Plasma Cutting Systems

HiFocus 280i / 360i / 440i

Plasma Cutting
cost-efficient and flexible as never before

made in Germany

Cutting of Metals
from 0.5 up to 100 mm
 Plasma Cutting cost-effcient and flexible as never before

If cutting shops and users quite often have to laser up to thicknesses of 80 mm. Conventional
change the cutting technology because of diverse plasma cutting just attains quality range 5 as per
material qualities, large thickness variations or DIN.
different shapes of workpiece then the new Groundwork for that are besides a suitable
Plasma Cutting Units HiFocus 280i, HiFocus 360i guiding system and a corresponding torch height
and HiFocus 440i will be the perfect solution. control first of all a sophisticated torch technology,
HiFocus-Plasma is the synonym for the an accurate and fast process parameter control
fulfilment of highest demands at the cutting of for the cutting current and a defined mixture of the
electrically conductive materials. The exceptional process gases, their pressures and flow rates by
cutting quality of cutting surfaces is characterised means of a gas console.
by dross-free cutting edges, lowest straightness
and inclination tolerances, lowest rawness and
maximum precision. These parameters in
connection with an outstanding repeatability and
productivity are justifying the world-wide
reputation of the HiFocus-Technology.
The cutting range of the new installations covers
now the wide scope of material thicknesses from
0.5 up to 80 (100) mm.
Kjellbergs HiFocus technology achieves laser-
like cuts according to quality range 2 to 4 as No matter, whether thin or thick material - cutting with
per DIN EN ISO 9013 and furthermore contrary to only one torch

Range of Application
Max. Material thickness in mm
cutting
current 10 20 30 40 50 60 70 80 90

280 A HiFocus 280i

360 A HiFocus 360i
Mild steel HiFocus 440i
440 A
Stainless steel

Recommended Maximum
cutting range
1)
cutting range
1) Piercing1)2)

1) These data are depending on the materials to be cut and their compositions.
2) Piercing capability is dependent on material, thickness as well as performance of THC and CNC. Please refer to operation manual.

HiFocus - Basis for optimal Quality and Efficiency

The integrated Soft-Switch-Inverter Technique
with its flexible adaptability of the process
sequence to the cutting job is the basis for
optimising the quality and the productivity:
Optimisation of the cutting process
through fast and steples adjustment of the
cutting current, reduced lead-in runs and
corner signals
Long consumable life due to micro-
processor controlled cutting process
Best cutting results with advanced
HiFocus torch technology (high focused
plasma beam) For a particular effective cooling an external
Possibility of control for all cutting para- cooling component was designed.
meters by analogue and serial interfaces By integrating the ignition module into the
Serial data transfer to computers for Plasmatorch Connection Unit PBA-360 the scope
diagnosis of installation could be reduced.
 High-Performance put into Practice by PerCut Torches

Quick-Change Torches reduce Preparation Time

Especially for the HiFocus technology the series Due to an ident gas the control identifies the
of PerCut torches was developed and is covering actual used torch head and depending on the
the high demands of this procedure. material the corresponding optimum data will be
adjusted.

For preparing welding seams or at 3D

applications special nozzles enable bevel
cutting up to an angle of 45 degrees. Fluid
cooling, swirl-gas technology and second-gas
ignition contribute to a long life of the
consumables.

PerCut 370.1M and PerCut 370.2M

The characteristic features of this method are the A complex geometry ensures highest efficiency of the
torches, here the exploded view of the PerCut 370.2M
increased constriction of the plasma arc through
smaller orifices, the optimised gas rotation and
the use of swirl gases.

For a fast change of consumables or a time-

saving conversion to an other performance range
both torch heads PerCut 370.1M (cutting current
up to 160 A) and PerCut 370.2M (up to 440 A)
generally are equipped with quick-change
system.

Only one Plasma Torch for Cutting and Marking

The torch heads PerCut 370.1M and PerCut
370.2M are suitable for cutting, marking and
punch marking operations without changing the
consumables.

The markings can be varied in width and depth by

selecting the current, speed and torch distance to
meet the requirements. Also for punch marking
different depths are adjustable.

Cutting sample marked with PerCut 370.1M

 Optimal Equipment ensures high Quality and Reliability

Efficient Gas Control Long Life of Consumables

The material-specific composition and the flow The optimised design of the consumables of the
rate of the plasma gases have a substantial PerCut torches is the precondition for reaching
influence on the result of the cutting of metallic highest cutting quality and for a long life time.
materials with the plasma beam.
Topmost accuracy during fabrication and the use
1)
The gas consoles PGE 3-360 for cutting of mild of properly selected materials or combinations of
steel and PGE 360 for cutting of all metalls are materials are required.
gas mixing units with manual adjustable flow
meters for the plasma and swirl gases. The user can profit only from those benefits if
besides an ideal process sequence always
For higher demands Kjellberg Finsterwalde has genuine Kjellberg consumables are used.
developed the gas console FlowControl, which
delivers automatically an optimised gas mixture. Cathodes should be changed in time. By means
It consists of the Plasmagas Valve Unit PGV 3 of a cathode dial gauge, which is available from
and the Plasmagas Control Unit PGC 3 and is Kjellberg Finsterwalde, the wear on the hafnium
characterised by following features: pin can be measured.
Safe dosage, even at different gas quantities
and control of the flow rate for five separate
gas control paths (3 for plasma gas, 2 for
swirl gas)

Optimum cutting quality through tailored

gas mixtures, compensation of pressure
fluctuations

Highest reproducibility because of micro-

processor control and monitoring

Gas parameters for standard materials

available from the installed data base, easy
storage for further optimised gas parameters
for other materials Cathode dial gauge

s o for
a l
king Cost-efficient by Upgrading
mar timeworn Cutting Installations
The plasma cutting units HiFocus 280i, HiFocus

s o for 360i and HiFocus 440i are furnished with an

a l
king
analogue and a serial interface for the adaptation
mar to CNC- controls. Therefore they are flexible to
combine with 2D and 3D guiding systems, like
profile cutting machines, robots or tube
manufacturing lines.
In addition PGE 360 and FlowControl can also
2)
If the guiding system is not provided with a data
be used for marking - switched via CNC-control. base then in case of a retrofit the data base of the
automatic gas control or that of the manual gas
control can be used.
1) PGE3-360 is not available for HiFocus 440i.
2) For further information regarding functionality and handling, please refer to
The further use of existing guiding systems
related cutting charts. enables a considerable cost-saving.
 Enhanced Possibilities by PLUS technology

Operating Data (Extract) 1)

Material Mild steels Stainless steel Aluminium

Plasma HiFocus HiFocus HiFocus HiFocus HiFocus HiFocus HiFocus HiFocus
cutting 280i 360i / 440i 280i 360i 440i 280i 360i 440i
unit
max. cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cutting
speed current speed current speed current speed current speed current speed current speed current speed current speed
(mm/min) (A) (mm/min) (A) (mm/min) (A) (mm/min) (A) (mm/min) (A) (mm/min) (A) (mm/min) (A) (mm/min) (A) (mm/min)

0,5 20 6.000 20 6.000

1 20 5.500 20 5.500 35 7.000 35 7.000 35 7.000 35 3.900 35 3.900 35 3.900
3 50 2.200 50 2.200 60 2.800 60 2.800 60 2.800 35 2.400 35 2.400 35 2.400
6 130 4.500 130 4.500 130 2.000 130 2.000 130 2.000 130 3.200 130 3.200 130 3.200
8 130 3.700 130 3.700 130 1.600 130 1.600 130 1.600 130 2.500 130 2.500 130 2.500
10 200 4.500 200 4.500 130 1.500 130 1.500 130 1.500 130 2.000 130 2.000 130 2.000
15 280 3.900 280 3.900 250 1.800 250 1.800 250 1.800 250 4.500 250 4.500 250 4.500
20 280 2.400 300 2.800 280 1.500 360 1.600 360 1.600 280 3.800 360 4.000 440 4.500
30 280 1.200 300 1.500 280 1.000 360 1.200 440 1.300 280 2.200 360 2.800 440 2.800

Material thickness (mm)

40 280 750 360 1.200 280 650 360 850 440 1.000 280 1.550 360 1.800 440 2.400
50 280 500 360 750 280 480 360 650 440 800 360 1.300 440 1.700
60 280 250 360 430 280 350 360 500 440 650 280 800 360 1.100 440 1.300
70 280 150 360 250 280 200 360 400 440 450 360 800 440 1.000
80 360 180 360 320 440 380 280 150 360 700 440 850
100 440 190
1) Listed cutting speeds are depending on material characteristics, gas parameter, guiding system as well as proper consumables. According to quality requirements cutting speeds may differ.
 Technical Data

Power source HiFocus 280i HiFocus 360i HiFocus 440i

1)
Mains voltage 3x 400 V, 50 Hz 3x 400 V, 50 Hz 3x 400 V, 50 Hz
Connected load, max. 67 kVA 87 kVA 127 kVA
Fuse, slow 100 A 125 A 200 A
Cross section mains cable, Cu 4 x 35 mm2 4 x 50 mm2 4 x 50 mm2
Open circuit voltage 330 V 330 V 330 V
Cutting current at 100% d.c. 280 A 360 A 440 A
Cutting voltage 200 V 200 V 200 V
Cutting power max. 56 kW max. 72 kW max. 88 kW
Marking current 5 - 25 A (PerCut 370.1M) 5 - 25 A (PerCut 370.1M) 5 - 50 A
10 - 50 A (PerCut 370.2M) 10 - 50 A (PerCut 370.2M)
Protection class IP 22 IP 22 IP 22
Dimensions (L x W x H) 1030 x 680 x 1450 mm 1030 x 680 x 1450 mm 1030 x 680 x 1450 mm
Weight 505 kg 517 kg 589 kg
Plasma torch PerCut M with head 370.1M PerCut M with head 370.1M PerCut M with head 370.1M
and 370.2 M and 370.2 M and 370.2 M
1) other voltages and frequencies on request

Torch PerCut 370.1M PerCut 370.2M

Max. cutting current 160 A 440 A

Duty cycle 100 % 100 %
Max. cutting range 0.5 up to 50 mm Mild steel: 0.5 up to 80 mm
Stainless st.: 1.0 to 100 mm
Plasma gas Air, O2, Ar, N2, H2 Air, O2, Ar, N2, H2
Purging gas Purging gas
Marking gas Ar Ar
Swirl gas Air, N2, O2 Air, N2, O2
Torch cooling Coolant “Kjellfrost” Coolant “Kjellfrost”

Configuration of HiFocus 360i for Cutting with all Gases and FlowControl
KWE External cooling unit
PGC+PGV FlowControl
H2 PBA Plasmatorch connection unit
N2/H2
Ar
including ignition module
Gas supply Air FB Remote control
O2
N2
PZL Hose parcel
Air
Gas supplies (3 pieces)

PGC PGV PZL 360

PBA-360
FB

CNC PerCut 370 M

Workpiece cable

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

Our products represent a high level of quality and reliability. We reserve the rights to change design and/or technical specification during the series fabrication.
Claims of any kind can not be derived from this prospectus.
08-10-05

, , , HiFocus, PGC, XL
and YellowXLife are trademarks of the Kjellberg-Foundation/
Kjellberg Finsterwalde and may be registered in Germany
and/or other countries.

Kjellberg Finsterwalde Plasma und Maschinen GmbH

Germany D - 03238 Finsterwalde Leipziger Str. 82
Phone: +49 3531 500-0 Fax: +49 3531 500-227
E-Mail: plasma@kjellberg.de Copyright 2008
Internet: www.kjellberg.de Kjellberg Finsterwalde Plasma und Maschinen GmbH
All rights reserved.