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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 Quality Guarantee
The plasma cutting unit possesses CE-conformity and meets the regulations and instructions of the
European Community.

EN Developed and manufactured on basis of the standard EN 60974-1 (VDE 0544, part 1) and BGV D1
(accident prevention rules).

S All Kjellberg plasma cutting units have the S-sign and are therefore applicable in environments with
increased hazard of electric shock.

ISO All products are manufactured under strict quality assurance control and proved by certificates and
product test records.
9001
The production takes place according to DIN EN ISO 9001.

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.

The new “Kjellfrost” (colourless) replaces the former “Kjellfrost” (blue) by and by. Please check carefully what
kind of coolant your cooling system contains before filling up with the new “Kjellfrost” and pay attention for the
following points :

The new antifreezer is nearly colourless (whereas the former was blue coloured).
The new “Kjellfrost” still is classified as a hazardous substance in sense of the standard for
hazardous substances, but not in the sense of the standard for the transportation of hazardous
substances.
Never mix the new “Kjellfrost” (colourless) with the old “Kjellfrost” (blue)!
Never add water to the new “Kjellfrost” for dilution or filling up: The corrosion inhibitors become
inactive and the coolant acidic, which is leading very fast to corrosive damages!
Therefore pure “Kjellfrost” has to be used for filling up!
In case the old coolant has to be replaced by the new antifreezer “Kjellfrost” (colourless) the
complete cooling circuit has to be drained fully and rinsed repeatedly with water. Only after this
procedure the new coolant may be filled up!
Safety regulations for handling, storing, etc. are given in a safety data sheet, which is available on
request (Tel. +49.3531.500203).

All details given on the label of the new antifreezer have to be followed consequently !

All former information in our Instruction Manuals contradictory to this advise are invalid!

Kjellberg Finsterwalde
January 2002

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 Vorsicht Caution
beim Umgang mit if handling coolant
Kjellfrost ! Kjellfrost!

- Kjellfrost nicht trinken - Don’t drink Kjellfrost.

- Von Nahrungsmitteln, Getränken - Keep it away from food, drinks and

und Futtermitteln fernhalten fodder.

- Berührung mit den Augen und der - Avoid the contact with eyes and
Haut vermeiden skin.

- Vor den Pausen und bei Arbeits- - Always clean your hands after end
ende Hände waschen of work.

- Beschmutzte, getränkte Kleidung - Don’t wear contaminated clothes.

sofort ausziehen

Erst-Hilfe-Maßnahmen First aid measure

- nach Verschlucken - After swallowing

Kein Erbrechen herbeiführen, Mund aus- Don’t bring up, clean the mouth, drink much
spülen, reichlich Wasser nachtrinken und für water, open the window for fresh air and call the
Frischluftzufuhr sorgen; unverzüglich den doctor.
Arzt hinzuziehen

- nach Augenkontakt
Augen bei geöffnetem Lidspalt mehrere - After eye-contact
Minuten unter fließendem Wasser ab-spülen Clean the eyes with much flowing water some
und Arzt konsultieren minutes and call the doctor.

- nach Hautkontakt
Sofort mit Wasser und Seife abwaschen und - After skin-contact
gut nachspülen Quickly clean it with much water and soap.

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 Contents pages
1 Safety instruction 6

2 The plasma cutting process 10

2.1 Dry plasma cutting 11
2.2 Swirl gas technology 11
2.2.1 Dry plasma cutting 11
2.2.2 Under water plasma cutting 11
2.3 Advantages and main features 11
2.4 Range of application 12
2.4.1 Dry plasma cutting 12
2.4.2 Under water plasma cutting 13

3 Technical data 14
3.1 Plasma rectifier FINEFOCUS 800 14
3.2 Plasma torches 14
3.2.1 Plasma machine torch PB-S77 W-x 14
3.2.2 Plasma hand torch PB-S75 WH-1 15
3.3 Components 15
3.3.1 Plasma gas controller PGE 1-800 15
3.3.2 Plasma gas controller PGE 2-800 15
3.3.3 Plasma ignition box PZ-800 16
3.3.4 Plasma gas supply unit PGA 3-800 16
3.3.5 Plasma torch connection unit PBA-800 16
3.3.6 Plasma counter PZE 1 16

4 Technical description 17
4.1 Plasma rectifier FINEFOCUS 800 17
4.2 Plasma torches 17
4.2.1 Plasma machine torch PB-S77 W 17
4.2.2 Plasma hand torch PB-S75 WH-1 17
4.3 Plasma components 18
4.3.1 Remote control FB 1 18
4.3.2 Plasma gas controllers PGE 1-800 and PGE 2-800 18
4.3.3 Cable set PZL-800 19
4.3.4 Plasma ignition box PZ-800 19
4.3.5 Plasma gas connection unit PGA 3-800 19
4.3.6 Plasma torch connectio unit PBA-800 19
4.3.7 Cable set PBL-800 20
4.3.8 Plasma counter PZE 1 20
4.3.9 Tractor unit FE1 20
4.3.10 Accessories for the plasma hand torch 20

5 Commissioning 21
5.1 Check out, placement and installation 21
5.2 Installation 21
5.2.1 Mains connection 21
5.2.2 Workpiece connection / current return line 22
5.2.3 Grounding 22
5.2.4 Connection of the FineFocus 800 22
5.2.5 Connection of the plasma torches 22
5.2.5.1 Connection of the plasma torches to the FineFocus 800 22
5.2.5.2 Plasma torch connection to the plasma ignition box PZ-800 / 23
plasma gas connection unit PGA 3-800
5.2.5.3 Plasma torch connection to the PBA-800 23

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 pages

5.2.6 Connection of the plasma gas controller PGE 1-800 23

5.2.7 Connection of the plasma gas controller PGE 2-800 24
5.2.8 Connection of the plasma ignition box PZ-800 24
5.2.9 Connection of the plasma torch connection unit PBA-800 24
5.2.10 Connection of the gas hoses between PGE 1-800/PGE 2-800 and 24
PGA 3-800
5.2.11 Connection of the gas hoses between PGA 3-800 and PBA-800 25
5.2.12 Connection of the plasma gas supply 25
5.2.12.1 Plasma gases 25
5.2.12.2 Swirl gases (oxygen, nitrogen) 26
5.2.13 Filling up the coolant 27
5.2.14 Connection to CNC-control 27

6 Operation 29
6.1 Control and display elements 29
6.1.1 Front wall controls and displays 29
6.1.2 Service elements inside of the plasma cutting unit 30
6.2 Cutting operation 31
6.3 Machine torch operation 32
6.4 Hand torch operation 32
6.4.1 Cutting 32
6.4.2 Plasma gouging 33
6.5 Switching OFF the plasma unit 33
6.6 Change of consumables 33
6.6.1 Change of spare parts on plasma torch PB-S77 W 34
6.6.2 Preparation of torch PB-S77 for dry cutting without swirl gas 34
6.6.3 Change of spare parts on plasma torch PB-S75 W/WH 36
6.7 Hints for trouble shooting and protective circuits 38

7 Maintenance 39
7.1 Plasma rectifier 39
7.1.1 Cleaning 39
7.1.2 Gas supply 39
7.1.3 Plasma gas pressure test 39
7.1.4 Cooling system 39
7.1.5 Electrical revision 40
7.2 Plasma torches 40

Enclosure Scheme “piercing sequences during plasma cutting” 41

Connection diagrams 42
Cutting data FineFocus 800 46
Wiring diagram FineFocus 800 51
Spare parts lists PB-S77 W and PB-S75 WH-1 52

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 1 Safety instructions
All endangerments through the plasma cutting process are related with the process itself.
Endangerments may occur due to:
• High contact voltage
• High-voltage (HV) ignition
• Heat and light radiation
• Gases and smoke
• Noise
• Hot metal and spatter
• Handling of pressure cylinders
The plasma cutting machine has been developed in compliance with following standards:
EN 60974-1 (VDE 0544 , part 1)
Safety requirements for installations for arc welding and welding power sources
EN 50078 (VDE 0544 , part 203)
Safety requirements for installations for arc welding in connection with
prEN 50192
Arc welding and plasma cutting systems
EN 50199 (VDE 0544 , part 206)
Electromagnetic compatibility (EMC)
BGV D1 (accident prevention regulation)
Welding, cutting and relating applications
The rules of the BGV D1 “Welding, cutting und related processes” from the 01.04.1990 and the
directive from April 2001 have to be followed strictly through the user. Before starting the Plasma
Cutting Machine carefully read this Instruction Manual. Only advised personnel are allowed to operate
the plasma installation!
Hint!
National and local codes governing plumbing and electrical installation shall take precedent
over any instruction contained in this manual!

Endangerments through high contact voltage

Attention!
Before opening the plasma rectifier generally the input power has to be disconnected
visible from the mains (unplug mains cable)!

Only advised personnel is allowed to carry out any maintenance and repair work to
the machine (see VDE 0105 or national codes).

Before starting the machine connect the workpiece cable and earth the workpiece!

Power sources with integrated cooling systems normally are having a high Ohmic conducting path
through the coolant to the housing. If the workpiece is not earthed the open circuit or cutting voltage
is applied to the housing after switching on the power source. But the resistance in a complete dirty
coolant in any case is more than 10kOhm, reducing the touch potential to a not dangerous level. The
touch voltage nevertheless is sensible.

With the plasma cutting unit the cooling circuit is insulated from the power source. Therefore a
contact potential does not appear.
Further requirements:
• Connect the power source only to a correct earthed mains socket with properly fitted protective
conductor
• Wear insulated protective clothing (safety shoes, leather apron, gloves)
• 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)

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 Working in environments with increased hazard of electric shock

The Plasma Cutting Machine is built in compliance with valid standards (EN 60974-1, BGV D1) and
therefore applicable in environments with increased hazard of electric shock:

• The plasma power source and the plasma torch are forming a safety-proofed installation, which
can be separated only by a special tool
• If the cover plate isn´t properly closed the power source can´t be switched ON
• The plasma hand torch can be operated only, if the insulating protective cap, which prevents
against touching the life nozzle cap, is properly fitted. (safety circuit)

Therefore the plasma cutting unit is S-marked and applicable in environments with increased hazard
of electric shock.
Attention!
Always follow valid instructions and local safety rules (BGV D1 and EN 60974-1)!

Endangerments through high-voltage ignition

For igniting the pilot arc a High Voltage Igniter is installed in the power source. When pressing the
ON-button (remote control or CNC-signal) the high voltage is applied to the cathode. After initiating
the pilot arc the HV-supply becomes switched off automatically. After the cutting process has started
the pilot extinguishes.

Attention! Never touch the nozzle if the power source is switched ON!

Therefore the nozzle cap of the plasma hand torch is shielded by the protective cap to prevent
touching.

The HV-ignition may establish electric or electro-magnetic fields, which can cause interference to
heart pace-makers and
other electronic devices
in proximity of plasma installations.

Endangerment through electromagnetic interferences

The plasma cutting installation complies with the instructions of the EN 50199 (VDE 0544, part 206)
“Electromagnetic Compatibiliy (EMC), product standard for Arc Welding Equipment”. This standard is
valid for Arc Welding Installations and related processes (e.g. plasma cutting), which are designed for
the use in industrial and private areas.
Warning!
It may be necessary to provide special measures if plasma cutting machines are used
in private areas (screened power cables, etc.)

The user is responsible for installing and using the installation according to the manufacturer´s
instruction. If electromagnetic disturbances are detected then the user is responsible to arrange the
technical solution with the assistance of the manufacturer.

Recommendations for assessment of the area (EN 50199)

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:

• Other supply cables, control cables, signalling and telephone cabels below and adjacent to the
installation
• Radio and television transmitters and receivers
• Computer and other control equipment
• Safety devices, e.g. protections for industrial equipment
• Health of the people around, wearing pacemakers or hearing aids
• Equipment for calibration and measuring
• 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

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 Recommendations of methods to minimize disturbances

If disturbance are detected it may be necessary to carry out following precautions:

• Filtering of the mains supply – shielding of the mains cable of the permanently installed plasma
cutting unit (good contact necessary between shielding and housing)
• Regular maintenance of the plasma cutting installation
• Doors and covers should be closed and properly fastened
• Cutting and workpiece cables should be kept as short as possible
• Potential equalization of all metallic components inside and adjacent to the installation (the
operator should be insulated from all metallic components)
• Earthing of the workpiece
• Selective screening of all other cables and equipment

Endangerment through heat and light radiation

The plasma arc produces intense ultraviolet and infrared rays that can hurt eyes and skin. Therefore
following precautions have to be arranged:

• Wearing of flame-retardant welding clothes (helmet, apron, gauntlet gloves, safety shoes)
• Hand or head shield with protective glasses of medium shade for watching the cutting process
• The cutting area should be prepared so that reflections and transmission of ultraviolet light is
reduced:
o Arranging painting of walls with dark colour
o Use of protective walls

Endangerment through fumes and smoke

Due to the plasma process itself hazardous substances may be produced. To avoid risks for health
the following has to be arranged:

• Keep cutting place well ventilated

• Remove fumes and smoke by exhaustion devices
• Remove all chlorinated and other solvents from the cutting area because they could form
phosgene gas when exposed to ultraviolet radiation
• Wear breathing mask when cutting galvanized materials
• Ensure that toxic limits become not exceeded
• When cutting is performed under water all toxic gases which are not taken of from the water itself
(~ 10 %) have to be exhausted

Attention!
In any case the user of the plasma cutting installation has to carry out measurements
of the concentration of toxic substances to proof the effectiveness of the exhaust
equipment!
Furthermore he is responsible the environment safe deposition of the solid
substances of the water bath.

Endangerment through noise

Be aware that during the plasma cutting a high noise level is produced.

noise level in distance of

mode of cutting cutting current material thickness
1.0 m 3.0 m
no load - - 70 dB (A) -
pilot arc 24 A - 96 dB (A) 88 dB (A)
dry cutting 250 A 10 mm 103 dB (A) 93 dB (A)
250 A 40 mm 105 dB (A) 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.

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 Endangerment through spatter

During plasma cutting sparks, slag and hot metal are produced. The risk of burns and fire exists!
To avoid endangerments the following has to be arranged:

• Removal of all potential flammable materials from the cutting area, at least in a distance of 10 m
• Cool down freshly cut material before handling or storing
• Make fire extinguishers available in the cutting area

Handling of pressure cylinders

For the plasma cutting process compressed gases are used. To avoid endangerments following
instructions have to be taken:

• Place cylinders upright in secured position

• Don´t use damaged cylinders, pressure reducers and armatures
• Use pressure reducers only for the gas it is determined
• Never lubricate pressure reducers with grease or oil
• Keep parts coming in contact with oxygen absolutely free of oil and grease
• When using oxygen the pressure reducer must be furnished with an explosion protection
• Perform gas pressure test acc. to chapter 7.3.1

Under water plasma cutting of aluminium

The molten aluminium forms in the water a granular slag which is having a relatively large surface. In
connection with the oxygen of the water hydrogen is exposed, which comes up to the surfaces and
get burned.

This chemical reaction between Al-granulates and the water can continue sometimes for longer
times. In connection with the compressed air, which mainly is used for the water level adjustment and
hydrogen-air-mixture will be formed, which is highly explosive (when containing 4 – 76 vol. % H2). If
this mixture will collect in the expansion chamber or underneath the cutting plate and becomes
ignited by the plasma arc the explosion may have fatal consequences.

Measurements to avoid oxyhydrogen gas

o Use nitrogen (poor quality is sufficient) for the water level adjustment instead of air.

o Water tables without level adjustment should ensure, that

• The hydrogen can escape unobstructed from the water and than get burned off
• The inside of the water table is even, to avoid the collection of granulates
• Slag and granulates become removed from the water table immediately after cutting
• No hydrogen can collect underneath the plates placed on the cutting table
• 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!

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 2 The plasma cutting process
2.1 Dry plasma cutting
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.

In the plasma torch this gas becomes heated up extremely and leaves it through the nozzle with a
high speed. Due to the high heat concentration all electrically conductive materials will melt and due
to the high speed and pressure of the plasma arc the molten material will be blown away forming a
very small kerf in the material.

The plasma arc hereby is transferred from the cathode, installed in the plasma torch and conducted
to the negative pole of the plasma power source to the workpiece (transferred arc).

The plasma cutting is a technology for cutting of electrically conductive metals, like constructional
steels, stainless, aluminium, copper, etc.

1 pilot resistor

2 HV-igniter

3 gas supply

4 cathode

5 nozzle

6 plasma arc (main arc)

7 workpiece

Fig. 1: principle of dry plasma cutting

The safe ignition of the main arc (cutting arc) will be achieved through (see fig. 1):
• disconnection of HV-igniter just after ignition of pilot arc
• pilot arc current is limited by the pilot arc resistor
• as far as the pilot arc contacts the workpiece the main arc will be initiated between cathode and
workpiece (transferred arc)

2.2 Swirl gas technology

A A
C C
B B Plasma torches for the swirl gas technology
D
are using a swirl gas for shielding the
plasma arc from the atmosphere.

This shielding action favourable can be used

for “dry”-cutting torches and “under water”-
cutting as well.

E E
Fig. 2: shows the principle of the swirl
F F gas technology in comparisation
to the conventional dry cutting

without swirl gas with swirl gas A – coolant inlet C – plasma gas E – cutting direction
B – coolant outlet D – swirl gas F – cutting edge

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 2.2.1 Dry plasma cutting

With the conventional dry plasma cutting the plasma arc is directly transferred from the nozzle to the
workpiece. Spatter and upcoming material can lead to double arcing and to reduced nozzle life and
poor cutting quality.

Plasma torches using the swirl gas technology are avoiding those disadvantages. The nozzle of the
plasma torch effectively is protected by the swirl gas cap and the surrounding swirl gas against
upcoming material, especially when cutting starts by piercing.

Flow rate and composition of the swirl gas can be optimised to obtain best cutting results on different
materials.

2.2.2 Under water plasma cutting

The unter water cutting process reduces the pollution of the environment, the noise level of the
process and the light radiation considerably in comparison to the dry cutting. The distortion of the
cutting material is very low.

But the consumption of electrical energy is higher.

One of the advantages of the swirl gas technology is the fact that the plasma torch is suitable for the
dry cutting and the underwater cutting as well without any adaptation to the torch.

Furthermore the cutting process grants highest stability, ensuring optimum cutting quality for both:
“dry” and “under water”.

2.3 Advantages and main features

By the application of the Plasma Fine-Focus-Principle acc. to Professor Manfred von Ardenne with its
extreme constriction of the plasma arc an extraordinary energy density will be achieved, resulting in
various technological advantages, as there are:

• double-straight-effect (high cutting quality of both sides on the cut)

• small cutting kerfs
• reduced loss of material
• low heat input
• low distortion
• excellent cutting quality

Further technological advantages will be achieved by the application of the swirl gas technology for
the dry cutting and the under water cutting in connection with the XL-Life-Time-System and the
plasma gas oxygen.

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
• Excellent cutting quality because of twelve-pulse rectification
• Micro electronic process control ensures high constancy of the cutting parameters
• CNC-interface allows automatic operation in connection with NC and CNC controlled profile
cutting systems, robots and other guiding machines
• Set value control from CNC systems possible
• Adjustable soft start minimizes consumption of nozzles and cathodes
• Integrated cooling circuit ensures longevity of consumables
• Easy operation by automatic ignition:
o pilot arc ignition by high-voltage igniter
o main arc excitation by pilot arc

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 • control devices for safe operation:
o plasma gas monitored by gas pressure controller
o coolant controlled by flow switches
o time limitation for pilot arc
o automatic current cut-off by nozzle-workpiece contact
• Comfortable torch change because of easy to reach connectors with safety circuit
• Clearly arranged service and display elements (symbol marking) for easy and comfortable
operation
• High efficiency and low operational costs through:
o internation cooling unit, reduces gas consumption
o possibility to use air as plasma gas
• transportable by crane or fork lift
• various plasma gases ensure optimum cutting quality at all electrically conductive materials: air,
oxygen, Ar/H2-, Ar/N2- and Ar/N2/H2-mixtures
• machine or hand torch operation by choice
• hand torch suitable for:
o plasma cutting with guiding bow, wheel guide, circle attachment or tractor unit
o plasma arc gouging

2.4 Range of application

2.4.1 Dry plasma cutting
The transferred arc principle allows cutting with swirl gas on all electrically conductive materials up to
60 mm (material depending) with a cutting power of max. 50 (60) kW. Cutting of mild steels, high
alloyed steels, non-ferrous metals (aluminium, etc.) and special alloys is practicable in a wide range.
mild steel - plasma gas air / swirl gas air:
High productivity, no or less dross formation; surface nitration or oxidation may
appear
- plasma gas oxygen / swirl gas air:
high productivity, no nitration or oxidation on the cutting surfaces
CrNi-steel - plasma gas air / swirl gas air:
High productivity, no or less dross formation; surface nitration or oxidation may
appear; cutting quality not like cutting with Ar/H2- resp. Ar/H2/N2-mixtures
- plasma gas Ar/H2- resp. Ar/H2/N2 – mixuteres / swirl gas N2:
Metallic clean surfaces; on thins sheet metal dross formation possible if using
Ar/N2-mixtures; can be avoided or reduced by adding of N2 to the plasma gas
(Ar/H2/N2 - mixture)
aluminium - plasma gas air / swirl gas air:
High productivity, no or less dross formation, cutting quality not so good as with
Ar/H2-mixture
- plasma gas Ar/H2 / swirl gas air :
Much better cutting quality as with plasma gas air

All plasma torches ar capable to start the cutting by running start or by piercing.

The torches are suitable for straight-, bevel-, profile- and position cutting. Cutting and gouging is
applicable to plates, sheet metal, tube and pipes, forced and forged parts, piled plates, casted parts
and scarp metal.

The stepless cutting adjustment offers the possibility to adapt the cutting current to the material
conditions.

After changing some few torch components (see chapter 6.6) the plasma machine torches of the
PB-S77 W-series are suitable for dry cutting processes without swirl gas.

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.

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 2.4.2 Under water plasma cutting

The under water plasma cutting technology enables the cutting of electrically conductive materials
with swirl gas up to 40 mm (material depending).

It is possible to cut mild steels, high-alloyed steels, non-ferrous metals and special alloys. The cutting
surfaces are showing a slightly roughness.

Following plasma gases are recommended:

mild steel - plasma gas air / swirl gas air:

high productivity, no or less dross formation, surface nitration or oxidation can
appear

- plasma gas oxygen / swirl gas air:

high productivity, no surface nitration and nearly no dross formation

CrNi-steel - plasma gas air / swirl gas air:

High productivity, no or less dross formation, surface nitration or oxidation may
appear, cutting quality not so good as with Ar/H2- or Ar/H2/N2-mixtures

- plasma gas Ar/H2- resp. Ar/H2/N2 – mixtures / swirl gas N2:

metallic clean cutting surface, dross formation specially with Ar/H2-mixture
possible, can be avoided by adding N2 to the plasma gas (Ar/H2/N2-mixture)

- plasma gas Ar/N2 / swirl gas N2:

very sharp cutting edges and metallic clean surfaces

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 3 Technical data

3.1 Plasma rectifier FINEFOCUS 800

Primary side
Input voltage U1: .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 35mm2
Power factor cos ϕ 0.8 (250A)
Efficiency 0.9
Secondary side Dry cutting Under water cutting
Cutting range 80 - 300A
Open circuit voltage UO 400V
Cutting current IS 80 - 300A
Pilot arc current IPB 24A
Cutting arc voltage US 200V
Cutting power PS 60kW (100% duty cycle)
Material thickness ds: quality cutting / severance 40 mm / 80 mm 25 mm / 40 mm
Characteristic droping
Ignition Pilot arc ignition by HV-ignitor
Main arc exitation by pilot arc
Workpiece cable 70 mm2
Weight m 556 kg
Dimensions (l x w x h) 1375 x 870 x 1505 mm
Safety class IP22
Thermal class F
Cooling By fan
Torch cooling Internal cooling circuit
coolant Coolant “Kjellfrost” (freeze-proofed up to –10oC) or “Kjellfrost-SUPER”
(freeze-proofed up to –25oC) with integrated corrosion protection
pressure 0,55 MPa (5,5 bar) at 6 l/min
tank capacity approx. 50 l
Table 2

3.2 Plasma torches

3.2.1 Plasma machine torch PB-S77W-x

PB-S77 W-1, PB-S77 W-2

Technology
- dry, without WG* cutting thickness/~current / piercing: 75 mm (250A) / 40mm (250A)
- dry, with WG* cutting thickness /~current / piercing: 60 mm (250A) / 40 mm (250A)
- UWP** with WG* cutting thickness /~current / piercing: 40 mm (250A) / 25 mm (250A)
Open circuit voltage UO max. 400 V
Pilot arc current IPb max. 24 A
Duty cycle 100%
Ignition High voltage ignition (max. 10 kV) with pilot arc
Torch diameter 58 mm
Weight m 15.7kg (10 m hose parcel)
Torch cooling Coolant “Kjellfrost” (freeze-proofed up to –10oC) or “Kjellfrost-SUPER”
(freeze-proofed up to –25oC) with integrated corrosion protection
Flow rate approx. 6 l/min
Plasma gases air, O2, Ar, N2, H2 and mixtures (quality, pressure and flow rate see
PGE 1-800 and PGE 2-800)

Swirl gas O2, N2 and mixtures

(quality, pressure, and flow rate see PGE 1-800)
Hose parcel length 6m / 10m / 15m (PB-S77 W-1) or 1m / 1.5m (PB-S77 W-2)
Connectors
Coolant outlet / cathode cable G1/2”
Coolant inlet M18x1.5
Pilot cable Single pin plug
Control cable solenoids 8-pin plug
Swirl gas G1/4”
Plasma gases G3/8” - air, O2, Ar(N2) and G3/8” left – air, H2
Table 3 (** UWP = under water plasma / * WG = swirl gas)

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 3.2.2 Plasma hand torches PB-S75 WH-1
PB-S75 WH-1/L PB-S75 WH-1/A
.11.828.701 .11.828.711
Cutting thickness (~current) / Piercing: 75 mm (250A) / 40 mm (250A)
Open circuit voltage UO max. 400V
Pilot arc current IPb max. 24A
Duty cycle 100%
Ignition High voltage ignition (max. 10 kV) with pilot arc
Weight m 10.7 kg (10 m hose parcel)
Torch cooling Coolant “Kjellfrost” (freeze-proofed up to –10oC) or “Kjellfrost-SUPER” (freeze-
proofed up to –25oC) with integrated corrosion protection
Flow rate approx. 6 l/min
Plasma gases air Ar/H2/N2 - mixtures
(free of dirt, oil and water, use (with PV-800)
micro filters)
pressure 0.8 MPa (8bar) 0.8 MPa (8bar)
Flow rate 1680 l/h (28l/min) 2800 l/h (46l/min)
Used as: ignition and cutting gases ignition and cutting gases
Hose parcel (length 6 or 10 m) Connectors
Coolant outlet/cathode cable G1/2”
Coolant inlet M18x1.5
Pilot cable Single pin plug
Control cable solenoids 7 pin plug
Control cable torch switch 3 pin plug
Plasma gases G3/8” (air) G3/8” (Ar)
G3/8” left (air) G3/8” left (H2)
Table 4

3.3 Components
3.3.1 Plasma gas controller PGE 1-800
Art.-No.: .11.824.222
Input voltage (solenoids) 24 V AC, 50 / 60 Hz
Dimensions (l x w x h): 360 x 240 x 425 mm
Weight: 14 kg
Plasma gases: air oxygen
(free of dirt, oil and water, use micro (99.5 %, dry, free of dirt, use micro
filter) filter)
Max. pressure: 0.8 MPa (8 bar) 0.8 MPa (8 bar)
Max. flow rate (torch connected): 2800 l/h 2800 l/h
Connector size: G1/4“ G1/4“
Swirl gases: air oxygen nitrogen
(free of dirt, oil and water, (99,5 %, dry, free of dirt, use (min. 99.9 %)
use micro filter) micro filter)
Max. pressure: 0.8MPa (8bar) 0.8MPa (8bar) 0.6MPa (6bar)
Max. flow rate (torch connected): 2800 l/h 3200 l/h 1200 l/h
Connector size: G1/4“ G1/4“ G1/4“
Table 5

3.3.2 Plasma gas controller PGE 2-800

Art.-No.: .11.824.227
Input voltage (solenoids): 24 V AC, 50 / 60 Hz
Dimensions (l x w x h): 360 x 240 x 425 mm
Weight: 10 kg
Plasma gases: argon hydrogen nitrogen
(99.996 %) (99.95 %) (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

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 3.3.3 Plasma ignition box PZ-800
Art.-no.: .11.821.980
Input voltage (solenoids): 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

Art.-no.: .11.825.245
Dimensions (l x w x h): 180 x 185 x 240 mm
Weight: 4.0 kg
Plasma gases, swirl gas: (see chapter 3.3.1 and 3.3.2)
Connection to: PGE 1-800/PGE 2-800 by gas hoses
Table 8

3.3.5 Plasma torch connection unit PBA-800

Art.-no.: .11.820.231 (3x solenoids)
Input voltage (solenoids): 24 V AC, 50 / 60 Hz
Dimensions (l x w x h): 170 x 220 x 335 mm
Weight: 3 kg
Plasma gases, swirl gas : (see chapter 3.3.1 and 3.3.2)
Connection to: PZ-800 and PGA 3-800 resp. power source and PGA 1-800/PGA 2-800 with hose
parcel extension PBL-800
Table 9

3.3.6 Plasma counter PZE 1

Art.-No.: .11.824.254
Dimensions (l x w x h): 180 x 185 x 140
Weight: 2.0 kg
Connection to: FineFocus 800 with 8pole control cable
Table 10

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 4 Technical description
4.1 Plasma rectifier FINEFOCUS 800
All components of the plasma power source are mounted into a movable housing and cooled by a
fan.
The control and signalling elements and the workpiece cable connector are placed in the front panel.
The back wall contains the fuses, the connectors for the CNC-cable and the control cables for the
components, like PGE 1-800 / PGE 2-800 and PZE 1 as well as the mains cable entry.
The connectors for the cathode supply cables, the remote control and the connection cables to the
PZ-800 are placed inside of the plasma rectifier and accessible after opening the front door. All
connectors are marked.
The internal cooling system consists of the pump, the coolant tank, the heat exchanger and the flow
controller for switching off the power source in case of insufficient flow rate.
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.
A high voltage igniter initiates the pilot arc.

4.2 Plasma torches

Attention!
The plasma cutting unit should be operated only with the plasma torches of the series
PB-S77 W-1 or PB-S77 W-2.
Before starting any installation or maintenance work the power source has to be
disconnected visible from the mains (unplug mains cable)!

The plasma torches of the PB-S77 W-series are suitable with the plasma gases air, oxygen, argon,
nitrogen and hydrogen. Secondary gases (swirl gas) are oxygen and nitrogen, mixtures of these
gases and air as well.

The cutting current is transferred to the cathode by a flexible copper cable, which in inserted is the
insulating water inlet hose.

The nozzle is fixed in the nozzle holder by a detachable nozzle cap. The cooling water circulates
between nozzle and nozzle cap. A special cooling tube arranges an effective cooling of the cathode.
Therewith a perfect cooling of all torch parts is granted.

Attention!
Before using a plasma torch it is necessary to ensure, that the torch is equipped with the parts
suitable for the plasma gases and the cutting technology! After each change of torch parts a
gas purge of about 20 sec. Is required, to blow out remaining water, which can damage the
torch during ignition (tumbler switch “Gas test”).

The operator is allowed to change only spare parts!

Only spare parts and consumables of Kjellberg origin have to be used!

Keep all parts (consumables included) coming in contact with oxygen free of oil and grease!

4.2.1 Plasma machine torch PB-S77 W

The plasma machine torch PB-S77 W is designed for a maximum cutting current of 300 A and
therefore suitable for thicknesses up to 80 mm. The main parts of the torch are torch head, torch
shaft, hase parcel and consumables. The torch is furnished with two plasma gas supply hoses and
one swirl gas hose.

4.2.2 Plasma hand torch PB-S75 WH-1

The plasma hand torch of the PB-S75 WH-1 series are suitable for a cutting current of max. 250 A,
which is sufficient for a max. thickness of 80 mm. The hand torch consists of torch head, handle with
torch switch, hose parcel and consumables.

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 Following hand torches are available: PB-S75 WH-1/L
- plasma hand torch for plasma gas air
PB-S75 WH-1/A
- plasma hand torch for plasma gas Ar/H2/N2-mixture
The plasma torches are easily to convert to the demanded plasma gas by changing the consumables
only: - ../L = delivered with air consumables
- ../A = delivered with consumables for Ar/H2/N2-mixture

The following tables ar showing cathode and nozzle specifications for the different plasma gases and
the current ranges.

technology
plasma cutting with guide bow (from 50 mm wheel guide RW 2) plasma gouging
cutting current up to 120A up to 160A up to 250A up to 160A
cathode K2 K2 K2 K2
nozzle L3 L1 L2 L9
nozzle orifice 1.4mm 2.0mm 2.5mm 4.0mm
Table 11: Consumables of the PB-S75 WH-1 for plasma gas air

technology
plasma cutting with guide bow (from 50 mm wheel guide RW 2) plasma gouging
cutting current up to 120A up to 160A up to 250A up to 160A
cathode K5 K5 K5 K5
nozzle A1 A3 A2 A9
nozzle orifice 1.4mm 2.0mm 2.5mm 4.0mm
Table 12: Consumables of the PB-S75 WH-1 for plasma gas Ar/H2/N2-mixture

Consumables are: the cathode, the nozzle, the nozzle cap, the cooling tube, the guide bow and the
O-rings 18x2 and 28x2 as well.
Torch tools are: the gas guide puller, the gas cap puller, the hexagonal wrench and the socket
spanner for the cathode and the nozzle cap.
The placement of parts and the change of consumables is explained in chapter 6.6.

4.3 Plasma components

4.3.1 Remote control FB 1

With the remote control FB 1 the cutting process with a machine torch (ignition of pilot arc) can be
started and stopped.

It is provided with an ON-(green) and OFF-(red) button. The 10 m control cable becomes connected
to the connector X 132, placed on the connection board of the FineFocus 800.

4.3.2 Plasma gas controllers PGE 1-800 and PGE 2-800

The plasma gas controllers PGE 1-800 or PGE 1-800 with PGE 2-800 are required for the dosage
and control of the plasma and swirl gases.

The PGE 1-800 is provided with the gas connectors, the pressure switches, the solenoid valves and
the flow controllers for the plasma gases air and oxygen and the swirl gases as well.

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.

The PGE 2-800 is provided with the gas connectors and contains the pressure switches, the solenoid
valves and the flow controller for argon, hydrogen and nitrogen.

By means of the installed tumbler switch from the PGE 2-800 the gas supply of the plasma gases
hydrogen and nitrogen can be stopped on demand. A 4-pole control cable connects the PGE 2-800
with the socket X122, placed on the back panel of the FineFocus 800.

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 4.3.3 Cable Set PZL-800

For many applications the standard hose parcels of the plasma torches with 6 or 10 m length are to
short. The operational radius can be extended upt to 55 m when using a cable set PZL-800 in
connection with the plasma ignition box PZ-800.

The cable set PZL-800 consists of:

• coolant outlet hose
• coolant inlet hose
• 8-pole control cable
• 10-pole control cable PZ-800
2
• cathode cable 70 mm

4.3.4 Plasma ignition box PZ-800

The plasma ignition box PZ-800 connects the plasma torch hose parcel respectively the cable set to
the PBA-800 with the
power source by the
cable set PZL-800. The
PZ-800 contains the
connectors for the
coolant inlet and outlet
hoses for the torch
hose parcel and the
PGA3-800 cable set PZL-800 and
the torch solenoid
supply cables as well.

Optionally the PZ-800

can be provided with
coolant return flow
blocker. All terminals
are accessible after
PZ-800
opening the side walls
which are protected by
safety contacts.

Fig. 3: plasma ignition box with plasma gas connection unit

4.3.5 Plasma gas connection unit PGA 3-800

For extending the operational radius with the plasma ignition box PZ-800 the plasma gas connection
unit PGA 3-800 is required. All connectors and terminals for the gas supply are placed on the
backside, connecting the PGA 3-800 with the PGE 1-800 / PGE 2-800 and the plasma torches resp.
the plasma torch connection unit.

The PGA 3-800 is fixed on the top of the plasma ignition box PZ-800.

4.3.6 Plasma torch connection unit PBA-800

The plasma torch connection unit is the connection point between the plasma torches PB-S77 W-2
and the plasma ignition box PZ-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.

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 4.3.7 Cable set PBL-800

The cable set connects the plasma torch connection unit PBA-800 with the plasma ignition box
PZ-800 resp. the FineFocus 800. The cable set PBL-800 consists of:

• coolant inlet hose

2
• coolant outlet hose with inserted cathode cable 35 mm
• pilot arc cable
• control cable (solenoids, safety circuit)

Furthermore the connection hoses for the PG 1 and PG 2 and the swirl gas from the PGA 3-800 have
to be connected.

4.3.8 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.

Following procedures are possible:

• Straight line cutting on rails
• Manual guiding along markings on the workpiece
• Circle cutting of diameters 150 to 1500 mm with the circle attachment

Further details of the tractor unit FE 1 are shown in the Instruction Manual .11.824.540.

4.3.10 Accessories for the plasma hand torch

Optional for the plasma hand torch are available the wheel guide RW 2 and the circle attachment
KSE 6 for cutting of circles 62 to 600 mm diameter.

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 5 Commissioning
After receipt of the plasma cutting unit verify by the delivery note that all components are present.
Contact the supplier if parts are damaged or missing.

5.1 Check out, placement and installation

The plasma cutting unti is designated for a service in explosion-proofed rooms or in the free air by
using a roofing under following conditions:
o o
• Ambient temperature: -10 C up to + 40 C
• Relative moisture: max. 90 %

Place the power source so that the air flow is not blocked. The cooling air is drawn in through the
front wall grating and is exhausted through the rear wall. A free distance of at least 250 mm should
be kept around the unit.

The plasma cutting machine is designed acc. to the requirements of the protection class IP 22
(DIN 40050), that means:
• Protection against penetration of solid parts above 12 mm size
o
• Drip-proof protection against straight dropping water (without negative influence up to 15 unit
inclination).

Avoid that dust (especially metallic particles), acid damp, corrosive substances and gases can enter
the unit. The life time and the function of the plasma cutting will be influenced.

The unit is moveable by hand. When transporting by forklift the unit has to be taken from the back
side.

Attention!
The centre point is near to the back of the unit!
Therefore never take the unit from the side or
the front! Danger of tilting exists!

For cran transportation all four lifting eyes have

to be used! The angle between the ropes or
o
chains should not exceed 45 ! Pay attention for
the weight of the unit.

For crane transportation lifting eyes are provided!

Fig. 4: crane transportation

5.2 Installation
5.2.1 Mains connection

Attention!
Before starting the installation be sure that the plasma cutting unit is switched OFF and visibly
disconnected from the mains (unplug mains cable)!
All installation of electrical systems must conform to national or local standards. Only
qualified and licensed personnel (see VDE 0105 or national/local instructions) is allowed to
open the unit to perform this installation work!
2
The mains cable, cross section 4 x 35 mm , becomes inserted through the cable entry and strain
relief at the rear of the power supply and connected to the mains terminals. For the connection to the
mains a wall-mounted power switch (main switch) with an in line following socket has to be provided.
Both parts must have the proper size, matching the input current.

The mains fuses acc. to chapter 3.1 have to be place before the power switch.

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.

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 5.2.2 Workpiece connection / current return line
For the connection of the workpiece cable a socket is provided in the front wall of the power source.
The workpiece clamp has to be fastened firmly to the cutting job or the table on which part to be cut is
placed.

Attention!
It is not allowed to use conductive parts of building, like steel construction, pipes, track ways
or similar devices for conducting the power back to the plasma cutting unit, as far cutting is
not performed at those parts

The workpiece and the cutting table have to be grounded carefully!

5.2.3 Grounding
Workpiece and cutting table have to be correct grounded. The plasma cutting unit FineFocus 800,
the plasma ignition box PZ-800 and the plasma torch connection unit PBA-800 are provided with
marked terminals, size M8 for the grounding. To avoid electromagnetic disturbances and for the
safety of the personnel the grounding has to be carried out very carefully, the size of the grounding
2
wire should have at least 16 mm .

5.2.4 Connection of the FineFocus 800

All control cables to the CNC-guiding system, to the components like PGE, PZE 1 as well as the
mains cable have to be connected to the back side of the unit. Whereas the connectors for the
cathode-, nozzle- and supply cables and hoses to the PZ-800 are placed in connection compartment,
which is accessible by opening the safety contact protected front doors.
The workpiece cable also becomes plugged in frontal.
Following components become connected to the power source FineFocus 800:
• the plasma torches of the PB-S77 W series
• the cable set PZL-800 for the extension of the operational radius with the PZ-800
• the cable set PBL-800 for the operation of the PBA-800
• the plasma gas control unit PGE 1-800 and PGE 2-800 for adjustment and dosage of the process
gases
• the plasma counter PZE 1
• the remote control FB to operate the plasma machine torches

5.2.5 Connection of plasma torches

Attention!
The plasma cutting unit generally has to be disconnected visibly from the mains (unplug
mains cable) before opening the power source or the ignition box!

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.

The plasma torches of the PB-S77 W-2 series only can be connected to the plasma torch connection
unit PBA-800.

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.

5.2.5.1 Connection of the plasma torches to the FineFocus 800

• open front door (use screw driver)

• connect water hoses, control cable and the optional hose parcel screening of the plasma torch
(table 10)
• connect gas hoses to the respective connecting hoses of the PGA 1/PGA 2

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 hose parcel PB-S77W-1 FineFocus 800 front side connection
Coolant outlet hose G1/2” Coolant outlet / cathode
Coolant inlet hose M18x1,5 Coolant inlet
Control cable, 8-pole plug Connection control cable X121
Pilot cable, 1-pin plug Nozzle +
Screening, cable lug M8 Terminal bolt M8
PGA 1-800 PGA 2-800
Swirl gas hose Connector M12x1 -
Plasma gas hose PG1 Connector G3/8“ Connector G3/8“
Plasma gas hose PG2 Connector G3/8“ left Connector G3/8“ left

Table 14: PB-S77 W-1 connection to FineFocus 800

After the installation is completed the front door has to be closed firmly. All cables and hoses have to
be placed without sharp bends and to be protected against twisting and damages!

The connection of the plasma torch PB-S75 WH-1 will be done in the same way.

Additionally the control cable “torch switch” has to be inserted into the socket X125 and the gas hoses
have to be connected to the PV-800.

5.2.5.2 Plasma torch connection to the plasma ignition box PZ-800 / plasma gas connection unit
PGA 3-800

Connection of the plasma torch PB-S77 W-1 to the PZ-800:

• remove side walls from PZ-800

• open green stress relief clamp
• insert water hoses and control cable of the plasma torch through the rear entry marked with
“PBL/PB” and perform connections
• connect gas hoses to the PGA 3-800

5.2.5.3 Plasma torch connection to the PBA-800

The connection of the plasma torches has to be done to the following connectors, placed inside of the
PBA-800. Following connections have to be carried out:

• Coolant outlet G1/2“

• Coolant inlet M 18x1,5
• Pilot arc supply

The hoses for the plasma gases and the swirl gas will be connected straight to the solenoid valves
which are placed sideward.

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). The outlets are placed
on the bottom.

If the plasma torch is connected directly to the power source the PGE 1-800 has to be placed and
fixed on the top of the FineFocus 800.

In any case the plasma gas control unit has to be placed so that the operator easily can reach it.

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 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.

If the plasma torch is directly connected to the FineFocus 800 the PGE 2-800 together with the
PGE 1-800 has to be fixed on the top of the power source.

In any case the plasma gas control unit has to be placed so that the operator has easy access to it.

5.2.8 Connection of the plasma ignition box PZ-800

For the connection of the plasma ignition box with the FineFocus 800 over distances up to 40 m the
cable set PZL800 is required.

Following connection have to be carried out between FineFocus 800 and PZL-800:

PZL-800 Plasma unit Plasma ignition box

Connection board Entry “PZL”
Coolant return hose (19x4) G1/2” G1/2” (connection board)
Coolant inlet hoase (13x3,5) M18x1.5 M18x1.5 (connection board)
8-pole control cable X121 X121 A (connection plate)
10-pole control cable X124 X114/X124 (rear wall)
2
Cathode cable 70 mm M 12 M 12 (distributor G ½“)
Table 15

Hint!
The safety contacts in the plasma ignition box prevent the operation of the plasma installation
in case the side walls are opened.

The green strain relief clamps in the plasma unit and in the ignition box have to be tightened carefully.
The cable set has to be placed without twisting and sharp bends to avoid damages.

5.2.9 Connection of the plasma torch connection PBA-800

The plasma torch connection unit will be installed to the guiding system of the user. For the correct
fastening the back wall of the PBA-800 is furnished with two distance pieces (with threads M6
inside/outside). For fastening the cable set PBL-800 it has to be inserted fromt top side into the
PBA-800. Both the gas hoses and the swirl gas hose have to be gas-tight.

After the connection is finished the cover plate has to be closed, otherwise the safety contact
prevents the start of the cutting unit.

Depending on the mode of application the PBA-800 becomes connected by the PBL-800 to the
plasma cutting unit FineFocus 800 / PGA 1-800 / PGA 2-800 or to the plasma ignition box PZ-800 /
PGA 3-800.

5.2.10 Connection of the gas hoses between PGE 1-800 / PGE 2-800 and PGA 3-800

The lengths of the gas hoses between the components of the plasma cutting complex FineFocus 800
depend from the installation place. Following types for the hoses have to be used:

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 1 Plasma gas PG1 (air): gas hose 6x3 black – G1/4“ (grey marked)
2 Plasma gas PG2 (O2): gas hose 6x3 blue – G1/4”
3 Swirl gas (N2, O2): Gas hose 4x3,5 blue – G1/4“ (grey/green marked)
4 Plasma gas PG3 (Ar): Gas hose 6x3 black – G1/4“
5 Plasma gas PG4 (H2): Gas hose 6x3 red – G3/8“ left
6 Plasma gas PG5 (N2): Gas hose 6x3 black – G1/4“ (green marked)

5.2.11 Connection of the gas hoses between PGA 3-800 and PBA-800
Following hoses up to 15 m are used:

1 Plasma gas PG1 (air, Ar, O2): Gas hose 4 x 3,5 blue-G3/8“
2 Plasma gas PG2 (air, air,H2): Gas hose 6x3 red – G3/8“ left
3 Swirl gas (O2, N2): Gas hose 4x3,5 blue – G1/4“ (grey/green gekennzeichnet)

The swirl gas hose remains always connected. But the plasma gas hoses for air/oxygen cutting are
placed on the upper connectors, for argon/nitrogen cutting to the lower connectors of the PGA-800.

5.2.12 Connection of the plasma gas supply

5.2.12.1 Plasma gases
The connectors for the supply hoses of the plasma gases are located in the rear wall of the plasma
gas control unit PGE 1-800 resp. in the rear wall of the PGE 2-800.

The quality of the plasma gases have to be granted (see chapt. 3.1)

Wrong qualities or dirty gases lead to double arcing and torch damages and will increase the
consumption on cathodes and nozzles.

All gas connectors of the plasma gas control units, plasma gas connection units and the plasma
torches are furnished with small filters to avoid coarse dirt can penetrate. For cleaning purpose they
can be screwed out by a screw driver

For the gas supply following gas hoses are used:

Plasma gas Colour code Connectors

air Black, grey marked G1/4“
oxygen Blue G1/4“
argon Black G1/4“
hydrogen Red G3/8“ left
nitrogen Black, green marked G1/4“
Table 16

Attention!
The inlet pressure should not exceed 1 MPa (10 bar), but should be at least 0.1 MPa
higher as stated cutting pressure, stated in the cutting charts! Please follow strictly
the regulations and instructions of the manufacturers for handling pressure
regulators and gas cylinders (BGV D1, local or national accident preventing rules).

Plasma gas air

Supply from pressure cylinder:
• Check cylinder valves (must be free of oil and grease), clean it if required
• Open shortly the valve for removing dust
• Adjust the pressure reducer to the cylinder
• Connect the gas hoses (black/grey marked, G1/4”-G1/4”) between pressure reducer, filter/micro
filter and connector “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

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 Supply from shop line or compressor:
• Arrange oil and water separator in the supply line or dry freezer, to be connected before the
PGE 1-800
• The oil separator isn´t required if the compressor works “oil free”
• Adjust pressure so that under gas flow the pressure gauge on the PGE 1-800 shows the value as
given as given in the cutting chart

Plasma gas oxygen

Attention!
All components coming in touch with oxygen have to be free of oil and grease!
Pressure reducers have to be provided with explosion protectors. Install micro filters
between gas supply and PGE 1-800!

• Check cylinder valves (must be free of oil and grease), clean it if required
• Open shortly the valve for removing dust
• Adjust pressure reducer with explosion protection to the supply (cylinder, shop line)
• Connect the gas hoses (blue marked, G1/4”-G1/4”) between pressure reducer, filter/micro filter
and connector “PG2” at the PGE 1-800
• Open 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

Plasma gases argon, hydrogen, nitrogen

• Check cylinder valves (must be free of oil and grease)
• Open shortly valves for removing dust
• Adjust pressure reducers to the cylinders
• Connect gas hose (black colour, G1/4”-G1/4”) between pressure reducer argon and the connector
“PG3” at the PGE 2-800
• Connect gas hose (black/green marked, G1/4” –G1/4”) between pressure reducer nitrogen and
connector “PG4” at the PGE 2-800
• Connect gas hose (red colour, G3/8” left – G3/8” left) between pressure reducer hydrogen and the
connector “PG5” of the PGE 2-800
• Open valves and adjust the pressure under gas flow so that the pressure gauges on the
PGE 2-800 are showing the values for all the gases as shown in the cutting chart

5.2.12.2 Swirl gases (oxygen, nitrogen)

The connectors for the supply hoses of the swirl gases are placed on the back of the plasma gas
control unit PGE 1-800.

For the gas supply following hoses are required:

Swirl gas Colour code connectors

nitrogen black / green marked G1/4“
hydrogen blue G1/4“
Table 17

• Check cylinder valves (must be free of oil and grease), clean them if required
• Open shortly the valves for removing dust
• Adjust the pressure reducers to the cylinders
• Connect the gas hoses (black/green, G1/4” – G1/4”) between pressure reducer N2 and the
connector “WG1” of the PGE 1-800
• Connect the gas hoses (blue, G1/4” – G1/4”) between pressure reducer O2 and filter/micro filter
and connector “WG2” of the PGE 1-800
• Open the valves and adjust the pressures so that under gas flow the pressure gauges on the
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!

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 5.2.13 Filling up the coolant
The plasma rectifier is equipped with an internal closed cooling circuit. The coolant “Kjellfrost” has to
be filled up before connecting the plasma torch or the cable set PZL-800 (pump venting).

The coolant “Kjellfrost” prevents pump freezing, and is additionally increasing the durability of the
pump, its packings and the cooling channels.
Attention!
The coolant “Kjellfrost” has to be used pure, and should not diluted by water (acid
formation)!
The tank is accessible after removal of the left frontal side wall.

During the change of consumables always a small loss of coolant accuses. Therefore this loss
should be compensated weekly.

After about 200 cutting hours resp. 6 month the complete coolant should be replaced (see chapter
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.

Following signals are available from the unit, respectively can be given to the unit:

contact signal kind of signal

A1-A2 Main arc ON Closing contact
A5-A6 Pilot arc ON Closing contact
A7-A8 Transition pilot arc to main arc Closing contact
A9-B2 Emergency STOP on NC (potentialfree contact) 6A, 24 V AC
B3-B4 Torch connected Closing contact
B5-B6 Potential cathode - nozzle Analogous signal 0-10V (10 V=250V)
B7-B8 Potential cathode - nozzle Analogous signal 4-20mA (20mA=250V)
C1-C2 Potential cathode – work piece Analogous signal 0-10V (10V=250V)
C3-C4 Potential cathode – work piece Analogous signal 4-20mA (20mA=250V)
C5-C6 Slope-up time 1 for cutting current Closing contact (signal from NC)
C7-C8 Slope-up time 2 for cutting current Closing contact (signal from NC)
table 18: X101 (25-pole femal plug) output signals from FineFocus 800

contact signal kind of signal

A1-A2 Power source release Closing contact
A7-A8 Torch ON Closing contact
A9-B2 Gas purge / cutting Closing contact
(closed: cutting, opened: gas purge)
B3-B4 Set point current Analogous signal 0-10V (0V=80A,10V=300A)
B5-B6 Set point current Analogous signal 4-20 mA
(4mA=80A,20mA=300A)
C1-C2 Plasma gas selection Ar/H2/N2 Closing contact
C3-C4 Plasma gas selection O2 Closing contact
C7-C8 Emergency STOP on NC (potentialfree contact) 6A, 24 V AC

Remark!
Before the connection is carried out the link X102:C7-C8 has to be removed. The
operation of the FineFocus 800 without the link or without emergency-OFF-signal
from the CNC-guiding system is not possible!

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 Table 19: X102 (25-pole male plug) signals from CNC

contact signal kind of signal

A1-A2 Safety circuit open Closing contact
A3-A4 Excessive temperature Closing contact
A5-A6 Plasma gas fault Closing contact
A7-A8 Ignition fault Closing contact
A9-B2 Pilot arc time exceeded Closing contact
B3-B4 Torch contact to workpiece Closing contact
B5-B6 Phase missing Closing contact
B7-B8 Cumulative error signal Closing contact
C1-C2 RESET from CNC Closing contact
C3-C4 Fault torch cooling Closing contact
Table 20: X103 (25-pole socket, error signal from power source)

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!

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 6 Operation
Attention!
It is not allowed to operate the machine 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
properly cooling the components!
Generally the plasma cutting unit has to be switched OFF and disconnected visibly from the
mains (unplug supply cable) before opening any cover from the power source or from other
components!

6.1 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.

For that reason the respective switches S101-S109 inside of the FineFocus 800 have to be switched
over (accessible after removal of the right frontal side wall).

6.1.1 Front wall controls and displays

Fig. 5: Front wall controls and displays

1. Arc voltage display P1 (0...400V) 5. Push button green S2 “Stand-by”

- indicates the cutting voltage - activated: - plasma cutting unit in stand-by position
(Main transformer, pump, fans, control ON)
2. Current display P1 (0...400A)
- indicates the cutting current 6. Potentiometer R7 “cutting current adjustment”
- cutting current setting 80 – 300 A
3. Red push button S3 „Emergency-STOP“(blocking switch)
- activated: power source OFF (except conrol transforer 7. Push button S13 „preset control“
and fans M1, M2, M3) - when activated: the adjusted current is shown on
- resettled: Power source ready for start the display (3) and can be set to the desired value
by potentiometer (7)
4. Key switch S1 „Mains ON“ - LED H8 (21) ON, indicates “error”
- position 0: power to control transformer and fan M1, M2, - plasma unit not ready for start
M3 OFF
- position 1: power to control transformer and fan M1, M2, 8. not used
M3 ON

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 9. Selector switch S8 “current upslope time main arc” 18. LED-signal lamp H7 red „phase missing“
- LED H7 ON: - one phase of the mains supply is
position function application missing
left standard soft start cutting start - plasma cutting unit not operable
piercing up to 10 mm -- thickness
centre slow soft start piercing up to 20 mm material
19. LED-signal lamp H8 red „cumulative error
right very slow soft start piercing up to 40 mm depending --
signal”
10. step switch S6 „gas selection“ - LED H8 ON: - mains phase missing
- selection of plasma gases (air, oxygen or Ar/H2/N2-mixture) - fault in cooling circuit (LED H9)
- gas pressure < 0.4 MPa (3 bar) (LED H10)
11. Tumbler switch S5 „gas purge“ - wrong selected plasma gas (selector switch S6,
- switch in upper position: purge ON LED H10)
- plasma cutting unit not ready to start - tumbler switch S5 „gas purge“ in ON position
- for gas pressure adjustment - thermal overload on rectifier G1/G2
- for measuring the gas flow rate - button S13 „preset control“ activated
- for blowing out water from torch after change of consumables - plasma cutting unit not ready for operation
- LED H8 “fault” ON
20. LED-signal lamp H9 green „cooling circuit o.k.”
12. LED-signal lamp H3 green „ready for start“ -LED H9 ON: flow switch in power source activated
- LED H3 ON: plasma unit ready for start
21. LED-signal lamp H10 green „plasma gas supply
13. not used correctly“
- LED H10 ON: selected plasma gas with pressure
14. LED-signal lamp H1 yellow „pilot arc“ >0.4 MPa
- LED H1 ON: pilot arc initiated
22. LED-signal lamp H11 yellow „thermal overload“
15. LED-signal lamp H2 yellow „main arc“ - LED H11 ON: - power source not ready for start
- LED H2 ON: main arc initiated - thermal overload of rectifiers
16. LED-signal lamp H5 red „pilot arc time exceeded“ 23. LED-signal lamp H12 yellow „coolant tempera-
- LED H5 ON: pilot arc time more than 15 sec., ture to high“
(approx. 5 sec.) re-ignition after H5 is OFF possible - LED H12 ON: - coolant temperature > 50oC
- plasma cutting unit not ready for
17. LED-signal lamp H6 red „nozzle contact“ operation
- LED H6 ON: nozzle has contacted the workpiece, re-
ignition necessary

6.1.2 Service elements inside of the plasma cutting unit

These service elements have to be switched in the desired position before the plasma cutting unit
becomes switched ON. With the tumbler switches S101-S109 the following functions can be
activated/deactivated.

1. Tumbler switch S101 "stand-by ON"

position 1: manual operation by green push button S2 on front wall
position 2: CNC-signal on X102:A1 - X102:A2

2. Tumbler switch S102 "gas purge"

position 1: manual operation by S5 in front wall
position 2: tumbler switch S5 out of order

3. Tumbler switch S103 "gas selection"

position 1: manual operation by step switch S6 on front wall
position 2: CNC-signal on X102:C1 - X102:C2 for Ar/H2/N2 / on X102:C3 - X102:C4 for O2

4. not used

5. Tumbler switch S105 "cutting start / piercing"

position 1: manual operation by step switch S8 in front wall
position 2: without CNC-signal standard soft start
CNC-signal on X101:C5-X101:C6 for slow soft start,
CNC-signal on X101:C7-X101:C8 for very slow soft start

6. Tumbler switch S106 "select control" (current set value)

position 1: manual operation by R7 on front wall
position 2: CNC-Signal on X102:B3-X102:B4 for outside voltage 0-10 V (80-300A)
CNC-Signal on X102:B5-X102:B6 for outside current 4-20 mA (80-300A)

Remark! JP4 on PCB LP 079661 has to be placed to UFremd resp. IFremd (see
sticker on left backside door)
7. not used

8. tumbler switch S109 "operation mode start – test/start"

positon 1: at signal “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)

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 6.2. Cutting operation
Attention!
The plasma cutting unit shall be operated only with the plasma torches of the following
series: PB-S77 W-1, PB-S77 W-2 and PB-S75 WH-1!
Before maintenance or repair work is carried out on the plasma torches (change of
consumables for instance) the power source generally has to be switched OFF and visibly
disconnected from the mains supply!

Before cutting is performed following inspections have to be done:

Inspection of the plasma torch

• Correct and undamaged condition of the plasma torch
• Torch parts are matching the cutting technology / plasma gases
• Consumables in correct condition

Inspection of the plasma rectifier

• Main fuses have outlined size (see chapt. 3.1 and 5.2)
• Workpiece cable properly fitted (see chapt. 5.2.2)
• Gas supply is in operational condition (see chapt. 5.2.12)

Attention!
Never direct the plasma torch towards the eyes or other parts of the body! Don´t touch nozzle
and nozzle cap if power is ON!
High voltage ignition can create electrical endangerment, the pilot arc can cause burns on
eyes and skin! Wear protective clothes and safety glasses!

Switching ON the plasma rectifier:

1. Plasma gas selection by selector switch S6 (10) “gas selection” or form NC (chapt. 6.1.2)

2. Turn key switch S1 (4) to position “I” – fan for heat exchanger ON
Cooling air must escape from rear wall. If not, change two phases on the mains supply cable.

3. Press green button S2 (5) or signal from NC

• Pump ON, red LED H8 “cumulative error” ON
• Gas purge starts
• Plasma torch should not show any leakage
• Green LED´s H3 (12) “ready for start”
H10 (21) “gas supply correct”
H9 (20) “cooling circuit correct” ON
and red LED
H8 (19) “cumulative error” OFF

4. Keep tumbler switch S5 (11) for at least 10 sec. In pos. “gas purge”
• coolant removal from torch head
• red LED H8 (19) “cumulative error” ON

5. The gas pressure has to be at least 0.9 MPa (pre pressure), to be adjusted under gas flow on the
PGE 1-800 resp. PGE 2-800 (tumbler switch on PGE 1-800 or S5) and checked at the
manometers of the PGE 1-800 and PGE 2-800. With the needle valves on the flow meters the
pressure required for the process (see cutting chart) has to be adjusted.

6. Switch OFF tumbler S5 (11), red LED “error” OFF, plasma cutting unit ready for start if:
• the green LED-signal lamps H3 (12), H9 (20) and H10 (21) are ON and
• the red LED-signal lamp H8 (19) “error” is OFF

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)

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 6.3 Machine torch operation
Ignition of pilot arc

The pilot arc will be established when pressing the ON-button of he remote control FB 1 or by the
ON-signal from the guiding system on plug 102:A7-A8 (remote control FB 1 is not connected) after
the gas pre-flow. The arc time is limited to 15 s. After contacting the workpiece the main arc
automatically becomes ignited and the cutting process starts.

Running cutting start

• Ignite pilot arc 10 to 20 mm before the edge of the workpiece

• Move plasma torch toward the workpiece
• As far as the pilot arc contacts the workpiece the main arc establishes
• At thin sheet metal the starting speed should be reduced
• The distance between nozzle and workpiece should be in a range of 6.0 to 8.0 mm

Piercing (see scheme piercing technology – page : 41):

Attention!
Upcoming hot material can lead to endangerments (risk of burns and fire)!

• After the ignition of the pilot the main arc establishes immediately
• Up to thicknesses of 15 mm the torch distance to the workpiece should be approx. 10 mm
• The torch should start movement simultaneously to reduce the danger of damaging torch parts
because upcoming material will effect nozzle, swirl gas nozzle or nozzle cap
• For thicker materials (up to 40 mm) the following procedure is recommended:
- Ignite pilot arc approx. 30 mm above the workpiece
- Lower down the torch
- If main arc strikes (transition signal “transition ON” before signal “main arc ON”) torch
movement should start and torch should be lifted a few Millimeters (up-coming spatter should
not effect the nozzle)
- After the material is pierced through return to the optimum cutting distance

6.4 Hand torch operation

Igniting the pilot arc only is possible with protective cap properly fitted to the torch head (safety
circuit). The torch distance to the workpiece depends on the cutting job and should range from 6.0 to
12.0 mm, adjustable on the guide bow.

Ignition of pilot arc

When pressing the torch switch after the pre-gas flow the pilot arc ignites. If the nozzle contacts the
workpiece ignition takes not place (HV short circuited).

The pilot arc time should not exceed 15 sec.

After touching the workpiece the pilot arc initiates the main arc automatically and cutting or gouging
can take place. Pilot arc and main arc will extinguish when releasing the torch switch, or if the torch
overruns the workpiece.

6.4.1 Cutting

Cutting start:
• Place guide bow or nozzle close to the workpiece
• Activate torch switch, gas preflow starts before pilot arc ignites
• 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

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 Piercing:

Attention!
Upcoming hot material and spatter can cause endangerments (risk of burns and fire)!

• Up to a thickness of 15 mm the guide bow can be placed directly on the workpiece

• After igntion of pilot arc main arc becomes established immediately
• Cutting movement should start just after then to
avoid that the upcoming hot material effects the
nozzle
• When tilting the torch during the piercing start the
molten material will be forced away from the nozzle. Cutting direction
With this method piercing up to 40 mm is practicable
Fig. 6: cutting with guide bow Workpiece

6.4.2 Plasma gouging

Attention!
Upcoming hot metal and spatter can cause endangerments (risk of burns and fire)!

• Hold the torch sideward so that the arc is directed in gouging direction. Place nozzle not on
workpiece during ignition.
• Press torch switch, pilot arc initiates after the
gas preflow Gouging direction
• Tilt torch so that the pilot arc touches the
workpiece, main arc starts
o
• Guide the torch with an inclination of 25 to
o
40 and an arc length of 10 to 30 mm over
the workpiece (see fig. 7)
• keep a distance of approx. 2.0 mm between
Workpiece
protective cap and workpiece. Contact to the
workpiece will cause a high wear on the
protective cap
Fig. 7: plasma gouging

6.5 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” all components become switched OFF, except the control transformer and the fans
of the heat exchanger.

Remark:
Switch S3 (3) is a blocking switch, which has to released by a left-hand rotation before the
plasma unit can be switched ON with the key switch S2 (5) again.

If the plasma cutting unit isn´t in use for a longer period it has to be disconnected visibl from the
mains.

6.6 Change of consumables (see fig. 8 and 9)

Attention!
Before carrying out service and maintenance work on plasma torches the plasma cutting unit
generally has to be switched OFF and disconnected visibly from the mains (unplug mains
cable)!

When changing consumables on the torch the plasma unit has to be switched OFF so, that an
accidental start is impossible (VBG 15 § 44). An unauthorised or accidental start can be
prevented by taking out the key from switch S1 (4).

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 Attention!
All components coming in touch with oxygen have to be kept free of oil and grease! This
specially refers to all consumables and the torch head.

Worn and defective parts have to changed in time.

The life time of the cathode mainly depends on the number of ignitions. The wear on the cathode K5
(2.3) can be checked by the test gauge (F).

The life time of the nozzle mainly depends of the cutting time, number of ignitions and the handling of
the torch (piercing, workpiece contact, etc.).

Be sure that the spare parts are suitable for the intended cutting process (plasma gas, etc.). The
change of spare parts should be done with special care. Use only the special torch tools (A – E)
supplied along with the torches.

6.6.1 Change of spare parts on plasma torch PB-S77 W (swirl gas technology) (fig. 8)

Removal of worn spare parts

1. Turn off the swirl gas cap (12) manually

2. Screw off the protective cap (11) together with the swirl gas cap (9) manually (take out swirl gas
nozzle from protective cap)
3. Unscrew nozzle cap (7) by socket spanner (D)
4. Take out nozzle (5)
5. Pull out the gas guiding cap (4) from the nozzle (5) by cap puller (C) (only for plasma gas air and
oxygen)
6. Unscrew cathode (2) by socket spanner (B)
7. Screw out the cooling tube (1) by spanner (A) resp. hexagonal wrench (E) (only if damaged or
when changing the plasma gas)

Inserting the new spare parts

1. Screw in the cooling tube (1) with spanner (A) or hexagonal wrench (E)
2. Screw in cathode (2), tighten with spanner (B)
3. Insert gas guide cap (4) in nozzle (5) (only for air and oxygen)
4. Insert nozzle (5)
5. Replace nozzle cap (7) by socket spanner (D) (hand tight)
6. Replace swirl gas nozzle (9) and protective cap (11) (hand tight)
7. Screw swirl gas nozzle (12) onto protective cap (11)

All O-rings (3, 6, 8 and 10) have to be replaced with care, avoid damages, twisting, etc.

6.6.2 Preparation of torch PB-S77 W for dry cutting without swirl gas

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
cap

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 fig. 8 Consumables plasma torch PB-S 77 W

part Designation Plasma gas Application

No. O2 air, Ar/N2 Ar/H2, Ar/H2/N2 at
1.1 Cooling tube air X
1.3 Cooling tube Ar/H2 X
2.1 Cathode K2-XL X Plasma
2.2 Cathode K2 X cutting
2.3 Cathode K5 X
3 O-ring 18x2 X X X with
4 Gas guide cap X X
5.1 Nozzle L1-XL, L2-XL, L3-XL swirl gas
5.2 Nozzle air L1, L2, L3
5.3 Nozzle Ar/H2 A1, A2, A3 (sry and
6 Rundring 28x2 X X X under water)
7 Nozzle cap X X X
8 O-ring 42x2 X X X
9 Swirl gas cap X X X
10 O-ring 48x2 X X X
11 Protective cap X X X
12 Swirl gas cap 4 , 4,5 , 5 4 , 4,5 , 5 4 , 4,5 , 5
13 Insulation sleeve X X X Dry cut without
14 Protective cap X X X swirl gas
tools
A Socket spanner cooling tube X X
B Socket spanner cathode X X X
C Gas cap puller X X
D Socket spanner nozzle cap X X X
E Hexagonal wrench 4 mm X
F Test gauge cathode wear X
Table 21

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 6.6.3 Change of spare parts on plasma torch PB-S75 W/WH (dry cutting without swirl gas) - fig. 9

Removal of worn spare parts

1. Pull off protective cap (9) (only hand torch)

2. Screw off nozzle cap (7) by socket spanner (D)
3. Take out the nozzle (5)
4. Pull out the gas guiding cap (4) from the nozzle (5) by cap puller (C) (only for plasma gas air and
oxygen)
5. Unscrew cathode (2) by socket spanner (B)
6. Take out gas guide (8) from the hand torch only if it is damaged or the torch has to be prepared
for an other plasma gas. Use guide puller (G).
7. Screw out the cooling tube (1) by spanner (A) (only machine torch), resp. pull out manually hand
torch or use hexagonal wrench (E), depending on the torch design, necessary only if the cooling
tube is damaged!

Inserting the new spare parts

1. Screw in the cooling tube (1) by socket spanner (A) or hexagonal wrench (E) resp. insert it
manually (hand torch air)
2. Screw in cathode (2), tighten with spanner (B)
3. Insert gas guide, if necessary (only hand torch)
4. Insert gas guiding cap (4) in nozzle (5) (only for plasma gas air and oxygen)
5. Insert nozzle (5)
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.

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 Fig. 9 Consumables plasma torch PB-S 75 W / WH

part Designation Plasma gas Application

No. air Ar/H2 O2 at
cutting gouging cutting gouging cutting
1.1 Cooling tube air (screwed) x x x Machine torch
Cooling tube air (plugged) x x Hand torch
1.3 Cooling tube Ar/H2 x x
2.1 Cathode K2-XL x
2.2 Cathode K2 x x Machine torch
2.3 Cathode K5 x x
3 O-ring 18x2 x x x and
4 Gas guide cap x x x x x
5.1 Nozzle L1-XL,L2-XL,L3-XL x Hand torch
5.2 Nozzle air L1, L2, L3 L9 (not O2)
5.3 Nozzle Ar/H2 A1, A2, A3 A9
6 O-ring 28x2 x x x x x
7 Nozzle cap x x x x x
8 Gas guide x x x x
9 Protective cap x x x x Hand torch
10 Guide bow x x x x
tools
A Socket spanner cooling tube x x x Machine torch
B Socket spanner cathode x x x x x
C Gas cap puller x x x Machine torch
D Socket spanner nozzle cap x x x x x and
E Hexagonal wrench 4 mm x x Hand torch
F Test gauge cathode wear x x
G Gas guide puller x x x x Hand torch
Table 22

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 Attention!
Take care that all torch parts complete installed! Never use a plasma torch without cooling
tube! Due to the ineffective cooling action cathode will be damaged very fast.
No other parts have to be changed or removed when changing the consumables!
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):
1. After pressing the green button S2:
• Automatic gas purge activated
• No water leakage on the torch head
2. Activate tumbler switch S5 “gas purge” for at least 20 sec.
• Drains out the water collected in the torch head
• Small drops can lead to damages during ignition

6.7 Hints for trouble shooting and protective circuits

If during the operation malfunctions are registered the cutting has to be stopped immediately and the
reason for it to be found.
Attention!
Before starting any repairs or maintenance on the installation generally the power source has
to be switched OFF and disconnected from the mains (unplug mains cable)! Only under the
advice of an licensed electrician or skilled personnel the unit should be opened (see VDE 0105
or follow national instructions).

Problem Cause Solution

fan does not start after key switch is fuses F1, F2 or F3 (4A, slow) are - replace defective fuse
turned to ON defective
fan starts, but after activating the green 1. safety circuit open - change direction of fan rotation (fan
button S2 “stand by” he FineFocus 800 switch not closed)
does not start - safety contact not closed on plasma
rectifier or PBA not closed
- close side wall of PZ-800
- check control cable of all components for
correct connection
2. fuse F10 (6.25 A) defective - replace defective fuse
3. fuse F9 defective - replace defective fuse
no ignition of pilot arc H8 (cumulative 1. tumbler switch S5 (gas purge) ON - correct switch position
error) and H3 (torch ready) ON 2.button S13 “preset control” activated - release button
pilot arc ignited, main arc does not strike 1.distance torch - nozzle to high - reduce torch distance
2.workpiece cable not connected - connect workpiece cable
pilot arc extinguishes, H5 “pilot arc time pilot arc time > 15 sec. re-ignition after H5 is OFF
axceeded” ON (protection circuit – pilot
arc time)
no standby mode, H10 (gas supply) 1. gas pressure < 0.3MPa - increase gas pressure
OFF and H8 (cumulative error) ON 2. gas corresponds not with selector - adjust switch S6 to the connected gas
(safety circuit gas control) switch position
no standby mode, H9 (cooling circuit) flow rate insufficient - clean pump filter
OFF and H8 (cumulative error) ON - check flow controller
(safety circuit – cooling circuit control) - rectify sharp bents on hoses
power source has switched OFF, H11 power source over loaded - cool down the power source with running
(thermal overload) and H8 (cumulative fans (key switch activated)
error) ON (safety circuit – thermal
overload)
H7 (phase missing) and H8 (cumulative 1. one phase of the mains missing - rectify fault in mains supply
error) ON (safety circuit – phase control) 2. fuse F4, F5 or F6 (0.5A, slow) defective - replace defective fuse
main arc interrupted, H6 (nozzle contact) nozzle has contacted workpiece during - adjust proper torch distance before new
short ON (safety circuit – nozzle control) cutting ignition start
Table 23

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 7 Maintenance
Attention!
Before carrying out any maintenance or repair work or opening cover plates the plasma power
source has to be disconnected visibly from the mains (unplug mains cable)! Only under the
advice of an licensed electrician or skilled personnel the unit should be opened (see VDE 0105
or follow national instructions).

7.1 Plasma rectifier

Following measures have to be taken regularly: 1. cleaning (al 4 to 6 month)
2. gas supply check
3. electrically inspection (all 6 month)
4. change of coolant (all 6 month)

7.1.1 Cleaning

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. Blowing out should be done carefully with dry compressed air, but better
is to use a vacuum cleaner.

7.1.2 Gas supply

Filter regulators and micro filters (oxygen) have to be checked and cleaned weekly.

Condense water has to drained out. Filter inserts have to be changed in time. The small filter screws
of the gas connections of the plasma cutting unit, the plasma ignition box plasma gas and
control/supply units have to be inspected every 4 months, and cleaned if necessary.

For that reason the pressure reducers of the gas cylinders have to be closed and the respective gas
hose removed from the control unit. The filter screws only can be taken out by a small screw driver.

7.1.3 Plasma gas pressure test

The complete check of the entire gas supply system is very important. Unnoticed escape of oxygen
or hydrogen can cause serious endangerments. The loss of argon increases the operational costs.

Therefore the following gas pressure test has to be carried out weekly when using the plasma gases
Ar/H2-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
• The plasma gas manometers should not indicate a pressure drop within 5 min.

If any loss of pressure is noticed, the reason has to be found out and eliminated immediately! The
pressure test has to be repeated after than.

Only regularly performed gas pressure tests are the guarantee for a safe operation of the gas supply
system!

Because of the existing risk of fire and explosion the gas pressure test have to be carried out
carefully and must be protocolled.

7.1.4 Cooling system

The coolant “Kjellfrost” or “Kjellfrost SUPER” has to be changed after 200 cutting hours or after
6 months.

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 Losses of coolant during the change of consumables have to be replaced. Therefore weekly the filling
level has to be checked.
- Remove left front side wall of the power source
- Unscrew water inlet hose of the plasma torch in the connection compartment of the
FineFocus 800
- Switch on pump and pump out the water and clean the water filter
- Fill up fresh coolant and close the inlet hose
- Check circuit for water tightness
- Close side wall

7.1.5 Electrical revision

According to existing regulation an electrical revision of the plasma cutting unit has to be arranged:
- after 6 months, if the installation is changing the location permanently
- after one year, if the installation remains on the place
a) The visual inspection should concentrate to following conditions and ensuring, that
• the power source is in a good condition
• the touch protection to parts functionally not activated is granted
• main fuses or excessive current protections are matching the line cross section
• cables and wirings are undamaged and have no burn marks
b) By measurement has to be proofed that the protection against excessive touch potential of parts
functionally not activated is granted (test of protective conductor):
• Measurement of the transitions resistance between marked protective conductor connection of
the plasma cutting unit and all touchable metallic parts not functionally activated: < 0.1 Ohm
c) The insulating capacity of winding and line insulation has to be proofed:
• If mechanical, thermal or chemical damages on the insulation is noticed
• If the plasma cutting unit is more than 15 years old or an aggressive environment exists
untimely disturbances will cause
• Insulation value between windings and housing (protective connector terminal) >2.5 MOhm
(dry and cold condition)
• Insulation value between primary and secondary coils of the transformer T1 >2.5 MOhm (dry
and cold condition)
Noticed faults have to be rectified by an expert immediately.

7.2 Plasma torches

The plasma torches have to be handled with care. Powerful handling and stress load have to be
avoided. All spare parts must be in clean condition and carefully changed in time (see chapt. 6.6).

Damages of parts inside the torch, as nozzle holder and cathode tube have to be avoided.
Besides the change of consumable parts under unsing the special torch tools no other action to the
torch head is allowed! Specially the nozzle holder and the cathode holder are sensitive parts.
Removal from the torch front side is not possible. Plasma torches must be transported and stored at
protected places with full inserted parts on the torch head only!
Hose parcels have to be protected against damages, like sharp bending, twisting, over rolling, and
thermal damages as well. At the plasma torches of the PerCut 101-1 series the filter screws have to
be cleaned from time to time after unscrewing from the gas connector.

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!

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 Cutting data FineFocus 800
torch: PB-S77 W mild steel (4 up to 40 mm)
material: St37b-2 plasma gas air with swirl gas air valid from: 18.08.2003

PG 1 PG 2 WG2
Material Current Nozzle WGK Ignition gas Cutting gas Swirl gas Ignition Torch Arc Cutting speed Cutting
thickness ∅ Air Air Air height distance voltage quality maximum kerf
[mm] [A] [mm] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [mm] [mm] [V] [m/min] [m/min] [mm]
1)
4 120 L3 4 7.0 / (28) 8.0 / 65 5.0 / 60 5.0 3.0 165 4.00 6.00 2.7
5 120 L3 4 7.0 / (28) 1) 8.0 / 65 5.0 / 60 5.0 3.0 165 3.20 5.50 2.7
8 120 L3 4 7.0 / (28) 1) 8.0 / 65 5.0 / 60 6.0 4.0 170 2.80 5.00 2.7
1)
10 120 L3 4.5 7.0 / (28) 8.0 / 65 5.0 / 50 6.0 4.0 170 1.70 2.50 3.1
1)
12 120 L3 4.5 7.0 / (28) 8.0 / 70 5.0 / 50 6.0 4.0 175 1.00 2.00 3.3
1)
6 230 L2 4 7.0 / (28) 8.0 / 65 5.0 / 50 6.0 4.0 153 3.20 8.00 4.0
1)
10 230 L2 5 7.0 / (28) 8.0 / 65 5.0 / 50 6.0 4.0 156 2.50 4.00 3.8
15 250 L2 5 7.0 / (28) 1) 8.0 / 65 5.0 / 50 6.0 4.0 161 1.80 3.30 3.9
25 250 L2 5 7.0 / (28) 1) 8.0 / 65 5.0 / 60 7.0 5.0 176 0.80 1.90 4.4
1)
40 250 L2 5 7.0 / (28) 8.0 / 60 5.0 / 70 7.0 6.0 186 0.40 0.80 5.4
1) set the max. volume flow (approx. 28 scale divisions)
Cutting parameters and results may differ because
of material composition, material surface and shape
Torch parts: of workpiece.
4 6 4 6 4 6 4 6 4 6 4 6 4 6

8 2 8 2 8 2 8 2 8 2 8 2 8
1.01 cathode K2 2

10
- for setting gas flow use switch “gas test”
10 0 10 0 10 0 0 10 10 10
1.02 gas guide cap PB-S75 air/O2
0 0 0
- change of gas flow during cutting possible, re-
adjusting not necessary
1.03 nozzle
- piercing up to 40 mm possible (pay attention to
L3 120 A 1.4 mm piercing sequences)
L2 250 A 2.5 mm 100 100 100 100 100 100 100

1.04 nozzle cap PB-S75

1.05 WGK – swirl gas cap 50 50 50 50 50 50 50

V 4340 – 4.0 mm orifice

V 4345 – 4.5 mm orifice 10 10 10 10 10 10 10

V 4350 – 5.0 mm orifice

1.06 swirl gas nozzle PB-S76 position selector switch of
front panel FineFocus 800
remarks:
- piercing delay has to be adjusted
on profile cutting machine
- scale adjustment = ball centre
- flowmeter activ, balls black

PGE 1-800 PGE 2-800

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 Cutting data FineFocus 800 (120 A)
Torch: PB-S77 W mild steel (3 up to 15 mm) valid from: 18.08.2003
Material: St37b-2 plasma gas O2 with swirl gas air

PG 1 PG 2 WG2
Material Current Nozzle WGK Ignition gas Cutting gas Swirl gas Ignition Torch Arc Cutting speed Cutting
thickness ∅ Air O2 Air height distance voltage quality maximum kerf
[mm] [A] [mm] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [mm] [mm] [V] [m/min] [m/min] [mm]
1)
3 120 L3 4 7.0 / (28) 8.0 / 50 5.0 / 100 5.0 3.0 140 5.60 8.00 2.0
1)
4 120 L3 4 7.0 / (28) 8.0 / 50 5.0 / 100 5.0 3.0 144 5.20 7.00 2.1
5 120 L3 4 7.0 / (28) 1) 8.0 / 50 5.0 / 100 5.0 3.0 146 4.50 6.00 2.2
6 120 L3 4 7.0 / (28) 1) 8.0 / 50 5.0 / 100 5.0 3.0 147 3.50 5.50 2.2
8 120 L3 4 7.0 / (28) 1) 8.0 / 50 5.0 / 100 5.0 3.0 148 2.70 4.70 2.5
1)
10 120 L3 4 7.0 / (28) 8.0 / 50 5.0 / 100 5.0 3.0 150 2.10 3.40 2.5
1)
12 120 L3 4 7.0 / (28) 8.0 / 50 5.0 / 100 5.0 3.0 153 1.75 2.80 2.5
1)
15 120 L3 4 7.0 / (28) 8.0 / 50 5.0 / 100 5.0 3.0 160 1.00 1.60 3.2
1) set the max. volume flow (approx. 28 scale divisions)

Torch parts: Cutting parameters and results may differ because

of material composition, material surface and shape
of workpiece.
1.01 cathode K3-XL 4 6 4 6 4 6 4 6 4 6 4 6 4 6

1.02 gas guide cap PB-S75 air/O2 2 8 2 8 2 8 2 8 2 8 2 8 2 8

- for setting gas flow use switch “gas test”
10
1.03 nozzle 0 10 0 10 0 10 0 0 10 0 10 0 10
- change of gas flow during cutting possible, re-
L3 120 A 1.4 mm adjusting not necessary
- piercing up to 40 mm possible (pay attention to
1.04 nozzle cap PB-S75
piercing sequences)
1.05 WGK – swirl gas cap 100 100 100 100 100 100 100

V 4340 – 4.0 mm orifice

1.06 swirl gas nozzle PB-S76 50
50 50 50 50 50 50

remarks: 10 10 10 10 10
10 10
- piercing delay has to be adjusted
on profile cutting machine position selector switch at
- scale adjustment = ball centre front panel FineFocus 800
- flowmeter activ, balls black

PGE 1-800 PGE 2-800

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 Cutting data FineFocus 800 (250 A)
Torch: PB-S77 W mild steel (4 up to 70 mm) valid from: 18.08.2003
Material: St37b-2 plasma gas O2 with swirl gas air
PG 1 PG 2 WG2
Material Current Nozzle WGK Ignition gas Cutting gas Swirl gas Ignition Torch Arc Cutting speed Cutting
thickness ∅ Air O2 Air height distance voltage quality maximum kerf
[mm] [A] [mm] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [mm] [mm] [V] [m/min] [m/min] [mm]
1)
4 200 L2 4 7.0 / (28) 8.0 / 65 5.0 / 50 5.0 3.5 142 4.20 8.70 3.2
6 200 L2 4 7.0 / (28) 1) 8.0 / 65 5.0 / 50 5.0 3.5 143 3.80 7.50 3.2
1)
8 200 L2 4 7.0 / (28) 8.0 / 65 5.0 / 50 5.0 3.5 144 3.40 6.00 3.2
10 200 L2 4 7.0 / (28) 1) 8.0 / 65 5.0 / 50 5.0 3.5 144 2.65 5.00 3.3
1)
12 200 L2 4 7.0 / (28) 8.0 / 65 5.0 / 50 5.0 3.5 145 2.20 4.00 3.4
15 250 L2 5 7.0 / (28) 1) 8.0 / 65 5.0 / 50 6.0 4 152 2.00 4.00 3.7
1)
20 250 L2 5 7.0 / (28) 8.0 / 65 5.0 / 50 7.0 5 160 1.35 3.00 4.4
25 250 L2 5 7.0 / (28) 1) 8.0 / 65 5.0 / 50 7.0 5 164 1.35 2.00 4.6
1)
30 250 L2 5 7.0 / (28) 8.0 / 65 5.0 / 70 8.0 6 166 0.95 1.50 4.6
40 250 L2 5 7.0 / (28) 1) 8.0 / 65 5.0 / 80 8.0 6 170 0.70 1.10 4.7
50 250 L2 6 7.0 / (28) 1) 8.0 / 55 5.0 / 80 9.0 7 190 0.35 0.80 5.8
1)
60 250 L2 6 7.0 / (28) 8.0 / 55 5.0 / 100 9.0 7 194 0.25 0.50 5.8
1)
70 250 L2 6 7.0 / (28) 8.0 / 65 6.0 / 100 9.0 7 225 0.10 6.5
1) set the max. volume flow (approx. 28 scale divisions

Cutting parameters and results may differ because

Torch parts: of material composition, material surface and shape
4 6 4 6 4 6 4 6 4 6 4 6 4 6
of workpiece.
1.01 cathode K3-XL 2 8 2 8 2 8 2 8 2 8 2 8 2 8

10 0 10 0 10 10 10
1.02 gas guide cap PB-S75 air/O2 0 10 0 0 0 0 10
- for setting gas flow use switch “gas test”
1.03 nozzle - change of gas flow during cutting possible, re-
L2 250 A 2.5 mm adjusting not necessary
- piercing up to 40 mm possible (pay attention to
1.04 nozzle cap PB-S75 100 100 100 100 100 100 100
piercing sequences)
1.05 WGK – swirl gas cap
V 4340 – 4.0 mm orifice 50 50 50
50 50 50 50
V 4350 – 5.0 mm orifice
V 4360 – 6.0 mm orifice 10 10 10 10 10 10 10
1.06 swirl gas nozzle PB-S76
position selector switch at
remarks: front panel FineFocus 800
- piercing delay has to be adjusted
on profile cutting machine
- scale adjustment = ball centre
- flowmeter activ, balls black

PGE 1-800 PGE 2-800

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 Cutting data FineFocus 800 (300 A)
torch: PB-S77 W mild steel (25 up to 70 mm)
material: St37b-2 plasma gas O2 with swirl gas air valid from: 18.08.2003

PG 1 PG 2 WG2
Material Current Nozzle WGK Ignition gas Cutting gas Swirl gas Ignition Torch Arc Cutting speed Cutting
thickness ∅ Air O2 Air height distance voltage quality maximum kerf
[mm] [A] [mm] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [mm] [mm] [V] [m/min] [m/min] [mm]
1)
25 300 L4 5 7.0 / (28) 8.0 / 65 5.0 / 50 7.0 5 160 1.90 2.35 4.1
1)
30 300 L4 5 7.0 / (28) 8.0 / 65 5.0 / 50 8.0 6 160 1.25 1.55 4.6
40 300 L4 5 7.0 / (28) 1) 8.0 / 65 5.0 / 50 8.0 6 170 0.85 1.10 4.8
50 300 L4 6 7.0 / (28) 1) 8.0 / 65 5.0 / 50 9.0 7 182 0.45 0.65 6.1
60 300 L4 6 7.0 / (28) 1) 8.0 / 65 5.0 / 50 9.0 7 185 0.35 0.50 6.1
1)
70 300 L4 6 7.0 / (28) 8.0 / 65 5.0 / 50 9.0 7 225 0.10 7.5
1) set the max. volume flow (approx. 28 scale divisions

Torch parts: Cutting parameters and results may differ because

of material composition, material surface and shape
of workpiece.
1.01 cathode K3-XL 4 6 4 6 4 6 4 6 4 6 4 6 4 6
1.02 gas guide cap PB-S75 air/O2 2 8 2 8 2 8 2 8 2 8 2 8 2 8 - for setting gas flow use switch “gas test”
1.03 nozzle 0 10 0 10 0 10 0 10 0 10 0 10 0 10 - change of gas flow during cutting possible, re-
L4 300 A 2.7 mm adjusting not necessary
- piercing up to 40 mm possible (pay attention to
1.04 nozzle cap PB-S75
piercing sequences)
1.05 WGK – swirl gas cap
V 4350 – 5.0 mm orifice 100 100 100 100 100 100 100

V 4360 – 6.0 mm orifice

1.06 swirl gas nozzle PB-S76
50 50 50 50 50 50 50

remarks:
10 10 10 10 10 10 10
- piercing delay has to be adjusted
on profile cutting machine
position selector switch at
- scale adjustment = ball centre
front panel FineFocus 800
- flowmeter activ, balls black

PGE 1-800 PGE 2-800

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 Cutting data FineFocus 800 (120-250 A)
torch: PB-S77 W high-alloyed steel (6 up to 45 mm)
material: 1.4301 plasma gas ArH2 N2 with swirl gas N2 valid from: 18.08.2003

PG 3 PG 4 PG 5 WG1
Material Current Nozzle WGK Ignition gas Cutting gas Cutting gas Swirl gas Ignition Torch Arc Cutting speed Cutting
thicknes
s ∅ ar H2 N2 N2 height distance voltage quality maximum kerf
[mm] [A] [mm] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [mm] [mm] [V] [m/min] [m/min] [mm]
6 120 A1 4 6.0 / 30 / 20* 8.0 / 40 7.0 / 15 6.0 / voll 5.0 2.5 138 1.50 3.80 2.9
10 120 A1 4 6.0 / 50 / 35* 8.0 / 40 6.0 / 100 6.0 3.0 128 1.30 1.75 2.9
15 120 A1 4.5 6.0 / 55 / 38* 8.0 / 75 6.0 / 60 6.0 3.0 143 1.00 1.15 3.0
20 120 A1 4.5 6.0 / 55 / 38* 8.0 / 75 6.0 / 60 7.0 3.5 148 0.65 0.85 3.1
10 200 A2 4 6.0 / 50 / 35* 8.0 / 50 5.0 / 90 6.0 4.0 125 1.70 2.40 3.4
15 200 A2 4 6.0 / 50 / 35* 8.0 / 75 6.0 / 80 6.0 4.0 148 1.30 1.90 3.8
20 200 A2 4 6.0 / 50 / 35* 8.0 / 75 6.0 / 80 7.0 5.0 150 0.90 1.40 4.0
15 250 A2 4 6.0 / 50 / 35* 8.0 / 75 6.0 / 100 6.0 4.0 148 1.70 2.20 4.0
20 250 A2 4 6.0 / 50 / 35* 8.0 / 75 6.0 / 100 7.0 4.5 155 1.00 1.60 4.2
30 250 A2 4 6.0 / 50 / 35* 8.0 / 75 6.0 / 100 7.0 5.0 164 0.80 1.00 4.2
40 250 A2 4.5 6.0 / 50 / 35* 8.0 / 60 6.0 / 100 8.0 5.0 154 0.55 0.70 4.3
45 250 A2 4.5 6.0 / 50 / 35* 8.0 / 50 6.0 / 100 8.0 6.0 155 0,45 0,50 4,7
* set the values, if you make use of PGE 2-800 (article-no. 11.824.228)

Cutting parameters and results may differ because

Torch parts:
of material composition, material surface and shape
4 6 4
of workpiece.
1.01 cathode K5 4 6 4 6 6 4 6 4 6 4 6

2 8 2 8 2 8 2 8 2 8 2 8 2 8
1.03 nozzle 0 10 0 10 0 10 0 10 0 10 0 10 0 10
- for setting gas flow use switch “gas test”
A1 120 A 1.,5 mm - change of gas flow during cutting possible, re-
adjusting not necessary
A2 250 A 2.3 mm
- piercing up to 40 mm possible (pay attention to
1.04 nozzle cap PB-S75 100 100 100 100 100 100 100 piercing sequences)
1.05 WGK – swirl gas cap
V 4340 – 4.0 mm orifice
50 50 50 50 50 50 50
V 4345 – 4,5 mm orifice
1.06 swirl gas nozzle PB-S76 10 10 10 10 10 10 10

remarks: position selector switch at

front panel FineFocus 800
- piercing delay has to be adjusted
on profile cutting machine
- scale adjustment = ball centre
- flowmeter activ, balls black

PGE 1-800 PGE 2-800

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 Cutting data FineFocus 800 (200-250 A)
torch: PB-S77 W aluminium (4 up to 60mm)
material: AlMg 3 plasma gas ArH2 with swirl gas N2 valid from: 01.10.2003

PG 3 PG 4 PG 5 WG 1 Cutting
material current nozzle WGK Ignition gas Cutting gas Cutting gas Swirl gas Ignition Torch Arc speed Cutting
thickness Dm Ar H2 N2 N2 height distance voltage quality maximum gape
[mm] [A] [mm] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [mm] [mm] [V] [m/min] [m/min] [mm]
4 200 A2 4.0 6.0 / 55 8.0 / 75 4.5 / 50 5 3 125 5.50 10.00 3.3
6 200 A2 4.0 6.0 / 55 8.0 / 75 4.5 / 50 5 3 126 5.00 9.00 3.4
8 200 A2 4.0 6.0 / 55 8.0 / 75 4.5 / 50 5 3 128 4.50 8.00 3.5
10 200 A2 4.0 6.0 / 55 8.0 / 75 4.5 / 50 6 3 130 4.00 7.00 3.6
12 200 A2 4.0 6.0 / 55 8.0 / 75 4.5 / 50 6 3 132 3.50 5.50 3.6
12 250 A2 4.0 6.0 / 55 8.0 / 75 4.5 / 50 6 3 133 4.00 6.50 3.6
20 250 A2 4.0 6.0 / 60 8.0 / 75 4.5 / 70 7 3 140 2.70 3.70 3.7
25 250 A2 4.5 6.0 / 60 8.0 / 75 4.5 / 70 7 3 142 1.80 2.70 4.1
30 250 A2 5.0 6.0 / 60 8.0 / 75 4.5 / 70 7 4 146 1.40 2.20 4.2
40 250 A2 5.0 6.0 / 60 8.0 / 75 4.5 / 70 8 4 152 1.00 1.40 4.4
50 250 A2 5.0 6.0 / 60 8.0 / 75 4.5 / 70 8 4 156 0.80 1.20 4.6
60 250 A2 5.0 6.0 / 60 8.0 / 75 4.5 / 80 8 5 178 0.50 0.80 5.5

Torch parts: Cutting parameters and results may differ because

of material composition, material surface and shape
4 6 4 6 4 6 4 6 4 6 4 6 4 6
of workpiece.
1.01 cathode K5 2 8 2 8 2 8 2 8 2 8 2 8 2 8

1.03 nozzle 0 10 0 10 0 10 0 10 0 10 0 10 0 10
- for setting gas flow use switch “gas test”
A2 250 A 2.3 mm - change of gas flow during cutting possible, re-
1.04 nozzle cap PB-S75 adjusting not necessary
- piercing up to 40 mm possible (pay attention to
1.05 WGK - swirl gas cap 100 100 100 100 100 100 100
piercing sequences)
V 4340 - 4.0 mm orifice
V 4345 - 4.5 mm orifice 50 50 50 50 50 50 50

V 4350 - 5.0 mm orifice

1.06 swirl gas nozzle PB-S76 10 10 10 10 10 10 10

Position selector switch at

remarks: front panel FineFocus 800
- piercing delay has to be adjusted
on profile cutting machine
- scale adjustment = ball centre
- flowmeter activ, balls black

PGE 1-800 PGE 2-800

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 Spare parts list

Plasma Machine Torch

PB-S77 W-1 .11.836.700.000E

Plasma Machine Torch

PB-S77 W-2 .11.836.900.000E

Plasma Hand Torch

PB-S75 WH-1 .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.

These details are required in any case to enable us to exactly ascertain your

wishes. We reserve for ourselves the right of alternations of the product and its

commercial production to keep abreast of technical developments.

Therefore, claims of whatever kind cannot be derived from this operation

instructions.

036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde

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 Spare parts list

PB-S77 W-1 (300 A, with solenoids) March 2003

.11.836.700.000E

Pos. Artikel-No. Designation Pcs.

00.00.01 .11.836.721.106 PB-S77 W-1 6m/300A/C 1.00

01.01.00 .11.836.721.900 PB-S77 W-1 o. SCHLAUCHP. 1.00

01.01.01 .11.836.921.100 BRENNERKOPF PB-S77 W 1.00
01.01.02 .12.51440 COOLING TUBE AIR PB-S75 1.00
01.01.03 .11.833.121.300 CATHODE K3-XL O2/AIR 1.00
01.01.04 .12.40860 GAS GUIDE CAP PB-S75 AIR 1.00
01.01.05 .10.505.908 O-RING 18.2 X 1.9 1.00
01.01.06 .11.828.901.414 NOZZLE L3-XL O2 120A 1,4mm 1.00
01.01.06 .11.828.901.420 NOZZLE L1-XL O2 160A 2.0mm 1.00
01.01.06 .11.828.901.425 NOZZLE L2-XL O2 250A 2.5mm 1.00
01.01.06 .11.828.901.427 NOZZLE L4-XL O2 300A 2.7mm 1.00
01.01.06 .11.828.901.429 NOZZLE L5-XL O2 350A 2,9mm 1.00
01.01.07 .10.505.923 O-RING 28 X 2.0 1.00
01.01.08 .12.37790 NOZZLE CAP PB-S75 1.00
01.01.09 .10.505.958 O-RING 42x2 1.00
01.01.10 .11.833.101.271 SWIRL GAS NOZZLE PB-S76 1.00
01.01.11 .10.505.961 O-RING 48x2 1.00
01.01.12 .11.833.101.261 PROTECTIVE CAP 1.00
01.01.13 .11.833.101.156 SWIRL GAS CAP 4 DRY V4340 1.00
01.01.13 .11.833.101.157 SWIRL GAS CUP 4,5 DRY V4345 1.00
01.01.13 .11.833.101.158 SWIRL GAS CAP 5 DRY V4350 1.00
01.01.13 .11.833.101.159 SWIRL GAS CAP 6 DRY V4360 1.00
01.01.14 .11.833.111.156 SWIRL GAS CAP 4 UWP V4540 1.00
01.01.14 .11.833.111.157 SWIRL GAS CAP 4,5 UWP V4545 1.00
01.01.14 .11.833.111.158 SWIRL GAS CAP 5 UWP V4550 1.00
01.02.00 .11.828.401.255 BUSH 1.00
01.03.00 .10.256.633 COUNTERSUNK SCREW BM 4X6 1.00
01.04.01 .12.58110 SOLENOID VALVE G 1/4" WITHOUT ORIFICE 1.00
01.04.02 .12.29270 FILTER, M5 X 22 1.00
01.04.03 .12.47580 ORIFICE 1,1 1.00
01.04.04 .12.36090 MIXING CHAMBER 9T 1506 1.00
01.04.05 .12.34620 PACKING 9T 1730 1.00
01.04.06 .12.58120 SOLENOID VALVE M12x1 WITHOUT ORIFICE 1.00
01.04.07 .12.47570 ORIFICE DIA. 0.35 1.00
01.05.00 .12.58060 INSULATOR PB-S75W 1.00
01.06.00 .10.902.175 INSULATION 1.00
01.07.01 .11.836.901.258 TUBE PLASTIC PB-S77 W 1.00
01.07.02 .11.836.721.257 THREAD SLEEVE PB-S77 W-1 1.00
01.08.00 .10.257.543 THREATED PIN M4x4 DIN913 1.00
01.09.00 .10.505.961 O-RING 48x2 1.00
01.10.00 .10.505.958 O-RING 42x2 1.00
01.11.00 .10.505.958 O-RING 42x2 1.00

02.01.02 .12.51440 COOLING TUBE AIR PB-S75 1.00

02.01.03 .12.40870 CATHODE K2 AIR/O2 1.00
02.01.04 .12.40860 GAS GUIDE CAP PB-S75 AIR 1.00
02.01.05 .10.505.908 O-RING 18.2 X 1.9 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
02.01.08 .12.37790 NOZZLE CAP PB-S75 1.00

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 Spare parts list

PB-S77 W-1 (300 A, with solenoids) March 2003

.11.836.700.000E

Pos. Artikel-No. Designation Pcs.

02.01.09 .10.505.958 O-RING 42x2 1.00

02.01.10 .11.833.101.271 SWIRL GAS NOZZLE PB-S76 1.00
02.01.11 .10.505.961 O-RING 48x2 1.00
02.01.12 .11.833.101.261 PROTECTIVE CAP 1.00
02.01.13 .11.833.101.156 SWIRL GAS CAP 4 DRY V4340 1.00
02.01.13 .11.833.101.157 SWIRL GAS CUP 4,5 DRY V4345 1.00
02.01.13 .11.833.101.158 SWIRL GAS CAP 5 DRY V4350 1.00
02.01.14 .11.833.111.156 SWIRL GAS CAP 4 UWP V4540 1.00
02.01.14 .11.833.111.157 SWIRL GAS CAP 4,5 UWP V4545 1.00
02.01.14 .11.833.111.158 SWIRL GAS CAP 5 UWP V4550 1.00

03.01.02 .11.828.911.230 COOLING TUBE PB-S75 ArH2 1.00

03.01.03 .11.828.911.550 CATHODE K5 ArH2 1.00
03.01.05 .10.505.908 O-RING 18.2 X 1.9 1.00
03.01.06 .11.828.511.620 NOZZLE A3 180A ArH2 2.0mm 1.00
03.01.06 .12.37780 NOZZLE A1 120A ArH2 1.5mm 1.00
03.01.06 .12.40910 NOZZLE A2 250A ArH2 2.3mm 1.00
03.01.07 .10.505.923 O-RING 28 X 2.0 1.00
03.01.08 .12.37790 NOZZLE CAP PB-S75 1.00
03.01.09 .10.505.958 O-RING 42x2 1.00
03.01.10 .11.833.101.271 SWIRL GAS NOZZLE PB-S76 1.00
03.01.11 .10.505.961 O-RING 48x2 1.00
03.01.12 .11.833.101.261 PROTECTIVE CAP 1.00
03.01.13 .11.833.101.156 SWIRL GAS CAP 4 DRY V4340 1.00
03.01.13 .11.833.101.157 SWIRL GAS CUP 4,5 DRY V4345 1.00
03.01.13 .11.833.101.158 SWIRL GAS CAP 5 DRY V4350 1.00
03.01.14 .11.833.111.156 SWIRL GAS CAP 4 UWP V4540 1.00
03.01.14 .11.833.111.157 SWIRL GAS CAP 4,5 UWP V4545 1.00
03.01.14 .11.833.111.158 SWIRL GAS CAP 5 UWP V4550 1.00

04.01.00 .16.500.308 PARTS FOR CUTTING WITHOUT SWIRL GAS 1.00

04.01.10 .11.828.401.275 INSULATING BUSH FOR DRY CUTTING 1.00
04.01.11 .10.505.961 O-RING 48x2 1.00
04.01.12 .11.828.401.265 PROTECTIVE CAP, COMPL. 1.00

05.00.00 .11.836.721.700 HOSE PARCEL PB-S77 W-1 6m 1.00

05.01.00 .10.575.037 HOSE 40 X 1,5 1.00
05.02.00 .11.836.721.710 PLASMA GAS HOSE O2/Ar, 6.32m 1.00
05.02.01 .12.49050 FILTER M 8X25, 9T2228 1.00
05.03.00 .11.828.921.715 GAS HOSE AIR 6m 1.00
05.03.01 .12.49050 FILTER M 8X25, 9T2228 1.00
05.04.00 .11.828.901.720 WATER INLET HOSE 6m 1.00
05.05.00 .11.828.901.730 WATER OUTLET HOSE 6m 1.00
05.07.00 .11.828.901.745 PILOT CABLE 6m 1.00
05.08.00 .11.836.721.707 SWIRL-GAS HOSE 6.53m 1.00
05.09.00 .11.836.721.740 STEUERLEITUNG 6.4m 1.00

20.00.00 .16.500.006 TORCH TOOLS: 1.00

20.01.00 .12.38180 SOCKET SPANNER FOR COOLING TUBE 1.00
20.02.00 .12.38170 SOCKET SPANNER FOR CATHODE 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
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

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 Spare Parts List

PB-S77 W-2 (300 A, without solenoids) March 2003

11.836.900.000E

Pos. Article-No. Designation pcs.

00.00.01 .11.836.921.001 PB-S77 W-2 1,0m/300A o.MV,m.MK 1.00

01.01.00 .11.836.921.900 PB-S77 W-2 o. SCHLAUCHP. 1.00

01.01.01 .11.836.921.100 Torch head PB-S77 W 1.00
01.01.02 .12.51440 COOLING TUBE AIR PB-S75 1.00
01.01.03 .11.833.121.300 CATHODE K3-XL O2/AIR 1.00
01.01.04 .12.40860 GAS GUIDE CAP PB-S75 AIR 1.00
01.01.05 .10.505.908 O-RING 18.2 X 1.9 1.00
01.01.06 .11.828.901.414 NOZZLE L3-XL O2 120A 1,4mm 1.00
01.01.06 .11.828.901.420 NOZZLE L1-XL O2 160A 2.0mm 1.00
01.01.06 .11.828.901.425 NOZZLE L2-XL O2 250A 2.5mm 1.00
01.01.06 .11.828.901.427 NOZZLE L4-XL O2 300A 2.7mm 1.00
01.01.06 .11.828.901.429 NOZZLE L5-XL O2 350A 2,9mm 1.00
01.01.07 .10.505.923 O-RING 28 X 2.0 1.00
01.01.08 .12.37790 NOZZLE CAP PB-S75 1.00
01.01.09 .10.505.958 O-RING 42x2 1.00
01.01.10 .11.833.101.271 SWIRL GAS NOZZLE PB-S76 1.00
01.01.11 .10.505.961 O-RING 48x2 1.00
01.01.12 .11.833.101.261 PROTECTIVE CAP 1.00
01.01.13 .11.833.101.156 SWIRL GAS CAP 4 DRY V4340 1.00
01.01.13 .11.833.101.157 SWIRL GAS CUP 4,5 DRY V4345 1.00
01.01.13 .11.833.101.158 SWIRL GAS CAP 5 DRY V4350 1.00
01.01.13 .11.833.101.159 SWIRL GAS CAP 6 DRY V4360 1.00
01.01.14 .11.833.111.156 SWIRL GAS CAP 4 UWP V4540 1.00
01.01.14 .11.833.111.157 SWIRL GAS CAP 4,5 UWP V4545 1.00
01.01.14 .11.833.111.158 SWIRL GAS CAP 5 UWP V4550 1.00
01.02.00 .11.828.401.255 BUSH 1.00
01.03.00 .10.256.633 COUNTERSUNK SCREW BM 4X6 1.00
01.04.01 .12.59950 THREATED CONNECTOR M8x1-G1/4" 1.00
01.04.02 .12.29270 FILTER, M5 X 22 1.00
01.04.03 .12.47580 ORIFICE 1,1 1.00
01.04.04 .12.36090 MIXING CHAMBER 9T 1506 1.00
01.04.05 .12.34620 PACKING 9T 1730 1.00
01.04.06 .12.59960 THREATED CONNECTOR 1.00
01.04.07 .12.47570 ORIFICE DIA. 0.35 1.00
01.05.00 .12.58060 INSULATOR PB-S75W 1.00
01.06.00 .10.902.175 INSULATION 1.00
01.07.01 .11.836.901.258 TUBE PLASTIC PB-S77 W 1.00
01.07.02 .11.836.921.257 THREAD SLEEVE PB-S77 W-2 CRNI 1.00
01.08.00 .10.257.543 THREATED PIN M4x4 DIN913 1.00
01.09.00 .10.505.961 O-RING 48x2 1.00
01.10.00 .10.505.958 O-RING 42x2 1.00
01.11.00 .10.505.958 O-RING 42x2 1.00

02.01.02 .12.51440 COOLING TUBE AIR PB-S75 1.00

02.01.03 .12.40870 CATHODE K2 AIR/O2 1.00
02.01.04 .12.40860 GAS GUIDE CAP PB-S75 AIR 1.00
02.01.05 .10.505.908 O-RING 18.2 X 1.9 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

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 Spare Parts List

March 2003
PB-S77 W-2 (300 A, without solenoids)
11.836.900.000E

Pos. Article-No. Designation pcs.

02.01.08 .12.37790 NOZZLE CAP PB-S75 1.00

02.01.09 .10.505.958 O-RING 42x2 1.00
02.01.10 .11.833.101.271 SWIRL GAS NOZZLE PB-S76 1.00
02.01.11 .10.505.961 O-RING 48x2 1.00
02.01.12 .11.833.101.261 PROTECTIVE CAP 1.00
02.01.13 .11.833.101.156 SWIRL GAS CAP 4 DRY V4340 1.00
02.01.13 .11.833.101.157 SWIRL GAS CUP 4,5 DRY V4345 1.00
02.01.13 .11.833.101.158 SWIRL GAS CAP 5 DRY V4350 1.00
02.01.14 .11.833.111.156 SWIRL GAS CAP 4 UWP V4540 1.00
02.01.14 .11.833.111.157 SWIRL GAS CAP 4,5 UWP V4545 1.00
02.01.14 .11.833.111.158 SWIRL GAS CAP 5 UWP V4550 1.00

03.01.02 .11.828.911.230 COOLING TUBE PB-S75 ArH2 1.00

03.01.03 .11.828.911.550 CATHODE K5 ArH2 1.00
03.01.05 .10.505.908 O-RING 18.2 X 1.9 1.00
03.01.06 .11.828.511.620 NOZZLE A3 180A ArH2 2.0mm 1.00
03.01.06 .12.37780 NOZZLE A1 120A ArH2 1.5mm 1.00
03.01.06 .12.40910 NOZZLE A2 250A ArH2 2.3mm 1.00
03.01.07 .10.505.923 O-RING 28 X 2.0 1.00
03.01.08 .12.37790 NOZZLE CAP PB-S75 1.00
03.01.09 .10.505.958 O-RING 42x2 1.00
03.01.10 .11.833.101.271 SWIRL GAS NOZZLE PB-S76 1.00
03.01.11 .10.505.961 O-RING 48x2 1.00
03.01.12 .11.833.101.261 PROTECTIVE CAP 1.00
03.01.13 .11.833.101.156 SWIRL GAS CAP 4 DRY V4340 1.00
03.01.13 .11.833.101.157 SWIRL GAS CUP 4,5 DRY V4345 1.00
03.01.13 .11.833.101.158 SWIRL GAS CAP 5 DRY V4350 1.00
03.01.14 .11.833.111.156 SWIRL GAS CAP 4 UWP V4540 1.00
03.01.14 .11.833.111.157 SWIRL GAS CAP 4,5 UWP V4545 1.00
03.01.14 .11.833.111.158 SWIRL GAS CAP 5 UWP V4550 1.00

04.01.00 .16.500.308 PARTS FOR CUTTING WITHOUT SWIRL GAS 1.00

04.01.10 .11.828.401.275 INSULATING BUSH FOR DRY CUTTING 1.00
04.01.11 .10.505.961 O-RING 48x2 1.00
04.01.12 .11.828.401.265 PROTECTIVE CAP, COMPL. 1.00

05.00.00 .11.836.921.700A HOSE PARCEL PB-S76 W-2/O2 1.5m 1.00

05.01.00 .10.575.037 HOSE 40 X 1,5 1.00
05.02.00 .11.836.921.710A PLASMA GAS HOSE O2/A 1.77m 1.00
05.02.01 .12.49050 FILTER M 8X25, 9T2228 1.00
05.03.00 .11.831.821.715A PLASMA GAS HOSE AIR 1.77m 1.00
05.03.01 .12.49050 FILTER M 8X25, 9T2228 1.00
05.04.00 .11.831.801.720A WATER INLET HOSE 1,87m 1.00
05.05.00 .11.831.801.730A WATER RETURN HOSE 1.87m 1.00
05.07.00 .11.831.801.745A PILOT CABLE 2,03m 1.00
05.08.00 .11.829.601.707B SWIRL GAS HOSE 1.97m 1.00

20.00.00 .16.500.006 TORCH TOOLS: 1.00

20.01.00 .12.38180 SOCKET SPANNER FOR COOLING TUBE 1.00
20.02.00 .12.38170 SOCKET SPANNER FOR CATHODE 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
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

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 Spare Parts List

PB-S75 WH-1/L and Ar/H2/N2, 2 solenoids Ocotber 2002

11.828.700.000E

Pos. Article-No. Designation pcs.

00.00.00 .11.828.701.006 PB-S75 WH-1/L 6m/250A HAND TORCH 1.00

00.00.00 .11.828.701.010 PB-S75 WH-1/L 10m/250A HAND TORCH 1.00
00.00.00 .11.828.711.006 PB-S75 WH-1/A 6m/250A HAND TORCH 1.00
00.00.00 .11.828.711.010 PB-S75 WH-1/A 10m/250A HAND TORCH 1.00

01.00.00 .11.828.701.900 PB-S75 WH-1/L without HOSE PARCEL 1.00

01.01.01 .11.828.701.100 TORCH HEAD PB-S75 WH/L 1.00
01.01.02 .11.828.701.230 COOLING TUBE PB-S75WH-1 1.00
01.01.03 .12.40870 CATHODE K2 AIR/O2 1.00
01.01.04 .11.828.701.153 GAS GUIDE PB-S75 WH 1.00
01.01.05 .10.505.908 O-RING 18x2 1.00
01.01.06 .12.40860 GAS GUIDE CAP PB-S75 AIR 1.00
01.01.07 .11.828.501.414 NOZZLE L3 AIR/O2 120A 1.4mm 1.00
01.01.07 .12.40850 NOZZLE L2 AIR/O2 250A 2.5mm 1.00
01.01.07 .12.43050 NOZZLE L1 AIR/O2 160A 2.0mm 1.00
01.01.08 .10.505.923 O-RING 28 X 2.0 1.00
01.01.09 .12.37790 NOZZLE CAP PB-S75 1.00
01.01.10 .11.828.701.160 PROTECTIVE CAP PB-S75 1.00
01.01.11 .41.40329392 O-RING 5 X 1,5 1.00
01.02.00 242.240.10.00 HANDLE 1.00
01.03.00 .10.262.086 NUT M 6X12 1.00
01.04.00 .10.235.059 TENSION WASHER 1.00
01.05.00 .11.828.701.840 GUIDE BOW, compl. 1.00
01.05.01 .11.828.701.841 GUIDE BOW 1.00
01.05.02 .11.828.701.842 BOW 1.00

02.00.00 .11.828.711.900 PB-S75 WH-1/ArH2 without HOSE PARCEL 1.00

02.01.00 .11.828.711.100 PB-S75 WH/ARH2 TORCH HEAD, COMPL. 1.00
02.01.02 .11.828.911.230 COOLING TUBE PB-S75 ArH2 1.00
02.01.03 .11.828.911.550 CATHODE K5 ArH2 1.00
02.01.04 .11.828.701.153 GAS GUIDE PB-S75 WH 1.00
02.01.05 .10.505.908 O-RING 18x2 1.00
02.01.07 .11.828.511.620 NOZZLE A3 180A ArH2 2.0mm 1.00
02.01.07 .12.37780 NOZZLE A1 120A ArH2 1.5mm 1.00
02.01.07 .12.40910 NOZZLE A2 250A ArH2 2.3mm 1.00
02.01.08 .10.505.923 O-RING 28 X 2.0 1.00
02.01.09 .12.37790 NOZZLE CAP PB-S75 1.00
02.01.10 .11.828.701.160 PROTECTIVE CAP PB-S75 1.00

05.00.00 .11.828.701.700 HOSE PARCEL PB-S75 WH-1 2MV 6m 1.00

05.01.00 .10.575.037 HOSE 40 X 1,5 1.00
05.02.00 .11.828.701.710 GASE HOSE Ar 4m 1.00
05.02.01 .12.49050 FILTER M 8X25, 9T2228 1.00
05.03.00 .11.828.701.715 GASE HOSE H2 4m 1.00
05.03.01 .12.49050 FILTER M 8X25, 9T2228 1.00
05.04.00 .11.828.701.720 WATERINLET HOSE 6m 1.00
05.05.00 .11.828.701.730 WATEROUTLET HOSE 6m 1.00
05.06.00 .11.828.701.740 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

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 Spare Parts List

PB-S75 WH-1/L and Ar/H2/N2, 2 solenoids October 2002

11.828.700.000E

Pos. Article-No. Designation pcs.

05.11.00 .12.50870 PROTECTING SLEEVE 9T 2252 1.00

05.13.00 .12.54960 MIXING CHAMBER, COMPL. 9T 2733 1.00
05.13.01 .12.58110 SOLENOID VALVE G 1/4" WITHOUT ORIFICE 1.00
05.13.02 .12.29270 FILTER, M5 X 22 1.00
05.13.03 .12.59840 ORIFICE 0,75 1.00
05.13.04 .12.36090 MIXING CHAMBER 9T 1506 1.00
05.13.05 .12.34620 PACKING 9T 1730 1.00
05.13.06 .12.58120 SOLENOID VALVE M12x1 WITHOUT ORIFICE 1.00
05.13.07 .12.60440 ORIFICE 0.25 1.00
05.14.00 .10.575.007 INSULATION HOSE IMCS-50/18-1000-SW 1.00
05.15.00 .10.256.633 COUNTERSUNK SCREW BM 4X6 1.00
05.16.00 .12.39300 BUSH 9T 1636 1.00
05.17.00 .11.828.701.791 BUSH 1.00
05.18.00 .10.258.015 THREATED PIN M 3x4 DIN 914 1.00

06.00.00 .11.828.701.701 HOSE PARCEL PB-S75WH-1 2MV 10m 1.00

06.01.00 .10.575.037 HOSE 40 X 1,5 1.00
06.02.00 .11.828.701.750 GAS HOSE Ar 7.8m 1.00
06.02.01 .12.49050 FILTER M 8X25, 9T2228 1.00
06.03.00 .11.828.701.755 GAS HOSE H2 7.8m 1.00
06.03.01 .12.49050 FILTER M 8X25, 9T2228 1.00
06.04.00 .11.828.701.760 WATER INLET HOSE 10m 1.00
06.05.00 .11.828.701.770 WATER OUTLET HOSE 10m 1.00
06.06.00 .11.828.701.780 CONTROL CABLE 7.95m 1.00
06.07.00 .11.828.701.785 PILOT CABLE 10m 1.00
06.08.00 .11.828.701.705 GASE HOSE L+AR/H2 2m 1.00
06.09.00 .11.828.701.782 CONTROL CABLE 10m 1.00
06.10.00 .10.575.040 COVER HOSE 32 x 1,5 mm 1.00

20.00.00 .16.500.006 TORCH TOOLS:

20.01.00 .12.38170 SOCKET SPANNER FOR CATHODE 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

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 036_102...108_BA_engl.doc 10.04.2003 Kjellberg Finsterwalde

- Seite 61 -
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 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.

We ourselves reserve the right of alternations to the product in order to follow the latest technical
development. Therefore, claims whatever kind can't be derived from this operating manual.

For any request you are kindly asked to quote Model Name and Model Number

• Please keep this Instruction Manual always ready for use. Read carefully all chapters
before starting the unit!
• 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. 82
Tel.: +49 3531 500-0 Fax: +49 3531 500-227
e-mail: kjellberg@kjellberg.de
Internet: www.kjellberg.de
(BA C:\C K (nur Daten)\036_102...108_BA_engl.doc C.K.: 02.04.2003)

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 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

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