21.74 /Überschriften/1.1/Wartung und Pflege @ 0\mod_1197635760829_19.doc @ 1922 @ 2 @ 1 Maintenance and attendance of the plasma torch Pos: 21.75 /Brenner/PerCut 200/210/PerCut 200 @ 5\mod_1288881318724_19.doc @ 41292 @ @ 1 PerCut 200 Pos: 21.76 /Brenner/PerCut 200/210/Tabelle-ETL-Zeichnung 200 @ 5\mod_1288877433556_19.doc @ 41259 @ @ 1...

  • Page 122: Plasma Machine Torch Percut 201 / 211

    Plasma machine torch PerCut 201 / 211 … Pos: 23.1 /Brenner/PerCut 200/210/Foto @ 6\mod_1296648334557_0.doc @ 54299 @ @ 1 Pos: 23.2 /Überschriften/1/BrennerPlasma-Maschinenbrenner PerCut 201 / 211 @ 8\mod_1335434376722_19.doc @ 153746 @ 1 @ 1 9 Plasma machine torch PerCut 201 / 211 …...

  • Page 123: Technical Data

    Plasma machine torch PerCut 201 / 211 … Pos: 23.4 /Überschriften/1.1/Technische Daten/t.d.fürBrenner @ 3\mod_1246277225034_19.doc @ 15393 @ 2 @ 1 9.1 Technical data Pos: 23.5 /Brenner/PerCut201/211/Technische Daten @ 8\mod_1335431720189_19.doc @ 153602 @ @ 1 PerCut 201 PerCut 211A PerCut 211M (.11.853.021) (.11.853.221) (.11.853.421)

  • Page 124: Technical Description

    9.2 Technical description Pos: 23.8 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/Sicherheitstechnische Einheit/Plasmabrenner PerCut 200/210M nur für HiFocus130- 161i, Brenner @ 5\mod_1288864100761_19.doc @ 41193 @ @ 1 The plasma torches PerCut 200 / 210A / 210M and PerCut 201 / 211A / 211M of Kjellberg Finsterwalde are determined for use with power sources HiFocus 130, HiFocus 160i and HiFocus 161i by EN 60974-1.

  • Page 125: Connection Of The Plasma Torch To The Plasma Torch Connection Unit Pba

    The plasma torch has to be fastened to the support of the guiding system by using an adequate insulation. A special torch holder is available from Kjellberg Finsterwalde. The plasma torches are connected to the connectors on and in the PBA. The following connections shall be established: ...

  • Page 126: Consumables And Their Exchange

    Plasma machine torch PerCut 201 / 211 … Pos: 23.17 /Überschriften/1.1/Verschleißteile und deren Austausch @ 0\mod_1197635517862_19.doc @ 1914 @ 2 @ 1 9.4 Consumables and their exchange Pos: 23.18 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Verschleißteilwechsel am Plasmabrenner -Plasmaanlage von Netz trennen @ 0\mod_1200055457147_19.doc @ 2774 @ @ 1 WARNING In order to change consumables, the plasma cutting system shall be switched OFF and secured against any accidental start.
  • Page 127 Plasma machine torch PerCut 201 / 211 … Pos: 23.24 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettungszeichen (grün)/Ethandiol-Brand-2.1-Verdampfung, Katodenabbrand @ 1\mod_1228291972637_19.doc @ 6570 @ @ 1 WARNING If an above the wear limits driven cathode produce a damage of the plasma torch, leaking coolant can impact glowing dross.
  • Page 128 PerCut 200 / 210A / 210M PerCut 201 / 211A / 211M Pos: 23.31 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/Auf Vollständigkeit der Verschleißteile achten @ 0\mod_1200055848051_19.doc @ 2782 @ @ 1 Make sure that all wearing parts are complete and correct installed! Especially the cooling tube has to be inserted.

  • Page 129: Plasma Machine Torch Percut 201 / 211A / 211M

    Plasma machine torch PerCut 201 / 211 … Pos: 23.33 /Überschriften/1.1.1/Plasma-Maschinenbrenner PerCut 201 / 211A / 211M @ 8\mod_1335434566622_19.doc @ 153764 @ 3 @ 1 9.4.1 Plasma machine torch PerCut 201 / 211A / 211M Pos: 23.34 /Brenner/PerCut201/211/VT-Übersicht +Aus-u.Einbau @ 8\mod_1335432657792_19.doc @ 153656 @ @ 1 Dismounting of used consumables Before dismounting the consumables of the PerCut 211A please insert the change head in the “Station for the change heads”...
  • Page 130 Plasma machine torch PerCut 201 / 211 … Pos: 23.36 /Brenner/PerCut 440/450/Montagehinweis Düse @ 6\mod_1299572476000_19.doc @ 55454 @ @ 1 Fig. 35.: Insert the nozzle into the torch head Pos: 23.37 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 131: Replacement Of The Current Socket And Current Plug In The Torch Shaft

    Maintenance and repair work at the current socket and current plug of the plasma torches may be carried out only by the service department or authorised repair shops of the company Kjellberg Finsterwalde! Pos: 23.40 /Überschriften/unterstrichene Überschrift/Inbetriebnahme des Brenners nach Verschleißteilwechsel @ 0\mod_1197636624124_19.doc @ 1954 @ 3 @ 1 9.4.3...

  • Page 132: Information For Using Of The Change Heads

    Plasma machine torch PerCut 201 / 211 … Pos: 23.43 /Überschriften/1.1/Wartung und Pflege der Wechselköpfe @ 0\mod_1197635679856_19.doc @ 1918 @ 2 @ 1 9.5 Information for using of the change heads Pos: 23.44 /Brenner/PerCut201/211/PerCut 211A und PerCut 211M @ 8\mod_1335433185709_19.doc @ 153674 @ @ 1 PerCut 211A and PerCut 211M Pos: 23.45 /Überschriften/1.1.1/Abbau des Wechselkopfes @ 0\mod_1197636750077_19.doc @ 1962 @ 3 @ 1 9.5.1...
  • Page 133 Plasma machine torch PerCut 201 / 211 … Pos: 23.51 /Brenner/PerCut201/211/Parkstation @ 8\mod_1335433261821_19.doc @ 153692 @ @ 1 Please use for storage of the change head the “Station for the change heads”. .11.853.421.100 PerCut 211M Magnet Fig. 37.: Parking station .11.852.401.830 suitable for change head PerCut 211M...
  • Page 134 Plasma machine torch PerCut 201 / 211 … .11.853.221.100 PerCut 211A magnet grommet hose Fig. 38.: Parking station .11.852.201.840 suitable for change head PerCut 211A Pos: 23.52 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...
  • Page 135 Plasma machine torch PerCut 201 / 211 … Pos: 23.53 /Brenner/PerCut451/Parkstation_Test @ 9\mod_1350378239923_19.doc @ 162013 @ @ 1 Use the parking station .11.852.201.840 for consumable change of plasma torch PerCut 451A or PerCut 211A, this station is equipped with a mechanism for blowing out of the coolant. Unscrew the change head from the torch shaft for change of consumables.

  • Page 136: Maintenance Of The Change Head

     An oxygen-suitable lubricant (e.g. lubricant for O LC 40 Fluid, article no. .10.616.104) can be obtained from Kjellberg Finsterwalde. Pos: 23.59 /Warnung, Vorsicht, Verbot, Gebot, Hinweis/Gebotszeichen (blau)/Zerstörung des Wechselkopfes / Brennerkopfesdurch Öl und Fett @ 0\mod_1200056509056_19.doc @ 2806 @ @ 1 The use of lubricant for o-rings: ...

  • Page 137: Control Of The O-Rings

    Plasma machine torch PerCut 201 / 211 … Pos: 23.61 /Überschriften/1.1.1.1/Kontrolle der O-Ringe @ 3\mod_1254404775036_19.doc @ 22196 @ 4 @ 1 9.5.2.1 Control of the O-rings Pos: 23.62 /Brenner/PerCut451/Kontrolle äußere O-Ringe @ 7\mod_1322145319775_19.doc @ 143118 @ @ 1 Check of the outer o-rings ...
  • Page 138 Plasma machine torch PerCut 201 / 211 … Pos: 23.65 /Brenner/PerCut201/211/Abb. innere + äußere O-Ringe @ 8\mod_1337001098417_19.doc @ 154183 @ @ 1 PerCut 211A PerCut 211M Fig. 39.: Inner and outer O-rings on the replaceable head Pos: 23.66 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 139: Control Of The Location Pin

    Plasma machine torch PerCut 201 / 211 … Pos: 23.67 /Überschriften/1.1.1.1/Kontrolle des Pilotstifts @ 3\mod_1254404885145_19.doc @ 22204 @ 4 @ 1 9.5.2.2 Control of the location pin Pos: 23.68 /Brenner/PerCut451/Kontrolle des Pilotstiftes @ 7\mod_1322145322193_19.doc @ 143156 @ @ 1 Control or change of location pin (01.20): ...

  • Page 140: Percut 211M

    Plasma machine torch PerCut 201 / 211 … Pos: 23.75 /Überschriften/1.1.1.1/PerCut 211M @ 8\mod_1335434722265_19.doc @ 153800 @ 4 @ 1 9.5.3.2 PerCut 211M Pos: 23.76 /Brenner/PerCut 440/450/Anbau PerCut 450M @ 3\mod_1254212110931_19.doc @ 22056 @ @ 1 Threading the change head through the torch shaft by means of 5- groove system. Turn to the right of the sealing at the head approx.

  • Page 141: Plasma Torch Connection Unit Pba-161

    Plasma torch connection unit PBA-161 Pos: 25.1 /PBA/PBA-160/Bild PBA-160+Hintergrund @ 1\mod_1218192590887_19.doc @ 5080 @ @ 1 Pos: 25.2 /Überschriften/1/Komponenten/PBA-161 @ 11\mod_1382690718042_19.doc @ 187736 @ 1 @ 1 10 Plasma torch connection unit PBA-161 - Plasma torch connection unit PBA-161 Pos: 25.3 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 142: Technical Data

    Plasma torch connection unit PBA-161 Pos: 25.4 /Überschriften/1.1/Technische Daten/t.d.fürPBA @ 3\mod_1246277805893_19.doc @ 15399 @ 2 @ 1 10.1 Technical data Pos: 25.5 /PBA/PBA-160/neo/Technische Daten PBA-161 @ 11\mod_1383578400424_19.doc @ 189843 @ @ 1 .11.820.248 Art. no.: 230 V AC, 50 / 60 Hz Operating voltage (see chapter „connection of gas supply“...

  • Page 143: Connection Of The Plasma Torch Connection Unit

    Plasma torch connection unit PBA-161 Pos: 25.10 /Überschriften/1.1/Anschluss der PBA @ 0\mod_1197635837730_19.doc @ 1926 @ 2 @ 1 10.3 Connection of the plasma torch connection unit Pos: 25.11 /PBA/Anschluss der PBA, Teil 1 @ 1\mod_1221139464674_19.doc @ 5130 @ @ 1 The plasma torch connection unit has to be fixed to the guiding system or to a robot, the customer is using.
  • Page 144 Plasma torch connection unit PBA-161 Pos: 25.14 /PBA/PBA-160/neo/Bild der Anschlüsse der PBA-161 @ 11\mod_1383578392686_19.doc @ 189783 @ @ 1 Connector of plasma gas 1 of PGE/PGV (G1/4“) Connector of plasma gas 2 of PGE/PGV (G1/4“-LH) Connector of plasma gas 3 of PGE/PGV (G3/8“-LH) Connector of swirl gas of PGE/PGV (M12x1) Connector of ignition gas to the torch (PU-3-SW, black connection hose)

  • Page 145: Wiring Diagrams

    Wiring diagrams Pos: 27.1 /Überschriften/1/Schaltpläne @ 0\mod_1215503515361_19.doc @ 4489 @ 1 @ 1 11 Wiring diagrams Pos: 27.2 /Anlagen/Schaltpläne/HiFocus/HiFo 80i,130,160i+161i/HiFo161i/Deckblatt @ 6\mod_1305016031117_19.doc @ 61181 @ @ 1 drawing no. for plasma cutting machine HiFocus 161i wiring diagram of the power source .11.034.902.SP1 wiring diagram of the CNC-interface .11.034.902.SP2...
  • Page 146 Wiring diagrams Pos: 27.4 /Anlagen/Schaltpläne/HiFocus/HiFo 80i,130,160i+161i/HiFo161i/SP1 @ 6\mod_1305018167340_19.doc @ 61209 @ @ 1 Pos: 27.5 /Anlagen/Schaltpläne/HiFocus/HiFo 80i,130,160i+161i/HiFo161i/Schaltteilliste @ 6\mod_1305611866013_19.doc @ 62070 @ @ 1 .11.034.902.Sp1 Code Beschreibung Description LP MR-Ablaufsteuerung .12.LP066476 PCB sequence control .12.LP066476...
  • Page 147 Wiring diagrams LP Adapter .12.LP066612 PCB adapter .12.LP066612 LP Frontwand .12.LP066565 PCB front panel .12.LP066565 LP Technologieschalter .12.LP066520 PCB technology switch .12.LP066520 Invertermodul 4 (160 A) Inverter module 4 (160 A) LP Netzteil .12.LP070320 PCB power supply .12.LP070320 LP Stromversorgung 24 V RS485 PCB current supply 24 V RS485 Konverter RS232 / RS485 Converter RS232 / RS485...
  • Page 148 Wiring diagrams .11.034.902.Sp1 Code Beschreibung Description L2.1 Entstördrossel Suppressor coil L2.2 Entstördrossel Suppressor coil Entstördrossel Suppressor coil Schneiddrossel Cutting coil Motor Lüfter Gerätekühlung Motor fan of unit cooling Motor Kühlmittelpumpe Motor coolant pump Motor Lüfter Wärmeübertragung Motor fan heat transfer Zähler Schneidzeit Hour meter cutting time Hauptschütz...
  • Page 149 Wiring diagrams .11.034.902.Sp1 Code Beschreibung Description C3-C4 Not-Halt von CNC Emergency stop of CNC A8-B7 Signal „PA Betriebsbereit“ Signal „PA ready for operation“ A8-C7 Signal „PA Schneidbereit“ Signal „PA ready for cutting“ 0 - 10 V 0 - 10 V +15 V +15 V externe aktive Ansteuerung...
  • Page 150 Wiring diagrams .11.034.902.Sp1 Code Beschreibung Description B7-B8 Steuerspannung 230 V AC Control voltage 230 V AC C1-C2 Signal “Gastest” Signal “Gas test” C1-C3 Signal “Zweitgas-Betrieb” Signal “Second gas operation” Magnetventil Druckreduzierung Solenoid valve pressure reduction Solenoid valve ZG_p2 Magnetventil ZG_p2 Signal “Datensatz 0/I”...
  • Page 151 Wiring diagrams Pos: 27.7 /Anlagen/Schaltpläne/HiFocus/HiFo 80i,130,160i+161i/HiFo161i/Beschreibung Begriffe SP1 @ 6\mod_1306246199064_19.doc @ 66590 @ @ 1 Translation of the terms at the wiring diagram .11.034.902.SP1 Code Terms of wiring diagram English Katode Cathode Werkstück Workpiece X1:1 Gas_OK Gas ok X1:2 Kühlkreislauf ok Cooling circuit ok X1:3 Temp_Modul_OK...
  • Page 152 Wiring diagrams Translation of the terms at the wiring diagram .11.034.902.SP1 Code Terms of wiring diagram English X23:2 -I_Ist Current actual value (-) X23:6 -U_Ist Voltage actual value (-) galvanische Trennung Galvanic separation X6.2 U_Normiert Standardised voltage X6.4 I_Normiert Standardised current X9.2 U-schneid-gross Higher open circuit voltage...
  • Page 153 Wiring diagrams Pos: 27.9 /Anlagen/Schaltpläne/HiFocus/HiFo 80i,130,160i+161i/HiFo161i/SP2 @ 6\mod_1305017738424_19.doc @ 61195 @ @ 1 Pos: 27.10 /Anlagen/Schaltpläne/HiFocus/HiFo 80i,130,160i+161i/HiFo161i/SP-HiFo161i+PGE3-161 @ 12\mod_1385116080987_19.doc @ 191925 @ @ 1...
  • Page 154 Wiring diagrams Pos: 28 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 155: Spare Parts Lists

    Dear customer, with the plasma cutting system you have purchased a quality product from the Kjellberg Finsterwalde Plasma und Maschinen GmbH. When ordering spare parts, please mention the complete article no. of the torch and also the complete designation with article no. of the spare parts according to this list.

  • Page 156: Spare Parts List Hifocus 161I

    Spare parts lists Pos: 29.4 /Überschriften/1.1/Ersatzteillisten/Stromquelle/Ersatzteilliste HiFocus 161i @ 6\mod_1305020014359_19.doc @ 61475 @ 2 @ 1 12.1 Spare parts list HiFocus 161i Pos: 29.5 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/161i/ETL_HiFo161i @ 6\mod_1305019146247_19.doc @ 61339 @ @ 1 .11.034.902 30.10.2013 Artikelnummer Bezeichnung Code Anzahl 01.00 .16.500.368 Front wall 01.01...
  • Page 157 Spare parts lists .11.034.902 30.10.2013 Artikelnummer Bezeichnung Code Anzahl 02.10 .10.164.200 Metall housing 6,00 02.11 .10.164.201 Crimp Contact, Female 0,75-1,5 qmm 41,00 02.12 .10.164.174 Female insert 7-pol.+PE crimp connection X121,X106 2,00 02.13 .10.164.170 Female insert 3-pol.+PE screw connection X122 1,00 02.14 .10.502.848 Connector G3/8"...
  • Page 158 Spare parts lists .11.034.902 30.10.2013 Artikelnummer Bezeichnung Code Anzahl 04.00 .16.500.504 Power source, right side 04.01 .10.164.194 PROTECTIVE TERMINAL 16qmm 1,00 04.02 .10.161.725.230 Contactor BF50 00 220-230V 50/60Hz 1,00 04.03 .10.161.725.002 Auxiliary Contact f. BF50-BF95 (Q1) 5,00 04.04 .10.161.702 Auxiliary Contact G481 (Q1) 1,00 04.05...
  • Page 159 Spare parts lists .11.034.902 30.10.2013 Artikelnummer Bezeichnung Code Anzahl 05.20 .10.190.376 Isolation trafo EI60/31 200V/30VA 1,00 05.21 .10.101.603 Operating hours counter 24V AC 50/60Hz 1,00 05.22 .10.162.742.24 Mini contactor D024 1,00 05.23 .10.161.748 Suppressor element diode 11BGX78 225 1,00 05.24 .10.161.710.24 Contactor BG0040A024 50/60 Hz 1,00...
  • Page 160 Spare parts lists Pos: 29.7 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/161i/Frontwand der Stromquelle @ 6\mod_1305019350894_19.doc @ 61353 @ @ 1 fig. 43.: front panel of the HiFocus Pos: 29.8 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...
  • Page 161 Spare parts lists Pos: 29.9 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/161i/Rückwand der Stromquelle @ 6\mod_1305019358801_19.doc @ 61398 @ @ 1 Fig. 44.:rear panel of the HiFocus Pos: 29.10 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...
  • Page 162 Spare parts lists Pos: 29.11 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/161i/Seitenansicht links der Stromquelle @ 6\mod_1305019352894_19.doc @ 61368 @ @ 1 Fig. 45.: left side view of the HiFocus Pos: 29.12 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...
  • Page 163 Spare parts lists Pos: 29.13 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/161i/Seitenansicht rechts der Stromquelle @ 6\mod_1305019360660_19.doc @ 61413 @ @ 1 Fig. 46.: right side view of the HiFocus Pos: 29.14 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...
  • Page 164 Spare parts lists Pos: 29.15 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/161i/Montageplatte der Stromquelle @ 6\mod_1305019355519_19.doc @ 61383 @ @ 1 Fig. 47.: mounting plate of the HiFocus Pos: 29.16 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 165: Spare Parts Lists Pge 3-161

    Spare parts lists Pos: 29.17 /Überschriften/1.1/Ersatzteillisten/Gaskonsole/Ersatzteilliste PGE 3-161 @ 12\mod_1385123819112_19.doc @ 192023 @ 2 @ 1 12.2 Spare parts lists PGE 3-161 Pos: 29.18 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/neo/ETL_PGE 3-161 @ 11\mod_1383648917841_19.doc @ 189965 @ @ 1 .11.825.104 27.11.2013 article no. designation code pcs.
  • Page 166 Spare parts lists Pos: 29.20 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/neo/ET-Übersicht-PGE 3-161 @ 11\mod_1383648926608_19.doc @ 190065 @ @ 1 Fig. 48.: Plasma Gas Control Unit PGE 3-161 Pos: 29.21 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 167: Spare Parts List Percut 200

    Spare parts lists Pos: 29.22 /Überschriften/1.1/Ersatzteillisten/Brenner/Ersatzteilliste Percut 200 @ 6\mod_1302768781283_19.doc @ 57225 @ 2 @ 1 12.3 Spare parts list PerCut 200 Pos: 29.23 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 200/210/ETL_PerCut200 @ 6\mod_1302766233956_19.doc @ 57199 @ @ 1 .11.850.021.E0 30.10.2013 pos. no. article-no. designation code pcs.
  • Page 168 Spare parts lists Pos: 29.25 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 200/210/ET-Übersicht_PerCut 200 @ 6\mod_1302767702050_19.doc @ 57212 @ @ 1 Pos: 29.26 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 169: Spare Parts List Percut 210M

    Spare parts lists Pos: 29.27 /Überschriften/1.1/Ersatzteillisten/Brenner/Ersatzteilliste PerCut 210M @ 6\mod_1297410840500_19.doc @ 54664 @ 2 @ 1 12.4 Spare parts list PerCut 210M Pos: 29.28 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 200/210/ETL_PerCut210 @ 6\mod_1297328690498_19.doc @ 54544 @ @ 1 .11.850.421.E0 30.10.2013 pos. no. article-no. designation code pcs.
  • Page 170 Spare parts lists .11.850.421.E0 30.10.2013 pos. no. article-no. designation code pcs. 60.00 .16.500.006 Torch tools 60.01 .12.38180 socket wrench f. cooling tube 1,00 60.02 .11.848.401.810 Torch tool - PerCut 440-450 1,00 60.03 .11.848.401.815 Gas guide puller PerCut 440-450 1,00 60.10 .10.615.909 Torque screwdriver 1,00...
  • Page 171 Spare parts lists Pos: 29.30 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 200/210/ET-Übersicht @ 6\mod_1297330516278_19.doc @ 54557 @ @ 1 Pos: 29.31 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 172: Spare Parts List Percut 201

    Spare parts lists Pos: 29.32 /Überschriften/1.1/Ersatzteillisten/Brenner/Ersatzteilliste PerCut 201 @ 9\mod_1355919364775_19.doc @ 171323 @ 2 @ 1 12.5 Spare parts list PerCut 201 Pos: 29.33 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 201/211/ETL_PerCut201 @ 9\mod_1355306452114_19.doc @ 165953 @ @ 1 .11.853.021.E0 30.10.2013 pos. article-no. designation code pcs.
  • Page 173 Spare parts lists Pos: 29.35 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 201/211/ET-Übersicht_201 @ 9\mod_1355309048090_19.doc @ 165971 @ @ 1 Pos: 29.36 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 174: Spare Parts List Percut 211A

    Spare parts lists Pos: 29.37 /Überschriften/1.1/Ersatzteillisten/Brenner/Ersatzteilliste PerCut 211A @ 8\mod_1337066000628_19.doc @ 154276 @ 2 @ 1 12.6 Spare parts list PerCut 211A Pos: 29.38 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 201/211/ETL_PerCut 211A @ 8\mod_1337063956733_19.doc @ 154204 @ @ 1 .11.853.221.E0 30.10.2013 pos. article-no. designation code pcs.
  • Page 175 Spare parts lists .11.853.221.E0 30.10.2013 pos. article-no. designation code pcs. 01.01 .11.853.221.100 quick change head PerCut 211A 1,00 01.01 .11.853.221.100K quick change head PerCut 211AK 1,00 01.01 .11.853.221.100L quick change head PerCut 211AL 1,00 01.01 .11.853.221.100N quick change head PerCut 211AN 1,00 01.07 .10.505.980...
  • Page 176 Spare parts lists .11.853.221.E0 30.10.2013 pos. article-no. designation code pcs. 50.08 .12.29270 Filter M5x22 1,00 50.09 .12.49050 Filter M 8 X 25, 9T2228 1,00 50.10 .12.49050 Filter M 8 X 25, 9T2228 1,00 60.00 .16.500.006 Torch tools 60.01 .12.38180 socket wrench f. cooling tube 1,00 60.02 .11.848.401.810...
  • Page 177 Spare parts lists Pos: 29.40 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 201/211/ET-Übersicht PerCut 211A @ 8\mod_1337065102945_19.doc @ 154240 @ @ 1 Pos: 29.41 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 178: Spare Parts List Percut 211M

    Spare parts lists Pos: 29.42 /Überschriften/1.1/Ersatzteillisten/Brenner/Ersatzteilliste PerCut 211M @ 8\mod_1337066063901_19.doc @ 154294 @ 2 @ 1 12.7 Spare parts list PerCut 211M Pos: 29.43 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 201/211/ETL_PerCut 211M @ 8\mod_1337064492870_19.doc @ 154222 @ @ 1 .11.853.421.E0 30.10.2013 pos. article-no. designation code pcs.
  • Page 179 Spare parts lists .11.853.421.E0 10.12.2012 pos. article-no. designation code pcs. 01.17 .10.505.826 o-ring 6x1,5 VMQ ISO 1629 70 shore 1,00 01.18 .10.505.913 o-ring 8x1 VMQ ISO 1629 70 shore, red 1,00 01.19 .11.852.401.174 PI- insulating socket - PerCut 451 1,00 01.20 .11.848.401.178 Pilot plug - PerCut 450M...
  • Page 180 Spare parts lists Pos: 29.45 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/PerCut 201/211/ET-Übersicht PerCut 211M @ 8\mod_1337065172335_19.doc @ 154258 @ @ 1 Pos: 29.46 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 181: Spare Parts List Pba-161

    Spare parts lists Pos: 29.47 /Überschriften/1.1/Ersatzteillisten/Komponenten/Ersatzteilliste PBA-161 @ 11\mod_1383649208485_19.doc @ 190165 @ 2 @ 1 12.8 Spare parts list PBA-161 Pos: 29.48 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/neo/ETL_PBA-161 @ 11\mod_1383648913660_19.doc @ 189945 @ @ 1 .11.820.248 05.11.2013 article no. designation code pcs. 01.01 .10.109.519 Micro switch A1 1,00 01.02...
  • Page 182 Spare parts lists Pos: 29.50 /Anlagen/Ersatzteiliste/HiFo80i,130,160i, HiFo161i/neo/ET-Übersicht-PBA-161 @ 11\mod_1383648923831_19.doc @ 190045 @ @ 1 Fig. 49.: Plasma Torch Connection Unit PBA-161 Pos: 30 /--------------- Seitenumbruch --------------- @ 0\mod_1197390577023_19.doc @ 1454 @ @ 1...

  • Page 183: List Of Abbreviations

    Remote control Masse, Bezugspotential, 0 V Ground, reference potential, 0 V Hauptbogen Main arc Hochfrequenz High frequency Identgas Identification gas Kjellberg Verbindungseinheit Kjellberg connection unit Kontrollgas Control gas Kühleinheit Cooling unit Leiterplatte Printed Circuit Board (PCB) Markiergas Marking gas Gasdruckregler...

  • Page 184: Index

    ........... 17 Workpiece ............52 Consumable overview FB..........see Remote control PerCut 200 / 210A / 210M ......98 Field, electromagnetic........19 PerCut 201 / 211A / 211M ......113 Consumables of the torch, exchange ..95, 110 Contact voltage, Endangerment by high ....17 Gas ..............
  • Page 185 PerCut 201 ........... 156 PerCut 210M ..........153 PBA....see Plasma torch connection unit PerCut 211A..........158 PerCut 200 / 210 … ..........91 PerCut 211M ..........162 PerCut 201 / 211 … ..........106 PGE 3-161............ 149 PGE 3-161 ....see Plasma gas control unit Spatter ...............
  • Page 186 Index Plasma torch connection unit......126 Torch.......... see Plasma torch Power source ..........41 Transport............50 Trouble shooting ..........76 Technical description plasma gas console ........81 plasma torch..........93, 108 Warranty claim ............. 7 plasma torch connection unit ......126 Wiring diagrams ..........129 power source...........42 Workpiece connection ........

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