Instruction Manual

Plasma Cutting Machine

HiFocus 280i + PGE-360

article no.: .11.034.302

for the CNC-controlled cutting with

Plasma Torch PerCut 370
(HiFocusplus-Technology), for cutting and
marking operations
Stand: 2008-11-25 BA2008-006
Contents DI 0026 page

1 General 1.1 Warranty claim 1-1

information 1.2 Norms and rules 1-1
A 0001 / A 0002 / A 0002.04 1.3 Notes on the Instruction Manual 1-1
1.4 Safety instructions 1-2
1.4.1 Endangerments through high contact voltage 1-3
1.4.2 Working in enviroments with increased hazard of electric shock 1-4
1.4.3 Endangerments through high voltage igntion 1-4
1.4.4 Endangerments through electromagnetic interferences 1-4
1.4.5 Endangerments through heat and light radiation 1-5
1.4.6 Endangerments through fumes and smoke 1-6
1.4.7 Measures for prevention of "Oxyhydrogen gas formation" 1-6
1.4.8 Endangerments through noise 1-7
1.4.9 Endangerments through spatter 1-7
1.4.10 Handling of pressure cylinders 1-8
1.4.11 Handling of coolant 1-8
1.5 The Plasma Cutting Process 1-9
1.5.1 Dry cutting 1-10
1.5.1.1 Plasma cutting without secondary gas 1-10
1.5.1.2 Plasma cutting with secondary gas 1-11
1.5.2 Under water cutting process 1-12
1.6 Maintenance 1-12
1.6.1 Maintenance general 1-12
1.6.1.1 Intervals of maintenance 1-12
1.6.1.2 Cleaning 1-13
1.6.1.3 Electrical revision 1-13
1.6.1.4 Plasma torch 1-14
1.6.2 Maintenance special 1-15
1.6.2.1 Gas pressure test 1-15
1.6.2.2 Cooling system 1-15
1.6.2.3 Preventive periodic maintenance - component change plan 1-16

2 HiFocus 280i 2.1 Technical data 2-1

G 0010 2.2 Technical description 2-1
2.3 Characteristic features and advantages 2-2
2.4 Ranges of applications 2-2
2.4.1 Range of torch head 370.1 2-3
2.4.2 Range of torch head 370.2 2-3
2.5 Plasma marking 2-4
2.6 Putting into operation 2-4
2.6.1 Check out, placement and installation 2-4
2.6.2 Installation 2-5
2.6.2.1 Mains connection 2-5
2.6.2.2 Workpiece connection / current return line 2-5
2.6.2.3 Earthing 2-6
2.6.2.4 Connection of HiFocus 280i 2-6
2.7 Control and display elements 2-7
2.8 Cutting operation 2-10
2.9 Remote control FB1 2-13
2.10 Cooling 2-13
2.11 Combination of the HiFocus with CNC-controls of guiding systems 2-13
and robots
2.12 Multiple machine operation 2-15
2.13 Start regime HiFocus 280i 2-16
2.13.1 "Premature OFF" from CNC 2-16
2.13.2 Start by remote control 2-17
2.13.3 Start by CNC 2-17
2.13.4 Start from CNC with special function ‘separate ignition signal’ 2-17
2.13.5 Start from CNC with special function ‘pre-impulse’ 2-17
2.14 Protective facilities 2-18
2.15 Trouble shooting 2-19

DI 0026 01.03.2007 - page 0-2 - Kjellberg Finsterwalde

 page

3 Plasma Machine 3.1 Technical data 3-2

Torch PerCut 370 3.2 Technical description 3-2
Z 0020
3.3 Connection of plasma torch to PBA-360 3-3
3.4 Wear parts and their exchange 3-3
3.4.1 Plasma Machine Torch PerCut 370.1 3-5
3.4.2 Plasma Machine Torch PerCut 370.2 3-6
3.4.3 Replacement of the current socket in torch shaft 3-6
3.4.4 Plasma Cutting Machine 3-7
3.5 Hints for use of the quick-change heads 3-7
3.5.1 Dismantling of the change head 3-7
3.5.2 Maintenance of change heads 3-7
3.5.3 Installing of the change heads 3-8
3.6 Maintenance and attendance 3-8

4 Plasma gas control 4.1 Technical data 4-2

unit 4.2 Technical description 4-3
PGE-360 4.3 Operation 4-3
Z 0026 4.3.1 Manual choice of cutting data on the PGE-360 4-6
4.3.2 Quick data-set choice over switch 4-7
4.4 Service and display elements of the PGE-360 4-7
4.5 Connection of the plasma gas control unit PGE-360 4-8
4.6 Connection of the gas hoses between PGE-360 and PBA-360 4-8
4.7 Connection of the gas supply 4-9
4.8 Assembly of clamping ring connections 4-10

5 Plasma torch 5.1 Technical data 5-2

connection unit 5.2 Technical description 5-2
PBA-360 5.3 Connection of PBA-360 5-3
Z 0022

6 Coolant unit 6.1 Technical data 6-2

KWE 360 6.2 Technical description 6-2
Z 0023 6.3 Ranges of application 6-2
6.4 Putting into operation 6-2
6.4.1 Check out, placement and installation 6-2
6.4.2 Mains connection 6-3
6.5 Filling up the coolant 6-3
6.5.1 Connection of the cooling unit with the plasma machine of 6-4
Kjellberg
6.5.2 Switching ON of cooling unit 6-4
6.5.3 Switching OFF of cooling unit 6-4
6.6 Protective facilities 6-4
6.7 Trouble shooting 6-5

DI 0026 01.03.2007 - page 0-3 - Kjellberg Finsterwalde

Enclosures

Cutting tables of HiFocus 280i+360i and PGE-360 (including overview of wear parts PerCut 370 - 370M)

Wiring diagrams of HiFocus 280i

Wiring diagrams of HiFocus 280i, 360i and PGE-360
Wiring diagrams of PGE-360

Order information and of HiFocus 280i with Plasma Machine Torch PerCut 370 - 370M
connection diagrams

Spare parts list of HiFocus 280i

Spare parts list of PGE-360
Spare parts list of PerCut 370.1
Spare parts list of PerCut 370.1M
Spare parts list of PerCut 370.1M Rotator, 4 mm head reduction
Spare parts list of PerCut 370.1M Rotator, 6 mm head reduction
Spare parts list of PerCut 370.2
Spare parts list of PerCut 370.2M
Spare parts list of PBA-360
Spare parts list of KWE 360

Protocol Protocol for the gas pressure test once a month

DI 0026 01.03.2007 - page 0-4 - Kjellberg Finsterwalde

1 General information

1.1 Warranty claim

We point out explicitly that only spare parts and consumables of Kjellberg origin
have to be used! Otherwise a warranty claim does not exist. Kjellberg as
manufacturer of the equipment can not make any guarantees for the safety of the
equipment according to the valid regulations.

1.2 Norms and rules

The CE mark indicated on our plasma cutting and welding machines shows the
conformity of our products with the latest effective European CE Guideline.

Development and production take place according to the following standards:

EN EN 60974 (VDE 0544).

All plasma systems and welding systems are in possession of the S-mark and

S
therefore applicable to work places with increased electrical endangerment.

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

1.3 Hints on the instruction manual

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 alteration to the product in order to follow the latest technical
development.

Therefore, claims whatever kind can’t be derived from this instruction 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 instruction manual always must accompany the machine.

For damages due to misuse or wrong service we will not take any
responsibility

Kjellberg Finsterwalde Plasma und Maschinen GmbH

Germany D - 03238 Finsterwalde Leipziger Str. 82
phone: +49 3531 500-0 Fax: +49 3531 500-227
e-mail: plasma@kjellberg.de
Internet: www.kjellberg.de

A 0001 - 05.03.2008 - page 1-1 Kjellberg Finsterwalde

 1.4 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
• electromagnetic disturbances
• heat and light radiation
• gases, smokes and dust
• noise
• hot metal and spatter
• handling of pressure cylinders
• handling of coolant

The plasma cutting machine has been developed in compliance with following standards:

EN 60974 (VDE 0544) installation for arc welding

The user has to follow national and local regulations (e.g. Employer’s Liability Insurance
Association)! Before starting the plasma cutting machine this instruction manual has to be read
carefully! Only advised personnel are allowed to operate the plasma installation!

Warning label

The warning label is visibly attached on the plasma cutting machine.

The operator and the maintenance personnel must familiarize themselves with the meaning of the
symbols before working at the unit.

1. The operator and the maintenance per-

sonnel must read and understand the
instruction manual as well as learning the
operation of the unit before work with it to
avoid endangerments. The safety regula-
tions of the respective company have to be
taken into account.

2. Smoke, dust and gases developed during

the cutting process are harmful for health
and may not be breathed in. Principally a
suitable fume extraction device has to be
used.

3. Wearing of protective clothing (helmet,

welder’s overall, leather apron, gauntlets,
safety shoes). The protective clothing has
to be isolating, dry and heavily inflamma-
ble.

Attention!
To reduce the risk to yourself and others, read and understand this marking and manufac-
turer's instructions

A 0002 - 01.09.2007 - page 1-2 - Kjellberg Finsterwalde

 4. Noise can damage the hearing! During the plasma cutting operation suitable ear protection has
to be used. The radiation of the plasma arc can lead to eye injuries and skin burns. Eyes and
skin have to be protected from the radiation of the plasma arc therefore. Protection devices are
safety goggles and hand shields, which must have a sufficient lens shade.

Attention!
The operator has to follow national and local regulations (e.g. Employer’s Liability
Insurance Association).

5. Electric shock can kill! Live electrical parts may not be touched.
Opening the plasma unit may be carried out only by an advised electrician. Before carrying out
any maintenance or repair work the unit has to be disconnected visibly from the mains!

6. Wearing of protective clothing (helmet, welder’s overall, leather apron, gauntlets, safety shoes).
The protective clothing has to be isolating, dry and heavily inflammable. Working with plasma
cutting machines possibly can lead to fire and explosions. Flammable and explosive materials
must therefore be kept away from the cutting area. It has to be ensured that suitable and easily
accessible extinguishing facilities are located nearby. The appropriate fire protection regulations
have to be taken into account.

7. Appropriate warning labels may not be removed, painted over or covered.

Further requirements and warnings:

• To ensure stableness of the plasma plant an inclination of 10°.may not be exceeded

• Connect the power source only with properly fitted protective conductor
• Place the torch on an insulated place, to protect the operator against workpiece and
ground potential
• Keep dry the working area and all parts of the unit
• Don’t start the unit if components or parts are defective
• The plasma cutting machine has to be earthed and connected to the workpiece before switch-
ing on
• Switch off the unit before touching the plasma torch and prevent accidental restart
• Arrange regular electric inspections (by an authorized electronics engineer)
• Keep doors and flaps closed as long as the unit is connected to the power supply
• Never shorten safety circuits (door contact, protective caps)
• Do not cut closed containers
• The plasma cutting machine may be used only for the appointed use. It may not be used e.g. to
defrost frozen pipes
• Do not touch the torch head, the workpiece or the water (if water table is used) when the
plasma unit is working
• Inflammable objects (e.g. lighters, matchsticks) may not be carried by the operator at the body
• During the operation of the plasma unit electromagnetic fields become originated which can in-
fluence the wearer of hearing aids, heart peacemakers or other body implants. Persons con-
cerned have to consult a specialized doctor before starting the job

1.4.1 Endangerment through high contact voltage

Attention!
Opening the plasma unit may be carried out only under responsibility of a qualified electri-
cian. Before starting any maintenance and repair work principally the power supply source
has to be switched off and visibly disconnected from the mains.
Before starting the machine connect the workpiece cable and earth the workpiece!

A 0002 - 01.09.2007 - page 1-3 - Kjellberg Finsterwalde

 Attention!

The following relates to cutting units with liquid cooling and hand torch connection:

Power sources normally are having a high ohmic conducting path through the coolant to the hous-
ing. If the torch trigger is activated and the workpiece is not earthed the open circuit voltage or the
arc voltage is applied to the housing as contact voltage. Because the resistance of the coolant,
even it is dirty, is in the range of > 10 kOhm the contact voltage breaks down to a value which is
absolute harmless. The touch voltage nevertheless is sensitive.

The cooling circuit is insulated from the housing of the plasma unit at devices with possibility con-
nected hand torch. The contact voltage does not occur. The housing of the pump is protected by a
residual- current circuit- breaker.

1.4.2 Working in environments with increased hazard of electric shock

The plasma cutting machine is built in compliance with valid standards EN 60974-1 and therefore
applicable in environments with increased hazard of electric shock.

The conditions for fulfilling these requirements are given by design measures in the plasma cutting
machine:

• The plasma power source and the plasma torch are forming a safety-proofed installation, which
can be separated only by a tool (as far as a central connector with mechanical locking is pre-
sent).The unit cannot be switched on as long no torch is attached or the attached torch isn't as-
sembled completely.
• Opening the control circuit effects switching off the open circuit voltage, which drops down
within the prescribed time below the limit
• Cutting with hand torch is only possible with mounted, electrically insulating protection cap,
which protects against accidental touching the live nozzle cap. If the protection cap is not avail-
able the torch can not switched on (security circuit).

Therefore the plasma cutting unit is S-marked and applicable in environments with increased haz-
ard to electric shock.

Attention!
The user has to follow national and local regulations (e.g. Employer’s Liability Insurance
Association) by all means!

1.4.3 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 the high voltage is applied to the cathode and nozzle. After initiating the pilot arc the
HV-supply becomes switched off automatically. After the cutting process has started the pilot ex-
tinguishes.
Attention!
Never touch the torch head if the power source is switched ON!

The HV-ignition may establish electric or electro-magnetic fields, which can cause

malfunctions and interferences around the plasma unit at

• heart pacemakers
• other body implants
• hearing aids
• other electronic devices

1.4.4 Endangerment through electromagnetic interferences

The plasma cutting installation complies with the instructions of the EN 60974-10 (VDE 0544, part 10)
"Arc Welding Equipment – part 10: requirements at the Electromagnetic Compatibility (EMC)". This
standard is valid for Arc Welding Installations and related processes (e.g. plasma cutting).

A 0002 - 01.09.2007 - page 1-4 - Kjellberg Finsterwalde

 WARNING

Warning of electromagnetic interferences

Through the operation of the plasma cutting machine in particular by the temporary high
voltage ignition procedure results electromagnetic fields, which can lead to the influencing
of a medical equipment (e.g. cardiac pacemakers, hearing aids, insulin pumps) and body
implants.
Persons concerned must consult their specialist before beginning of work at plasma cut-
ting machines.

WARNING

The plasma cutting unit is an attachment of the class A according to EMC classification to
CISPR11:
This class A cutting mechanism is not intended for the use in living quaters, in which the
current supply is made by a public low-voltage utility system. It can be possibly difficult,
both by line-bound and radiated disturbances, to ensure within these ranges electromag-
netic compatibility.

General
The user is responsible for installing and using the installation according to the manufacturer’s in-
struction. 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 60974-10)
Before installing the equipment the user shall make an assessment of potential electromagnetic
problems in the surrounding area, and shall take the following into account:
• Other supply cables, control cables, signalling and telephone cables; 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 and other body implants

• Equipment for calibration and measuring

• Immunity of other equipment in the environment. The user shall ensure that other additional
protection measures in the environment are compatible
• Time of day that cutting has to be carried out.

Recommendations of methods to minimize disturbances

If disturbances are detected it may be necessary to carry out further precautions, such as those:
• Filtering of the mains supply
• Shielding the mains cable of the permanently installed plasma cutting (safe contact is neces-
sary
between shielding and housing)
• Regular maintenance of the plasma cutting installation
• All cover plates, service openings and flaps have to be closed before starting the unit.
• No alternations on adjustments and settings should be done at the plasma unit whitout the
acceptance of the producer
• Cutting cables should be kept as short as possible and closely together or take course close to
the bottom
• Potential equalization of all metallic components should be considered 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

Attention!
The user has to follow national and local regulations (e.g. Employer’s Liability Insurance
Association).

A 0002 - 01.09.2007 - page 1-5 - Kjellberg Finsterwalde

1.4.5 Endangerment through heat and light radiation
The radiation of the plasma arc can lead to eye injuries and skin burns. Eyes and skin have to be
protected from the radiation of the plasma arc therefore.

Safety measures:
• Wearing of total protective clothing (helmet, welding overall, possibly apron, gauntlet gloves, sa-
fety shoes).The protective clothing has to be insulated, dry and flame-resistant.
• Protection devices are safety goggles and hand shields, which must have a sufficient lens
shade.
• The cutting area should be prepared so that reflections and transmission of ultraviolet light is
reduced:
- use of protective walls
- arranging painting of walls with dark colour

Attention!
The user has to follow national and local regulations absolutely (e.g. Employer’s Liability
Insurance Association).

1.4.6 Endangerment through fumes, smoke and dust

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

• Keep cutting place well ventilated

• Remove fumes and smoke by exhaustion devices
• Removed 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

Attention!
The user has to follow national and local regulations (e.g. Employer’s Liability Insurance
Association)!

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!
1.4.7 Measures for prevention of „Oxyhydrogen gas formation”
(Does only apply for plasma cutting of aluminium in combination with water)
The molten aluminium which is blown out of the cutting gap forms in water an aluminium granule
which is oxidizing in water very fast because of its large surface.
Hydrogen is generated due to the bond of oxygen of the water. The hydrogen raises in the water ta-
ble to the surface, is ignited during the cutting process and burns out (reddish flame).
This reductive process can last for days in the slag of the water table. Mainly compressed air is used
for the automatic level control of the water table, and by that a hydrogen-air mixture will be gener-
ated (oxyhydrogen gas).

Attention!
If such a mixture (highly explosive at a hydrogen content of 4 to 76 vol. %)
is formed in the displace chamber or below the plate and is ignited by the
plasma arc, a wasteful explosion possibly will happen.
For water tables with level control:
• Nitrogen (with lower purity) has to be used instead of air.

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 For water tables without level control it has to be ensured, that:
• hydrogen can escape freely everywhere and is burnt out,
• the inside contour of the water table is even so that no granule can gather at inaccessible
spaces,
• the slag and the granule are removed from the water table without delay,
• that no hydrogen can gather below the plate which is placed on the table grating.
• The guiding machine has to be positioned after the cutting outside the water table to avoid,
that hydrogen or oxyhydrogen (hydrogen-air mixture) cangather in hollow spaces (like switch
boxes).
Attention!
It is not allowed to store the plates on the cutting grating for a longer time!

1.4.8 Endangerment through noise

Be aware that during the plasma cutting a high noise level is produced.
Depending on the technological process and the cutting parameters in a meter distance from the
pilot arc the following sound level is reached:

Process: Dry plasma cutting

max. sound level material technology
with a height of:

FineFocus F
cutting material

HiFocusplus

HiFocus F
1m 3m 6m

HiFocus
current* thickness
measured calculated
(A) (mm)
(dB(A)) (dB(A)) (dB(A))

20 1,5 90 80 75 5,2
60 8 92 82 77 9,5
80 20 102 92 87 8,5
mild steel
90 12 103 93 88 8,5
130 30 107 97 92 9,5
160 50 102 92 87 5,8
280 70 112 102 97 CrNi 6,5
300 10 113 103 98 mild steel 7,2
360 80 113 103 98 AlMg3 7,3
400 100 114 104 99 7,0
CrNi
600 150 122 112 107 7,0
cutting pressure
*depending on the type of the unit
(bar)

Therefore suitable protective measures have to be arranged in any case(ear protectors, muffs,etc.)
The user has to follow national and local regulations (e.g. employer’s liability insurance associa-
tion).

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1.4.9 Endangerment to 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

1.4.10 Handling of pressure cylinders

Attention!
For the gas supply only high- quality, preferable two- step pressure regulators have to be
used, guaranteeing a constant supply pressure. The quality of the pressure reducer influences
the cutting quality and reliability of the complete unit. Pressure reducers that are conform to
the quality requirements are mentioned in the order specifications of Kjellberg.
Furthermore the user has to follow local and national standards.
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
• only employ the pressure reducer for corresponding gas
• never lubricate pressure reducers with grease or oil
• all parts, which coming with oxygen into contact, must be 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 “Gas pressure test”

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1.4.11 Handling of coolant „Kjellfrost“
(only valid for units with liquid cooled torches)

For all liquid- cooled plasma torches Kjellberg Finsterwalde is using the coolant „Kjellfrost”,
suitable as anti- freezer as well.
„Kjellfrost” contains anti- corrosive inhibitors. Thereby all the components of the cooling device are
protected effective against corrosion.
Please notice following items particularly:
• „Kjellfrost“ 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.
• Danger dominant ingredient: Ethylenglykol (Ethandiol)
• Never add water to the new„Kjellfrost“ (for dilution or filling up). Only pure „Kjellfrost“ has to be used for
filling up!
• The safety data sheet can be requested when required: (Tel. +49.3531.500203).

Attention

All details given on the label of the new anti-freezer have to be followed consequently!
− „Kjellfrost“ is injurious to health
− Don’t drink Kjellfrost
− Keep it away from food, drinks and fodder
− Always clean your hands before a break and after end of work
− Avoid the contact with eyes and skin
− Safety goggles recommended during filling
− Wear protection suit
− Wear gloves from Nitril or Viton (see safety data sheet)
− Immediately taking off soiled, watered clothes
− Special danger of skidding by run out or spilled "Kjellfrost"
− Keep away from children
Erste Hilfe
− after swallowing
Don’t bring up, clean the mouth, drink much water, open the window for
fresh air and call the doctor , present packing or label.
− after eye contact
Clean the eyes with much flowing water some minutes and
call the doctor
− after skin contact
Quickly clean it with much water and soap

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 warning

Leaked or slopped coolant "Kjellfrost" and evaporation of water portions can cause an
increasing concentration of the component ethanediol.
If there is a sufficient energy-rich ignition source, it can cause an inflammation and
combustion of the ethanediol-debris.
Absorb leaked or slopped coolant "Kjellfrost" with liquid-binding material (sand, diatomite,
oil binder, acid binder, universal binder) immediately.
Dispose the absorbed material according to official regulations.

WARNING

Leaking coolant "Kjellfrost" additional with influence of extreme heat causes a very fast
vaporation of water portions and an increasing concentration of the component ethanediol.
This can take place, for instance, if leaking coolant impacts the glowing dross at the cut-
ting table as a result of a damaged plasma torch by collision or above the wear limits
driven cathode.
This can cause an inflammation and combustion of the ethanediol-debris.
Absorb leaked or slopped coolant "Kjellfrost" with liquid-binding material (sand, diatomite,
oil binder, acid binder, universal binder) immediately.
Dispose the absorbed material according to official regulations.

Fire-fighting measures against ethanediol-fires

Suitable extinguishing agents:
- water spray
- alcohol resistant foam
- carbon dioxide (CO2)
- extinguishing powder
Fight larger fires with water spray or alcohol resistant foam.
Special hazards caused by the substance, its products of combustion or resulting gases:
- carbon monoxide (CO)
- oxides of carbon, nitrogen (NOx), sulphur
- as well as not identified organic and inorganic compounds.
Special protective equipment:
Do not inhale explosion gases or combustion gases.
Additional information:
Dispose of fire debris and contaminated fire fighting water in accordance with official regulations.

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1.5 The plasma cutting process
The plasma is defined as a gas having atoms and molecules which are partly split into ions and e-
lectrons 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 form-
ing a very small kerf in the material.
The plasma arc hereby is transferred from the cathode, installed in the plasma torch and con-
ducted 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 steels, aluminium, copper, etc. It is suitable for straight, profile, template and bevel
cutting. So plates, tubes, profiles, formed and casted parts can be cut or worked.

plasma cutting
process

dry cutting under water cutting

process process

without secondary with secondary gas with secondary gas

gas (conventional) (swirl gas technology) (swirl gas technology)

without enhanced with enhanced

constriction of the constriction of the
plasma arc plasma arc

1.5.1 Dry cutting process

1.5.1.1 Plasma cutting without secondary gas

fig. 1-1: principle of plasma cutting
without secondary gas
Depending on the cutting task various cutting 1 pilot resistor
technologies can be used. The cutting without 2 HV-igniter
secondary gas is described with fig. 1-1. 3 gas supply
4 cathode
5 nozzle
6 plasma arc (main arc)
7 workpiece

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A safe ignition of the pilot arc is granted when following subsequent points:
• If a plasma hand torch is available, then the central connector of the plasma hand torch must be
tightened to the limit stop.
• The proper mounting of the consumables.
• The cathode must always be firmly tightened.
• The nozzle end must always be kept clean of dirt, especially of metal spatter. A soft wire brush
can be used for cleaning.
• The required parameters in regard to gas pressure and mains voltage must be observed.
Attention!
By no means may pliers or other inappropriate tools be used, as this will inevitably damage
the consumables (creation of burrs that lead to malfunctioning).

The safe formation of the main arc (cutting arc) will be achieved through (see fig. 1-1):

• disconnection of HV-igniter just after ignition of pilot arc

• pilot arc current is limited by the pilot arc resistor
• Automatic power increase if pilot arc contactes the workpiece

Generally the workpiece cable must have full contact to the workpiece.
When using the hand torch the distance holder should be used.

1.5.1.2 Dry cutting process with secondary gas (swirl gas technology)

Dry cutting process with secondary gas without enhanced constriction of the plasma arc

Plasma torches for the secondary gas technology are using a swirl gas for shielding the plasma arc
from the atmosphere. With the conventional dry plasma cutting the plasma arc is directly trans-
ferred 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 cut-
ting results on different materials.

The figure shows the principle of the swirl gas technology in comparison to the conventional dry
plasma cutting.

A A
B B
C
fig. 1-2:
plasma torch with swirl gas
compared to conventional plasma
torch

A coolant circuit

B plasma gas

C swirl gas

ohne Wirbelgas
without swirl-gas

A 0002 - 01.09.2007 - page 1-12 - Kjellberg Finsterwalde

 Dry cutting process with secondary gas and with enhanced constriction of the plasma arc (HiFo-
cus technology)

The former described cutting technologies are producing a cut with more or less inclination of the
cutting surfaces, especially at thin materials. On plates up to 5 mm the cut angle can amount to 5
to 10 degrees really. The new HiFocus technology reduces the inclination considerably. The cut-
ting surfaces in the thin sheet metal range (0.5 - 8.0 mm) are nearly perpendicular, resulting in
much higher part accuracy. The reason is the intensive constricted and stabilized plasma arc.

Reworking of the metallic clean and free-of-dross cut surface is normally not necessary.

Detailed cutting data to the kind of materials and qualities of material are to be found in the appen-
dix of the instruction manual.

1.5.2 Under water cutting process

The under 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 process. 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”..

1.6 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 a licensed electrician the unit should be opened
(see VDE 0105 or follow national instructions)!

1.6.1 General

1.6.1.1 Intervals of maintenance

Following measures have to be taken regularly:

1. weekly:
visual inspection of the condition of the plasma power source, all system components and the
plasma torches, control of the filling level of the coolant (fill up on demand)

2. monthly:
by application of hydrogen and oxygen, Æ inspection of the gas supply, gas pressure test acc.
to chapter 1.6.2.1

3. after 4 to 6 months :
Cleaning the power source and all components

4. all 6 months :
electrical revision

5. yearly :
complete change of coolant („Kjellfrost“)

A 0002 - 01.09.2007 - page 1-13 - Kjellberg Finsterwalde

1.6.1.2 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, more
effective is to use a vacuum cleaner.
When working in shifts or under unfavourable conditions the regular cleaning should take place in
shorter intervalls.
For ensuring an effective cooling filter mattes, if existing, should be cleaned in water (approx. 40°C)
by using standard detergents.
Manual cleaning is useful as well (beating; exhausting; with compressed air, e.g.)
In the same way all components of the system have to be cleaned.

Filter regulators and micro filters have to be cleaned weekly. Condense water has to be drained;
filter inserts have to be replaced in time.

The small filter screws inside the gas connectors of the plasma gas control units have to be in-
spected every 4 to 6 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.

1.6.1.3 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 overcurrent 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):

- the transition resistance between marked protective conductor connection of the plasma cutting
unit and all touchable metallic, not alive parts has to be < 0.1 Ohm if line cross section is
> 6 mm2 (otherwise pay attention to EN 60204-1) !

c) The insulating capacity of winding and line insulation has to be proofed:

- 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 > 5 MOhm (dry
and cold condition)

Noticed faults have to be rectified by an expert immediately.

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1.6.1.4 Plasma torch

The plasma torches have to be handled with care. Powerful treatment and stress load have to be
avoided. All spare parts must be in clean condition and carefully changed in time (see instruction
manual of the plasma torch).

Damages of parts inside the torch, like nozzle holder and cathode tube have to be avoided.

Besides the change of consumable parts by using the special torch tools no other action to
the torch head is allowed! 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 160-1 series the filter screws have
to be cleaned from time to time after unscrewing from the gas connector. (only valid for liquid cooled
torches)

Attention!
Plasma torches have to be water tight at any time! Defective torches generally will be re-
paired by the Kjellberg Service Centre or a licensed repair shop!

Attention!
All components and parts coming in touch with oxygen have to be kept free of oil and grea-
se! This refers specially to the torch head and the consumables!

Only O R I G I N A L Kjellberg spare parts and consumables may be used!

A 0002 - 01.09.2007 - page 1-15 - Kjellberg Finsterwalde

1.6.2 Special

1.6.2.1 Gas pressure test

When using oxygen, hydrogen or inflammable gas mixtures the check of the gas supply system is
particularly important. An unnoticed gas leakage can have serious consequences.

The following gas pressure test has to be carried out separately for hydrogen, oxygen and every
other inflammable gas mixture monthly:

1. Remove connecting plug of plasma torch, insert test plug X121 and remove plugs from the so-
lenoid valves 4 of the plasma torch connection unit so that solenoid valves don't switch. The
test plug X121 is stored in a plastic bag at the handhold of the rear panel. It can be ordered
stating the article no.11.820.101.205.
2. Start the plasma unit and switch on gas test switches for filling the gas hoses
3. Close exit valves at the pressure reducers ( gas test switch remains open)
4. Check the initial pressures of the attached gases at the respective plasma gas control unit (ma-
nometer or label "initial pressure" at PGC). The adjusted initial pressures have to be kept con-
stant for at least 3 min on the adjusted value.

If a pressure drop appears, the reason has to be investigated and removed immediately. After that
the pressure test has to be repeated.

After a successful completion of the gas pressure test the following actions have to be carried out:

1. turn off gas test switches

2. switch off plasma unit
3. remove test plug X121, replace connecting plug of the plasma torch and plugs of the solenoid
valves 4

Attention!
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 by oxygen, hydrogen
and inflammable gas mixtures, the gas pressure test has to be carried out carefully and
proofed by protocol.

Protocol about the monthly gas pressure test see enclosure.

1.6.2.2 Coolant system

Possible losses of coolant during the replacment5 of consumables or during the change of plasma
torch have to be compensated. The yellow LED on the power source indicates the "Filling level-
"(21). The LED flashes if the level is to low.

The coolant has to be exchanged completely every year.

Attention: Don't use compressed air to empty the coolant container!

The used coolant has to be removed from the cooling circuit of the plasma unit as follows:

• Remove the hose parcel of the plasma torch from the back wall of the plasma unit and empty it
• Take off the coolant supply and return hoses from the plasma unit and place them in a suitable
collecting container
• Open the drain cock at the KWE and drain coolant
• Clean the filter of the plasma unit after the coolant is completely drained. Unscrew there to the
filter and clean or replace the filter insert (article no. 10.639.577). Screw on the filter again
• Open the tank of the KWE and clean it
• Reconnect the coolant supply and return hose to the plasma unit again
• Close the drain cock and fill up the tank with fresh coolant mixture "Kjellfrost-15" resp. "Kjell-
frost- 25"
• connect the torch hose parcel to back wall of the plasma unit again
• carry out leak test on bolted connections

A 0002.07 -- 20.04.2007 page 1-14 Kjellberg Finsterwalde

1.6.2.3 Preventive periodic maintenance - component change plan

To guarantee a high availability of the unit, the strict adherence of the stated maintenance measures is nec-
essary.

Depending on the existing individual operating conditions of the user, it can make sense to carry out a pre-
ventive periodic maintenance with component change in addition to these maintenance measures according
to the following plan:

preventive periodic maintenance - plasma power source:

component change plan HiFocus 280i, 360i and 440i
time interval component Article No. quantity
1 year or after coolant .12.62360 unit depending
1000 cutting hours
coolant filter element .10.639.577 1
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
2 years or after coolant .12.62360 unit depending
2000 cutting hours
coolant filter element .10.639.577 1
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
3 years or after coolant .12.62360 unit depending
3000 cutting hours
coolant filter element .10.639.577 1
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
4 years or after coolant .12.62360 unit depending
4000 cutting hours
coolant filter element .10.639.577 1
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
coolant pump, complete .11.141.102.320 see KWE 360
torch hose package by manufacturer or
authorised service
5 years or after coolant .12.62360 internal to the unit
5000 cutting hours
coolant filter element .10.639.577 1
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
fan .10.140.696 1
6 years or after coolant .12.62360 unit depending
6000 cutting hours
coolant filter element .10.639.577 1
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
coolant and gas cable condition depending
As of 7th. year repetition of the component change plan

A 0002.07 -- 20.04.2007 page 1-15 Kjellberg Finsterwalde

2 Plasma power source HiFocus 280i

2.1 Technical data

primary side:
input voltage U1: 3x 400V ±10%, 50Hz
max. connecting load: 67 kVA (100% ED)
fuse, slow/ switch: T 100 A
cross section Cu: 4 x 35 mm2
power factor cos phi: 0,89 (280 A)
efficiency: 0,91

cutting side:
range of torch range of torch head 370.1 range of torch head 370.2
open circuit voltage U0: 330 V 330 V
cutting current IS: 10 – 160 A (180 A) 10 – 280 A
arc voltage US: (100 %) 200 V 200 V
cutting power PS: 36 kW 56 kW
duty cycle X: 100 % at 180 A 100 % at 280 A
thickness ds : 0,5 – 20 mm *) 10 – 60 mm *)
pilot arc current IPB: max. 18 A max. 40 A

workpiece cable: conductor cross section Cu: 95 mm2

characteristic: drooping (CC)
ignition process: pilot arc ignition by high voltage ignition unit;
(at plasma torch connection unit PBA-360)
main arc ignition by pilot arc

weight m: 505 kg
dimensions (lxbxh): 1030 x 680 x 1450 mm (with undercarriage „castors and wheels“)
protection class: IP22
insulation class: F
cooling: by fan

torch cooling: external circulating cooling

coolant: coolant mixture
„Kjellfrost -15“ (freezing protection up to -15oC) or
„Kjellfrost -25“ (up to -25oC) with integrated corrosion protection
pressure: 0,9 MPa (9,0 bar)
*) … depending on material and cutting technology
Fig. 1: Technical data HiFocus 280i

G 0010 - 01.04.2006 - page 2-1 - Kjellberg Finsterwalde

2.2 Technical description
All components of the plasma power source are mounted into a movable housing. The control and
signalling elements are placed in the front panel together with the gratings for the cooling air intake.
The back wall contains the connectors for the cooling unit and the workpiece cable, the mains cable
entry, the connectors for the remote control, CNC-interface, as well as the components for the arc
ingnition, plasma gas control and adjustment, and furthermore the gratings for the cooling air
exhaust.
The terminals for the hose parcel extensions PZL-360 and the fuses F1-F5 are accessible after
opening a cover plate, placed in the back wall.
A filter is to find on the back wall for the external circulating cooling. The volume flow, the pressure
and the temperature of coolant are supervised by plasma machine.
The power module contains the main transformer, the IGBT-bridge, the cutting choke coil, the main
rectifier, the pilot resistors and the power contactors. A high volt igniter initiates the pilot arc.
The complete cutting process is controlled and monitored by means of a micro-processor control.

2.3 Characteristic features and advantages

By the application of the Plasma Fine-Focus-Principle acc. to Professor Manfred von Ardenne with
its extreme constriction of the plasma arc extraordinarily energy densities will be achieved, which will
be additionally increased in the HiFocus range with HiFocusplus technology, resulting in various
technological advantages.

These mainly are:

• plasma cutting with laser-like quality from 0.5 to 60.0 mm

• dross-free up to 40 mm (dependet on workpiece)
• precise cutting surfaces and excellent contour precision of the parts, less rework reduces costs
considerably
• low heat input
• low distortion

Technological advantages:

• longevity of consumables because of second gas ignition and nozzle-saving piercing with swirl
gas technology
• minimized consumption of gas and energy due to the highly constricted plasma arc
• reduced investment and operation costs compared with a laser installation
• flexible capability for various CNC-guiding systems and robots

G 0010 - 01.04.2006 - page 2-2 - Kjellberg Finsterwalde

 Further features and advantages:

• stepless current adjustment from 10 - 280 A (100 % duty cycle) for cutting up to 60 mm
thickness (material depending)
• stepless adjustable marking current from 5,0 A - 50 A for optimal process adaptation
• nozzle saving piercing by adaptable pilot arc current
• optimal process sequence by micro processor control
• adjustable current down slope at corner-, start- and stop-signals
• automatic monitoring of all important processes (torch cooling, ignition time, pilot arc time, etc.)
• digital cutting current and arc voltage display
• automatic display of the preset cutting current value
• indication of process conditions and process faults by LED and display
• interface for adaptation to CNC or robot controls
• serial data transfer (RS 485) for control of the HiFocus 280i from CNC
• serial data transfer to PC for diagnostic purposes (RS 232)
• longevity of consumables due to extreme effective water cooling
• hose parcel extensions (15, 25, 35, 45 or 55 m) for increasing the operational radius to
max. 55 m
• plasma machine torches PerCut 370.1 and PerCut 370.2 with quick-change head reduces
downtime and increases flexibility
• stepless dosage and measurement of the gases by means of pressure controller or volume flow
controller respectively flowmeter enable optimum control of the cutting process
• special torches (robot cutting, with short or inclined shaft, tube inside cutting) are available on
request
• up-to-date industrial design, movable or transportable by crane
• plasma cutting with plasma gases air and oxygen ensure optimal cutting results on mild steel

2.4 Ranges of application

With the HiFocus 280i the user is in the position to receive laser-like qualities when cutting mild
steels, stainless steels and aluminium at thickness from 0.5 to 60.0 mm (material depending).
Normally no finish work is required because the cut is clean and nearly free of dross.

The plasma cutting system is recommended for following technologies (consider cutting tables):

2.4.1 Range of Torch head 370.1

HiFocus-technology
material: mild steel and aluminium preferably for:
• narrow cutting gaps through small nozzle orifice
cutting current: 20 - 50 A • direct corner cutting
• high cutting quality acc. to DIN EN ISO 9013 „u“
material thickness:* 0.5 - 6.0 mm (mild steel) • cutting of inside contours
1.0 - 8.0 mm (aluminium) • very small heat effected zone
• longevity of cathode and nozzle
plasma gas / swirl gas: 0.5 MPa (5 bar) • minimized gas consumption
• dross-free plasma cutting

HiFinox-technology
material: high alloyed steel (1.4301) preferably for:
• narrow cutting gaps through small nozzle orifice
cutting current: 20 - 60 A • metallic clean surfaces (1.4301), slightly increased cutting
angle as at mild steel
material thickness:* 1.0 - 6.0 mm • cutting of inside contours
• very small heat effected zone
plasma gas / swirl gas: 0.5 MPa (5 bar) • a little dross, dross-free plasma cutting in the range 2-6 mm

HiFocusPLUS-technology
material: mild steel preferably for:
• high cutting performance because of 3 times higher
cutting current: 50 - 180 A cutting speed
• dross-free cutting over a wide range of parameters
material thickness:* 4.0 - 20.0 mm

plasma gas / swirl gas: 1.0 MPa (10 bar)

G 0010 - 01.04.2006 - page 2-3 - Kjellberg Finsterwalde

 HiFocus F -technology
material: mild steel preferably for:
high alloyed steel • flying cutting start
aluminium • cutting up to max. 50.0 mm
• metallic clean surfaces, also at thicker materials
cutting current: 130 - 180 A • sometimes slightly increased cutting angle at the cutting
surfaces
material thickness:* 2.0 - 20.0 mm (mild steel)
5.0 - 20.0 mm (high alloyed steel)
6.0 - 20.0 mm (aluminium)

plasma gas / swirl gas: 0.6 MPa (6 bar)

HiFocus FPLUS-Technology
material: High alloyed steel preferably for:
• flying cutting start
cutting current: 130 - 180 A • cutting up to max. 35.0 mm
• metallic clean surfaces, also at thicker materials
material thickness:* 5 – 20 mm (high alloyed steel) • small cutting angle

Plasma gas / swirl gas: 0.65 MPa (6.5 bar)

* material depending, standard qualities, linear cuts

2.4.2 Range of Torch head 370.2

HiFocus F -technology
material: high alloyed steel preferably for:
aluminium • flying cutting start
• cutting up to max. 80.0 mm
cutting current: 200 - 280 A • metallic clean surfaces, also at thicker materials
• sometimes slightly increased cutting angle at the cutting
material thickness:* 10.0 - 70.0 mm (high alloyed steel) surfaces
10.0 - 80.0 mm (aluminium)

plasma gas / swirl gas: 0.7 MPa (7 bar)

HiFocus FPLUS-technology
material: mild steel preferably for:
• flying cutting start
cutting current: 200 - 280 A • cutting up to max. 60.0 mm
• metallic clean surfaces, also at thicker materials
material thickness:* 10 – 60 mm • small cutting angle

Plasma gas / swirl gas: 1.0 MPa (10 bar)

* material depending, standard qualities, linear cuts

Cutting is possible in all positions and applicable for straight cutting (line or profile) and bevel cutting
as well, on plates, sheet metal, tubes and pipes, forced and forged parts, piled plates, casted parts
and scarp metal.

Because of the variable current setting the cutting power easily can be adapted to the process
requirements.

G 0010 - 01.04.2006 - page 2-4 - Kjellberg Finsterwalde

2.5 Plasma marking, plasma notching, plasma punching

definition
Plasma marking Marking of electrically conductive materials by means of plasma beam
(marking)
Plasma notching Marking of electrically conductive materials by means of plasma beam
(notching) with a larger penetration depth
Plasma punching Marking of electrically conductive materials by means of plasma beam
(punching) with a larger penetration depth in a point (punctual notching)

The penetration depth at the punching among other things gets certain also through the residence time of
the torch over the centre punch point and with that by the control of the guiding system or the robot

The application of the "FineFocus Principle“ offers numerous technological advantages for the marking
process.

These especially are:

ƒ small marking lines
ƒ low heat input
ƒ low distortion
ƒ high marking speed
ƒ excellent marking quality

The direct transferred plasma arc enables the marking of all electrically conductive materials with no regard
to thickness and quality (Mild steels, high alloyed steels and special alloys). Aluminium is less well suitable
due to its specific material properties for marking.
The marking process is applicable at all kind of material, like sheet metal, tubes, profiles, forged and casted
parts, laminated sheet packages, scrap metal products and cast iron products.
The marking current is stepless adjustable to conform optimal with the marking requirements.

G 0010 - 01.04.2006 - page 2-5 - Kjellberg Finsterwalde

 marking gas material penetration electrical coment
depth power

marking Ar Mild steels, + + very good marking quality for all

high alloyed steels materials except aluminium
special alloys
notching N2 ++ ++ larger penetration depth
as with plasma gas Ar
mild steel
notching+ Air +++ +++ larger penetration depth
as with plasma gas Ar and N2
punching punctual punching (see notching and notching+)
Fig. 2: used gases for marking und notching (punching)

Information
The marking record can be used without consumable part changes, however, the optimal
marking quality is not achieved by it in every case.

Information
At the permanent change between cutting of mild steel (with plasma gas O2) and marking
(with marking gas Ar) the life time of an O2 cathode S002 R002 R012 ( t012) can be reduce
except for 30%.
In this case argon becomes alternatively recommended nitrogen or air instead of the
marking gas.

Information
The Use of an Ar/H2 cathode is recommended for long marking processes with marking
gas argon :
- for plasma torch PerCut 370.1: cathode S042 or S052
- for plasma torch PerCut 370.1 3D: cathode R042 or R052
- for plasma torch PerCut 370.2: cathode T051

G 0010 - 01.04.2006 - page 2-6 - Kjellberg Finsterwalde

 torch material cutting cutting current plasma gas cathode change of
marking marking current marking Ar/H2-cathode
1
gas )
O2 Ar/H2
PG MG
mild steel cutting 20 - 160 O2 S002
PerCut 370.1

marking 5 - 14 Ar S002 S042

high alloyed cutting 60 - 75 N2/H2 S042
steels 120 - 160 Ar/H2 S052
marking 6 - 16 Ar S042
S052
mild steel cutting 20 - 130 O2 R002
120 - 130 O2 R012
PerCut 370.1 3D

marking 5 - 14 Ar R002 R042

R012 R042
high alloyed cutting 30 - 60 N2/H2 R042
steels 115 - 160 Ar/H2 R052
marking 6 - 16 Ar R042
R052
mild steel cutting 120 - 360 2) O2 T012
PerCut 370.2

marking 10 - 35 Ar T012 T051

notching 23 - 35 N2 T012 T051
notching+ 10 - 35 Air T012
high alloyed cutting 250 - 440 2) Ar/H2 T051
steels
marking 15 - 35 Ar T051
1
) for long marking the change of an Ar/H2-cathode is recommended
2
) maximum cutting current depending on an available unit (280 A, 360 A or 440 A)
Fig. 3: overview: allocation of process gases and cathodes for cutting and marking / notching

Attention! Marking is not possible with the Plasma Gas Control Unit PGE 3-360!

2.6 Putting into operation

After the 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.

2.6.1 Check out, placement and installation

The Plasma Cutting Unit is designed for a service in explosion-proofed rooms or in the free air by
using a roofing under following conditions:

• ambient temperature: -10°C up to +40°C

• relative moisture: max. 90% at 20oC
max. 50% at 40oC

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

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 The Plasma Cutting Machine is designed acc. to the requirements of the protection class IP 22
(DIN EN 60529), that means:

• protection against penetration of solid parts above 12 mm size

• drip-proof protection against straight dropping water (without negative influence up to 15o
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 movable
by hand. When transporting by forklift the unit has to be taken from the side.

Attention!
The centre point of the unit is near to the back! Danger of
tilting exists!

For crane transport lifting eyes are provided.

Attention!
For crane transport all four lifting eyes have to be used! The
angle between the ropes or chains should not exceed 45o!
Pay attention for the weight of the unit (fig. 2-1)! fig. 2-1: crane transport

Attention!
When manually moving the system, the danger posed by touching the free-standing wheels
must be taken into account!

Attention!
To ensure the stability of the unit, an inclination of more than 10° may not be
exceeded.!

2.6.2 Installation

2.6.2.1 Mains connection

The plasma cutting unit is supplied with the ready installed mains cable (4 x 35 mm2, 5 m long). The
connection to the mains has to be carried out through a wall-mounted power switch. The mains
fuses have to be arranged before the power switch acc. to chapter “Technical data of plasma
machine”.

2.6.2.2 Workpiece connection / current return line

For the connection of the workpiece cable a socket is provided in the rear wall of the power source.
The workpiece clamp has to be fastened firmly to the cutting job or the table on which the 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!

G 0010 - 01.04.2006 - page 2-8 - Kjellberg Finsterwalde

2.6.2.3 Earthing

Workpiece and cutting table have to be correctly earthed. The Plasma Cutting Unit HiFocus 280i and
the Plasma Torch Connection Unit PBA are provided with marked terminals, size M8 for the
earthing. To avoid electromagnetic disturbances, and for the safety of the personnel the earthing of
the plasma power source and the plasma components has to be carried out very carefully. The size
of the earthing wire should have at least 16 mm2.

2.6.2.4 Connection of the HiFocus 280i

All the connecting and control cables

will be placed to the back wall of the
power source. All “live” parts and the
fuses are accessible only after opening
the cover plate, which is protected by a
safety contact.

1 Connector remote control 8pol. socket

2 Connector control cable standard value 5pol. plug
3 Connector guiding system resp. height control 25pol. socket
4 Connector PGE 3-360, PGE-360, PGV 25pol. socket
5 Connector control cable PZL-360 10pol. socket
6 Fuses F1 - F15
7 Connector remote control switch (optional) 7pol. socket
8 Connector control cable cable set PZL-360 8pol. socket
9 Connector ”coolant return / cathode” G1/2”
10 Connector ”coolant entry / nozzle“ M18x1,5
11 Connector external cathode cable terminal M12
12 Connector reserve
13 Mains cable entry PG 34
14 Workpiece connection socket
15 Terminal earthing terminal M8
16 Cover flap
17 Connector control cable cable set PZL-360 4pol. socket
18 Connector serial interface RS 485 CNC 9pol. plug
19 Connector serial interface RS 485 PGC 9pol. socket
20 Connector cooling IN G1/2”
21 Connector cooling OUT G1/2”
22 Filter of coolant
23 Connector PZE 3 8pol. socket
24 Connector KWE 360 5pol. socket
25 Connector “Premature OFF”from CNC active 8pol plug

Abb. 2-2:
Connector external cathode
cables 2 x 50 mm²: fig. 2-3:
Cable lugs placed against back wall of the power source HiFocus 280i
each other (11)

Following components are suitable for the connection to the HiFocus 280i:

• the cable set PZL-360 for extension of the operational radius up to 55 m until the PBA-360
• the plasma gas valve unit PGV 3 in connection with the PGC 3 for the adjustment and the
dosage of the process gases
• the plasma gas control unit PGE-360 for the adjustment and dosage of the process gases
• the plasma gas control unit PGE3-360 for the adjustment and dosage of the process gases
• the plasma counter unit PZE3 for counting of the ignitions, the cutting time and arc inter-
ruptions
• the remote control FB for the operation of the plasma machine torches

G 0010 - 01.04.2006 - page 2-9 - Kjellberg Finsterwalde

2.7 Control and display elements of the power source
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!

Attention!
The plasma unit only has to be operated with plasma torches of the PerCut 370 series!

fig. 2-4: control and display elements

1. red push button S3 "Emergency stop", (reset button) 6. button „down slope“ - selection
- activated: plasma unit OFF (except control transformer - time adjustment in connection with potentiometer
and fan of control) “down slope” (14)
- unlocked: plasma unit ready for operation
7. LED-signal lamp green „cooling circuit o.k.“
2. key switch S1 "Mains ON" - LED ON: cooling circuit operates (volume flow,
- position 0: supply to control transformer and fan of pressure and temperature are OK)
control OFF
- position 1: power to control transformer and fan of 8. LED-signal lamp green „gas supply o.k.“
control ON, PGC on - LED ON: gas pressure for plasma and swirl gas
- position 2: power for control transformer and fan of > 0.3 MPa (3 bar)
control ON, PGC on, device can be
switched on by S2 9. LED-signal lamp green „temperature power source
o.k.“
3. illuminated button green S2 "stand-by" - LED ON: rectifier within thermal limit
- activated: - plasma unit ready for operation
- power ON for main transformer, cooling 10. LED-signal lamp white „pilot arc“
unit, fan and controls - LED ON: pilot arc ON
- signal lamp ON: plasma cutting unit ready for operation
11. LED-signal lamp white „main arc“
4. selector switch S5 "cutting technology" - LED ON: main arc ON
- position CNC: CNC-controller (all areas)
- position 1: HiFocus-range 1 12. potentiometer "cutting current"
- position 2: HiFocus-range 2 - cutting current adjustment (10 – 280 A):
- position 3: HiFocus-range 3 (flying cutting of steel) 10 – 180 A (torch PerCut 370.1)
10 – 280 A (torch PerCut 370.2)
5. tumbler switch "gas test"
- upper position: gas test ON 13. potentiometer "current reduction"
- for adjusting the plasma gas pressure - current reduction during signal „corner“ from CNC
- for measuring the flow rate of plasma gas - read value on current display (19), after switch
- for current reduction at corner signal „gas test“ (5) is set to upper position (max. value:
- for water drain from torch head after change of spare parts 30 % of rated current)
- LED signal lamp yellow “sumerror” (16) ON
- plasma unit not ready for operation 14. potentiometer "down slope"
- for current reduction on the end of the cut in
connection with push “down slope selection” (6)

G 0010 - 01.04.2006 - page 2-10 - Kjellberg Finsterwalde

 15. selector switch "up slope" 19. current display
up slope for HiFocus 280i, 360i, 440i - indicates cutting current (actual value)
- indicates cutting current (pre-set value)
switch PerCut 370.1 PerCut 370.2
10 – 180 A (torch PerCut 370.1)
position [ms] [ms]
10 – 280 A (torch PerCut 370.2)
1 200 200 - indicates error codes (ER 1 – ER 55), look at error
2 350 350 list / error codes
3 1000 1000 - indicates “down slope time” in ms
4 2000 2000
20. voltage display
…standard values - indicates the voltage
- indicates “gas test” (GAS)
16. LED-signal lamp yellow „sum error“ - the volume flow and the temperature of coolant are
- LED ON: plasma cutting unit not ready for operation displayed alternately by using the push button “down
error is defined through errorcodes slope selection” (6)
(ER1 and ER10 - ER55) on current display (19)
21. LED-signal lamp yellow “filling level”
17. LED-signal lamp yellow „process error“
- LED flashes: - warning – filling level is too low
– LED ON: error is defined through errorcodes
- warning – volume flow or pressure
(ER4 - ER9) on current display (19)
are too low
- LED on: - switching off of volume flow or pressure
18. potentiometer „marking current“
is too low
- adjustment of marking current
5 – 25 A (torch PerCut 370.1)
10 – 50 A (torch PerCut 370.2)

Information
on the Meaning Comment
display

voltage

current

serial connections between plasma unit

CNC and guiding system activated
display only during cutting breaks

FB- remote control (FB) is connected display only during cutting breaks

6A5 gas test active gas flows

6(L gas change long between different cutting programs

6(5 gas change short between cutting and marking

G 0010 - 01.04.2006 - page 2-11 - Kjellberg Finsterwalde

 K,FO
machine type (HiFocus 280i)
280 ,
will be displayed one after another for short
time after the start

U-1 serial no. (U-1 to U-4, U … Unit)

206 Software version number (example: 2.06)

set value current

25 (example: 25 A)
display only during cutting breaks

actual value arc voltage

112 (example: 112 V) display during cutting and marking
actual value cutting current
25 (example: 25 A)

0FF disturbance end

plasma unit is waiting for an OFF – signal

CNC from guiding unit (CNC)

0FF disturbance end

plasma unit is waiting for an OFF- signal

FB- from remote control (FB)

5 ,7L flow rate of coolant (example: 5,7 l/min)

100 “down slope time“ (example: 100 ms) will be displayed by activating the tappet
switch “down slope selection” (6) in
alternation, warnings and Errors will be
displayed automatically
21( temperature of coolant (example: 21°C)

100 “down slope time“ (example: 100 ms)

ER 1 error codes (ER 1 - ER55) see error list / error codes

Error during test run, at least at one

ER( error check
module temperature to high

6A5 gas flows in gas flows in after the end of cutting

G 0010 - 01.04.2006 - page 2-12 - Kjellberg Finsterwalde

2.8 Cutting operation
Before cutting can start the following steps have to be taken:
Inspection of the plasma torches:
- the torch must be in a correct and undamaged condition
- the inserted consumables must match the intended cutting technology and have to be in a good
shape
Inspection of the plasma power source:
- the mains fuse are of the required size (see chapter “Technical data of plasma machine”)
- the workpiece cable is correct connected (see chapter “Workpiece connection”)
Inspection of the installed plasma components:
- the gas supply system is correct installed, connections are safe and tight (see chapter
„connection of gas supply” – instruction manual of plasma gas unit)
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!

Operation sequences
1. release red emergency button S3 left rotation
“Emergency Stop” (1)
2. turn key switch S1 “Mains ON” (2) to “I” for changing consumables to - Mains voltage to control transformer
“PGC” - PGC operation display “Data set parameters”
displays consumables (only in connection with
FlowControl)
3. illuminated button green S2 switch ON plasma unit by main test:
“ready for operation” (3) transformer, fan, controls and cooling - the displays arc voltage (20) and cutting current (19)
unit appear for a short moment after the start:
(20): “HiFo”, serial-no., actual value arc voltage
(19): “280i”, software-no., current set value
Display example:
(20): K,FO U-1 168
(19): 360 , 206 250
- Preflow:
- illuminated button green S2 “ready for start (3) ON
- LED signal lamp yellow “cumulative error” (16) OFF
- LED signal lamp green “cooling circuit o.k.” (7) ON
- LED signal lamp green “gas supply o.k.” (8) ON
- CAN1 - connection o.k. (only in connection with
FlowControl)
- LED signal lamp green
“temperature power source o.k.” (9) ON
By that the unit is ready for operation!
4. rotary switch S5 “technological cutting technology selection acc. to
range” (4) cutting chart
5. operation PGC 3 PGE-360 or PGE preselection plasma regime (conforming
3-360 the required cutting program), activation
of plasma and swirl gases acc. to cutting
(see resp. service manual) chart
6. potentiometer “cutting current” adjustment of cutting current value readable on current display (19)
(12)
7. potentiometer “marking current adjustment of marking current value readable on current display (19)
(18)
(not with PGE 3-360)
8. potentiometer “current reduction” current reduction by “corner” signal from value shown on current display (19) when activating
(13) CNC tumbler switch “gas test” (5)
9. potentiometer "down slope" (14) adjustable by tumbler switch “down readable on current display (19) (in ms)
slope selection”
10. rotary switch "up slope" (15) position: 1 (preference value)
11. activation of tumbler switch “gas adjust to symbol „gas test“ test:
- gas purge for removal residual coolant from torch
test” (5) on power source or head after change of consumables
switches / buttons “gas test” on - LED signal lamp yellow “cumulative error” (16) ON
PGE/PGC, resp. automatically - display “gas” (GAS) on voltage display (20)
when witching on the power
source or when changing the gas,
activation “gas test”
12. move plasma torch to start position adjust ignition height acc. cutting chart, piercing over
workpiece surface, cutting start outside workpiece
(flying start) only possible with cutting technology
HiFocus F

G 0010 - 01.04.2006 - page 2-13 - Kjellberg Finsterwalde

 13. activation of ON - button of Ignition of pilot arc Plasma torch ON
remote
control FB - LED signal lamp white “Pilot arc” (10) ON
or (automatically after pilot arc contacts workpiece)
signal from CNC- control of the Main arc ON - LED signal lamp white “Main arc” (11) ON
guiding system
14. cutting acc. to selected program
15. Plasma torch “OFF” - when overrunning the workpiece or plasma arc distinguishes
- “OFF”-button on remote control
activated or
- “OFF”- signal from CNC
16. Plasma unit “OFF” key switch S1 “Mains ON” (2) to “0”, or plasma unit switched OFF, the plasma arc
to ”PGC” for changing consumables or distinguishes

pressing the red Emergency button S3

“Emergency stop” (1)
table 2-2: sequence of operation

Ignition of pilot arc

The pilot arc will be established when pressing the ON-button of the remote control FB or by the ON-
signal from the guiding system on (X102 (B2, B3)) after the gas preflow. The arc time is limited to
10 s. After contacting the workpiece the main arc automatically becomes ignited automatically and
the cutting process starts.

Pilot arc and main arc immediately will stop after the OFF signal from remote control FB or from the
guiding machine, or if the torch is overrunning the workpiece.

Running cutting start

(only possible in HiFocus F technology and if the selector switch S5 [4] “cutting technology range” is switched to HiFocus-
range 3!)

• 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 swirl gas cap and workpiece should be in a range of 1.0 to 4.0 mm. The
respective torch distances are given in the cutting starts

Piercing

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

• when piercing above the workpiece the distance for ignition has to be adjusted, depending on
the plate thickness (values are given in the cutting chart)
• after the ignition of the pilot the main arc establishes immediately
• the torch should start movement simultaneously with the ignition to reduce the danger of
damaging torch parts. Upcoming material can effect nozzle, swirl gas nozzle or nozzle gas
• for thicker materials the following procedure is recommended:
- adjust ignition height acc. cutting chart (1.2 - 2 x cutting distance)
- piercing delay acc. cutting chart
- lift torch during transfer arc slightly to avoid that spatter can damage the torch head
- after the material is pierced through the torch returns to the optimum cutting distance

G 0010 - 01.04.2006 - page 2-14 - Kjellberg Finsterwalde

Abb. 2: schematic diagram of a cutting process with height control system

Sequence steps of height control

1 process ON / setting plasma torch to ignition height
2 torch ON / gas pre-flow / waiting for pilot arc ON
3 keep torch to ignition height / waiting for current ON, main arc ON
4 hole piercing, lifting up to pierce height temporary (at larger material thickness)
5 lowering torch to cutting height, delay time for height control
6 cutting with voltage-dependent height control
7 complete cutting process, torch lifting to transitional position

G 0010 - 01.04.2006 - page 2-15 - Kjellberg Finsterwalde

Adjustment parameters
h1 reference position
h2 ignition height of plasma torch
h3 pierce height = elevated torch height at hole piercing (at larger material thickness)
h4 cutting height
h5 transitional height (torch height between several cuts)
h6 additional height = pierce height - ignition height (h6 = h3 - h2)
t1 pierce time
t2 control delay for the height control:
The dynamic processes at the hole piercing has to be completed before the
actual value is taken for the height control.
P1 first setting
pSG / QSG pressure / flow rate of start gas
pWG / QWG pressure / flow rate of swirl gas
vs cutting speed

Switching OFF the plasma cutting unit

The HiFocus 280i will be switched OFF by turning the key switch S1 (2) to position „0“. By that all
active components of the HiFocus 280i are switched off. When activating the red push button S3 (1)
“emergency-stop” all components become disenergized, with exception of the control transformer
and the fan of the control.

Attention!
The red emergency stop S3 “emergency OFF” (1) is a reset-switch. For starting the power
source by the green push button S2 (3) the emergency stop must be reset by a left rotation.
If the plasma cutting unit is not used fore a longer period it should be disconnected visibly
from the mains.

2.9 Remote control FB1

With the remote control FB the cutting process with the machine torch PerCut (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 X132, placed on the back wall of the HiFocus 280i.

Attention!
If the remote control is plugged in ignition of the plasma torch from the CNC control is not
possible.

G 0010 - 01.04.2006 - page 2-16 - Kjellberg Finsterwalde

2.10 Cooling
The cooling of plasma torches occurs through the external cooling unit KWE 360.

2.11 Combination of the HiFocus with CNC-controls of guiding systems and robots
The control cable for the combination of the HiFocus 280i with CNC-controls of guiding systems or
robots has to be connected to the 25 pole socket (system Wieland), placed in the back wall of the
power source. The respective cable the user has to prepare himself. The necessary materials can
be supplied on request from Kjellberg Finsterwalde.

The potential-free contacts are dimensioned for a current load of max. 500 mA DC at a control
voltage of 24 V. Relay contacts have to be furnished with a protective diode.
Remark!
Before connecting the control cable remove the link X102 (C3-C4). It is not possible to
operate the HiFocus 280i without the link or without emergency-OFF signal from the guiding
system!

X102 signal remarks

inputs
B2-B3 „torch ON“ from CNC potential free closing contact
B4-B5 „corner ON“ from CNC potential free closing contact
C3-C8 „data set selection I/O“ from CNC potential free closing contact
A7 0 -10 V (≙ 10 A - 280 A) Í active control analogue input for active Í remote control
0 - 10 V (≙ 5 A - 25 A) Marking control (potential free potentiometer
(Torch PerCut 370.1) outlet from CNC required)
0 - 10 V (≙ 10 A - 50 A) Marking
(Torch PerCut 370.2)
Í Í
B6 GND
Í
C6 +15 V
C5-C6 active control ON link
C3-C4 emergency stop from CNC potential-free break contact
remove wire link from X102
X102 signal remarks
outputs
A1-A2 „main arc ON“ from PA potential-free closing contact
A3-A4 „pilot arc ON“ from PA potential-free closing contact
A5-A6 “current ON” form PA potential-free closing contact
C1-C2 emergency stop from CNC potential-free break contact
C7-A8 Plasma machine ready to start potential-free closing contact
B7-A8 Plasma machine ready for start potential-free closing contact
A9 cathode potential (0 up to -200 V) Í cutting
B8 nozzle potential (0 up to -100 V) Í nozzle
C9 workpiece potential (0V) Í potential Í voltage
table 2-3: signals between power source and CNC interface

Attention!
If the remote control is plugged in ignition of the plasma torch from the CNC control is not
possible.

X104 signal remarks

outputs
1 GND reference point
2 current actual value “I” is 0 - 10 V 1 V × 50 A
3 voltage actual value “U” is 0 - 10 V 1 V × 25 V
4 free
5 free
table 2-4: signals of current actual value and voltage actual value

G 0010 - 01.04.2006 - page 2-17 - Kjellberg Finsterwalde

 Serial interface RS 485

By means of the serial interface RS 485 on the back side of the machine additional to the interface
X102 records can be read or transferred. The interface connectors have the following function:

X 4.1 Connection to CNC

X 4.2 Connection to PGC

Further information regarding received or transmitted parameters and their limits for communication
between CNC/PC and power source are shown in the description „Serial interface part 2“.

The descriptions part 1 - 3 can be ordered separately.

Switching On the plasma unit through X106

The cable connector X106 offers the possibility to start and stop the Plasma Cutting Unit directly
from the guiding system.

By an internal switch, placed on the right side of the PCB- box the unit can be switched over to the
function switching On from guiding system.

Attention!
According to existing safety standards it must not be possible to start the unit external
(through CNC) and from the power source as well.
The On/Off- function should be practicable only from one place! Kjellberg clearly pointes
out that in case the switching On is carried out from the CNC the user has to realize the
safety function (e.g. avoiding self- acting restart after input power break).
Furthermore by safety reasons the actuation of the key- switch during the change of
consumables as stipulated in the instruction manual is obligatory.

The green illuminated push button S2 “Stand- by” (3) which is installed in the front wall of
the power source in this case is Off by safety reasons.

X106 signal comment

Inputs
1-2 ON without lock potential-free make contact
3-4 2. Emergency stop from CNC potential-free break contact

X106 signal comment

Outputs
5-6 2. Emergency stop from plasma unit potential-free break contact
7 free
Table 0-5: signals distance control of CNC

2.12 Multiple machine operation

For a multiple machine operation each plasma unit has to be provided with a separate machine
number. Therefore the PCB Sequence control (LP 067101) is furnished with the Jumpers J7 and J8
(see following chart). The jumper block is placed in the centre of the PCB close to the connector X29
(see fig.).Ex works the unit is adjusted to 1. The actual machine number will be shown for a short
moment on the Arc voltage display (20) just after the plasma machine is switched on.
U-1, U-2, U-3 or U-4 (Unit 1-4)

Table 2-6: allocation of machine numbers fig. 2-6: jumper block J6 - J9

G 0010 - 01.04.2006 - page 2-18 - Kjellberg Finsterwalde

2.13 Start regime HiFocus 280i
2.13.1 “premature OFF” from CNC
connection at socket X132
“
contact signal CNC
1 +24V
5 “Premature OFF”

The link 1 – 5 activates the function “Premature OFF” by the supplied Plug X132. This function
means that the plasma unit still is cutting for 1s before the arc distinguishes. Within this time cutting
current and gas flow become modified in order to optimise the life time of the consumables.
Furthermore the Plug X132 can be used to control this function from the guiding machine. Possibly
that could be necessary when cutting small profiles (< 2s). But than the life time of consumables
becomes reduced.

fig. 2-7: back wall of the power source HiFocus 280i

fig. 2-8: distribution of the

cutting current IS
without function
„Premature OFF“

fig. 2-9: distribution of the

cutting current IS
with function
„Premature OFF“

G 0010 - 01.04.2006 - page 2-19 - Kjellberg Finsterwalde

2.13.2 Start by remote control:
connection at socket X132

contact signal
4 FB-operation
1 +24V
2 FB ON
3 FB OFF
The link 1- 4 switches into the operation mode with remote control (FB).

FB ON = ON button short pressing, plasma unit switches ON

FB OFF = OFF button pressing, switches plasma unit OFF

2.13.3 Start by CNC:

connection at socket X102

contact signal
B2 ON from CNC
B3 ON from CNC
contact closed: switches plasma unit ON
contact closed: switches plasma unit OFF

2.13.4 Start from CNC with special function “separate ignition signal”
connection to socket X102 (process start signal) and X132 (ignition signal)
plug contact signal
X132 1 +24V
2 FB ON
3 FB OFF
X102 B2 ON from CNC
B3 ON from CNC
• operation mode chosen by link X132 (1 - 3)
• “ON” activated by ON from CNC (X102 B2-B3)
• gas preflow activated (e.g. when lowering Z-axle)
• arc ignition after release impulse to socket X132 (1-2)
• OFF by opening contact X102 (B2-B3)

2.13.5 Start from CNC with special function (pre-impulse):

connection to socket X102 (process signal) and X132 (ignition signal)
plug contact signal
X102 B2 ON from CNC
B3 ON from CNC

• ON is made through a short ON impulse from CNC (X120 (B2-B3)); pulse duration 100 ms up to
max. 180 ms
• gas preflow activated (e.g. when lowering Z-axle)
• arc ignition occurs after closing of the contacts X102 (B2-B3)
• re-closing of the contacts have to occur not later than 10 s after first impulse, otherwise the
plasma unit goes automatically into the condition OFF
• OFF by opening contact X102 (B2-B3) during the cutting process or automatically due to the
timeout after first start impulse

G 0010 - 01.04.2006 - page 2-20 - Kjellberg Finsterwalde

2.14 Protective facilities
The plasma cutting unit is ready for operation, if after actuating the key switch S1 “main ON” (2) and
the green illuminated push button S2 “stand-by” (3) and the green LED-signal lamps

• "temperature power source o.k." (9)

• "gas supply o.k." (8) and
• "cooling circuit o.k." (7) are ON,
• and the pre-set value of the cutting current (19) is indicated.
• And the yellow LED “sumerror” (16) is OFF

The protection circuits are acting as described in the following and switching OFF the power source:

• emergency-stop, door contact, emergency-stop from CNC

after using the key switch S1 “main ON” (2) the power source will not start when pressing the
green illuminated button S2 “stand-by” (fan and cooling unit do not run)
• pilot arc limitation
(protects pilot resistors and reduces consumption on nozzle and cathode)
- switches OFF pilot arc after ca. 10 s
- yellow LED „process error“ (17) and “ER 7” lights in the current display (19) for 2 s, restart in
this period not possible
• nozzle protection circuit
- interrupts main arc when upcoming material touches the nozzle
- yellow LED „process error“ (17) and “ER 7” lights in the current display (19) (protection circuit
can be deactivated by placing the jumper JP9 to PCB LP 067101)

Under following conditions the yellow LED „sumerror“ (16) is ON and the green signal lamp S2
“stand-by” (3) is OFF:

• coolant flow control

- cooling unit switches of, if the required pressure is not reached after approx. 20 s
- cooling unit switches of after ca. 1 min, if:
coolant flow < 1,6 l/min (small torch head PerCut370.1)
coolant flow < 3,5 l/min (big torch head PerCut370.2)
- green LED „cooling circuit o.k.“ (7) OFF (attention! if long extensions are in the circuit it can
take 1 min to have the cooling circuit activated)

• gas pressure control

- switches OFF if gas pressure is < 0,3 MPa (3 bar) and when swirl gas cap is missing
- green LED „gas supply o.k.“ (8) OFF

• temperature control
- switches OFF the rectifier in case of thermal overload
- green LED “temperature power source o.k." (9) OFF

The cutting willingness of the unit is signaled if subsidiary to the standby the gas test is ended.

G 0010 - 01.04.2006 - page 2-21 - Kjellberg Finsterwalde

2.15 Trouble shooting
If during the operation malfunctions are registered the cutting has to be stopped and the reason to
be found out.

Attention!
Opening the plasma unit may be carried out only under responsibility of a qualified
electrician. Before starting any maintenance and repair work principally the power supply
source has to be switched off and visibly disconnected from the mains.

error reason / solution

1. after turning the key switch S1 “mains ON” (2) to position 2 - Red Emergency stopS3 “Emergency OFF” (1) not actuated (Reset
and activating the illuminated green Push button S2 “Ready switch)
for start” (3) fan and cooling unit do not start - Wire link X102 (C3-C4) (“Emergency OFF” from CNC) not plugged
- Rear cover plate resp. flap on PBA open
- Control cable plasma torch not connected on X121
- Motor circuit breaker F7 on cooling unit OFF
2. Fan and cooling unit ON, LED signal lamp yellow Low pressure of selected gases (see cutting chart)
“cumulative error” (16) ON and LED signal lamp green “gas
supply o.K.” (8) OFF
3. LED signal lamp yellow “Cumulative error” (16) ON, LED - pump of cooling unit rotates in wrong direction Æ change two phases
signal lamp green “Cooling circuit o.K.” (7) OFF, error - coolant flow
signal ER41 on current display (19) < 1,6 l/min (small torch head PerCut370.1) resp.
< 3,5 l/min (big torch head PerCut370.2)
- less or no coolant
- main switch S1 of Cooling unit OFF
- motor circuit breaker F7 on cooling unit OFF
4. LED signal lamp yellow “cumulative error” (16) ON and Thermal overload on rectifier Æ cool down by running fan resp.
LED signal lamp green “temperature power source o.k.” complete cleaning of the unit and the filter mat behind the fan on the
(9) OFF PCB box acc. to service instruction
5. LED signal lamp white “main arc” (11) OFF: no cutting - Pilot arc time > 10 s;
power (main power source OFF), plasma machine - no current flow to workpiece
switches off after approx. 10 s, error signal ER 4 on - Workpiece cable not connected
Current display (19) - Ignition height not correct
- Pilot arc without contact to workpiece

The plasma sequence control of the HiFocus 280i (PCB LP 067101) is displaying certain error
codes, if during service or operation errors are noticed. The current display (19) indicates code
numbers from ER 1 - ER55 and additionally the respective LED light. The description of these errors
and the rectification is given in the following chart:

G 0010 - 01.04.2006 - page 2-22 - Kjellberg Finsterwalde

 error chat / error codes – HiFocus 280i

information Meaning Reason

on the
display
(19)
ER 1 gas error manual gas console (PGE):
- gas pressure to low
- control gas not o.k.
automatic gas control (FlowControl):
- see operation screen PGC
ER 4 error arcing time pilot arc arcing time > 10 s;
no current flow to workpiece
- workpiece cable not connected
- ignition height not correct
- pilot arc without contact to workpiece
ER 5 error ignition no ignition within 2 s
ER 6 break of main arc main arc distinguishes without OFF- signal
(arc without contact to workpiece)
ER 7 error distance torch distance during cutting to small
ER 8 gas test error gas test time > 3 min when pressing a gas test button, resp. at GASTEST-signal
from guiding machine
ER 9 break of pilot arc break of pilot arc during ignition phase (main arc not established)
ER10 disturbance only with automatic gas consoles (FlowControl):
communication CAN communication between PGC Ù PGV interrupted
ER1 1 error in data bank only with automatic gas consoles (FlowControl):
allocation installed torch head not suitable to selected data bank
ER20 general error in power source
ER21 current flow from module 1 during cutting break recognised (K7.1 is ON)
inform
ER22 current flow from module 2 during cutting break recognised (K3 is ON) the
error power source
ER25
current flow to workpiece during cutting break recognised (K1 is ON) service!

ER26 nozzle monitoring detects inadmissible voltage during cutting break

ER27 check measuring cable cathode voltage and fuse F1 in PBA
ER30 general Error at plasma torch
ER31 current flow from module 1 during gas preflow recognised (K7.1 is ON)
ER32
error plasma torch
current flow from module 2 during gas preflow recognised (K3 is ON)

ER35 current flow to workpiece during gas preflow recognised (K1 is ON)

ER40 general Error at cooling system

ER41 - pressure of coolant to low
- temperature of coolant to high
ER42 flow rate of coolant to small:
ER43 error cooling system < 1,6 l/min (small torch head PerCut 370.1) resp.
< 3,5 l/min (big torch head PerCut 370.2)

ER44
fan switch (S4) in power source not closed

ER50 general disturbance at modules

ER51 - temperature of module 1 or 2 to high
disturbance module
ER52 - module 2 switches ON, but no current flow is detected (K3 OFF)

ER55 - input voltage module 1 or 2 not o.k. (under- or overvoltage)

ER( error check error during test run, at least at one module temperature to high
0FF
CNC
error end disturbance over, control waits for OFF-signal from guiding machine (CNC)

0FF
FB-
error end disturbance over, control waits for OFF-signal from remote control (FB)

G 0010 - 01.04.2006 - page 2-23 - Kjellberg Finsterwalde

 Instruction Manual

Plasma Machine Torch

of the series

PerCut 370.1
PerCut 370.2
Article No.: .11.846.621 – PerCut 370.1
Article No.: .11.846.721 – PerCut 370.2
3 Plasma Machine Torch PerCut 370
3.1 Technical Data
PerCut 370.1 (.11.846.621) PerCut 370.2 (.11.846.721)
with bayonet coupling with bayonet coupling

PerCut 370.1M (.11.846.821) PerCut 370.2M (.11.846.921)

with threaded coupling with threaded coupling
Current carrying capacity, max.
Cutting current, IS: 160 A 440 A
Pilot arc current, IPb: 25 A 40 A
Duty cycle 100 % 100 %
Ignition high voltage ignition (max. 17 kV) by pilot arc
Clamping diameter 58 mm
Torch cooling Coolant mixture
„Kjellfrost -15“ (freezing protection up to -15oC) or
„Kjellfrost -25“ (up to -25oC) with integrated corrosion protection
Flow rate coolant min. 4,0 l/min min 5,2 l/min
Plasma gas Luft, O2, Ar, N2, H2 and mixtures
(for quality, pressure and flow rate see particular Plasma Gas
Regulate Unit or Plasma Gas Control Unit)

Swirl gas N2 and Luft

(for quality, pressure and flow rate see particular Plasma Gas
Regulate Unit or Plasma Gas Control Unit)
Length of the hose set: 1 m / 1,5 m / 2,0 m
Terminals
Coolant return / cathode cable G1/2“
Coolant inlet M18x1,5
Pilot conduit pilot plug 4 mm
Swirl gas M12x1
Plasma gases G3/8“-LH and G3/8“-RH
Control gas G 1/8“
Gas of identification for torch head G 1/8“-LH
Control cable 7-pol. plug
Weight 6,1 kg (1,5 m hose set) 6,2 kg (1,5 m hose set)
Fig. 1: Technical data

Z 0020 - 01.03.2007 - page 3-2 - Kjellberg Finsterwalde

3.2 Technical Description
Attention!
The plasma torches of the PerCut 370 series are only suitable for the HiFocus 280i, 360i and
440i! They form in connection with the mentioned plasma cutting units a closed technical
safety system and ensuring a safe operation acc. to EN 60974-7.
Attention!
Before starting any installation or maintenance work the power source has to be switched off
and visibly disconnected from the mains (unplug mains cable)!
The plasma torches are suitable for cutting with the plasma gases air, oxygen, argon, nitrogen and
hydrogen. Secondary gases (swirl gases) can be oxygen, air and nitrogen.
The cutting current is transferred to the cathode by a flexible copper cable, which is inserted in the
insulating coolant return hose. The pilot current is transferred to the nozzle via a flexible copper cable,
which is inserted in the insulating coolant supply hose.
The nozzle is fixed in the nozzle holder by a detachable nozzle cap. The coolant circulates between
nozzle and nozzle cap, a special cooling tube ensures an effective cooling of the cathode. This
system ensures am efficient cooling of all thermally stressed torch parts.

Attention!
Before using a plasma torch it is necessary to ensure that the torch is equipped with the
suitable parts for the selected plasma gases and cutting procedure! After each wear part
change, a gas purge (approx. 20 s) is required to blow out all residual coolant which can
damage the torch during the high-voltage ignition.
The operator is only allowed to change consumables of the plasma torch!
Only original Kjellberg spare and consumables shall be used!
All parts (consumables included) which get into contact with oxygen shall be kept free of oil
and grease!
The plasma machine torch consists of the torch head, the torch shaft, the hose set and the
consumables. The torch contains two gas hoses and one swirl gas hose for the plasma gas supply.

3.3 Connection of the plasma torches to the Plasma Torch Connection Unit
Attention!
Before opening the plasma cutting unit or the plasma ignition unit, the plasma cutting unit
has to be switched OFF and disconnected visibly from the mains (unplug mains cable)!

The plasma torches of the series PerCut 370 are generally to be connected to the respective plasma
torch connection unit PBA.

The plasma torch has to be fastened to the support of the guiding system by using an adequate
insulation. A special torch holder is available from Kjellberg Finsterwalde.

The plasma torches are connected to the connectors in the PBA. The following connections shall be
established:

• Coolant return M 18x1.5

• Coolant inlet G1/2”
• Pilot current cable pilot plug 4 mm
• Control gas G1/8”
• Gas of identification G1/8”
• Control cable 7pole plug

The plasma gas hoses and the swirl gas hose shall be connected with the respective gas connections
in the magnetic valve groups.

Z 0020 - 01.03.2007 - page 3-3 - Kjellberg Finsterwalde

3.4 Consumables and their exchange
Attention!
In order to change
consumables, the plasma
cutting machine shall be
switched OFF and secured
against any accidental start fig. 3-1:
(BGV D1 § 44). An unauthorised
start-up is prevented by e.g. key switch on front
pulling out the key of the key- panel of power source
operated switch after switching
off the plasma cutting unit.

Attention!
All parts which come into contact with oxygen shall be kept free of oil and grease! When
replacing consumables, the torch head and the consumables has to be kept free of oil and
grease!

Attention!
The operator has to follow national and local regulations (e.g. Employer’s Liability Insurance
Association).

Used or damaged consumables shall be replaced in due time. (Reference: visible change of the
cutting quality)

The service life of the cathode depends on the cutting time and on the number of ignitions.

WARNING

If an above the wear limits driven cathode produce a damage of the plasma torch,
leaking coolant can impact glowing dross.
Leaking coolant "Kjellfrost" additional with influence of extreme heat causes a very fast
vaporisation of water portions and an increasing concentration of the component
ethanediol.
This can cause an inflammation and combustion of the ethanediol-debris.
Absorb leaked or slopped coolant "Kjellfrost" with liquid-binding material (sand, diatomite,
oil binder, acid binder, universal binder) immediately.
Dispose the absorbed material according to official regulations.

Z 0020 - 01.03.2007 - page 3-4 - Kjellberg Finsterwalde

 Ascertaining of the cathode wear with the meter

max. cathode
plasma plasma position
cathode article no. plasma unit burn-back
gas torch no.
(mm)
for
maximu
quality
m*)
cut

S 002 X .11.843.021.310 1,65 1,80

O2, Air 11.01, 12.01

new!
S 002 Y .11.843.021.320 PerCut 370.1 1,80 2,20

HiFocus 280i,
S 012 X .11.843.121.310 13.01 HiFocus 360i 1,65 1,80
HiFocus 440i
O2

T012 .11.836.921.300 31.02 1,80 2,20

PerCut 370.2

T051** .11.836.911.500 Ar H2 36.02 <1,50 ** 1,5**

*) … Attention: A higher cathode burn-back can lead to the destruction of the torch
**) … cathode with peaked head, cathode wear check with checking gauge as fig. 3-

Table 3-2: max. cathode burn-back by cathodes with a flat head

to zero: to read off:

:

fig.3-2 Ascertaining of the cathode fig. 3-3: cathode wear check

wear with the meter with wear gauge
Art.-No.: .36.000.015 (only for cathode T051 for the torch PerCut 370.2)

The service life of the nozzle mainly depends on the cutting time, the number of ignitions and the
handling of the torch (how piercing is carried out, spatter, etc.).

Be sure that the consumables are suitable for the intended cutting procedure (fig. 3-4 resp. fig. 3-5).

The consumables shall be replaced with great care and only with the mounting aids (6x.0x) which
are part of the delivery.

The torch can remain in the fixing equipment of guiding machine.

Z 0020 - 01.03.2007 - page 3-5 - Kjellberg Finsterwalde

 Attention!
After screwing off the protective cap to replace the swirl gas cap without any further
replacement of consumables, the tightness of the nozzle cap must absolutely be checked and, if
required, tightened again before mounting the protective cap!

Attention!
Completeness of parts has to be checked! Especially the cooling tube must be inserted. Other
wise the cooling is ineffective and the torch gets damaged. Only genuine Kjellberg parts have
to be used! Any caused damage leads to the loss of guarantee when you use parts of other
manufacturers! No other parts as mentioned here can be changed in the torch head side!

3.4.1 Plasma Machine Torch PerCut 370.1

Removal of consumables
1. turn off the protective cap (1x.06)
together with the swirl gas cap
(1x.05) by hand (press out swirl
gas cap)
2. unscrew the nozzle cap (1x.04)
with socket wrench (61.02)
3. pull out nozzle (1x.03) together
with gas guide (1x.02) by using the
nozzle- / gas guide puller (61.01)
4. pull out gas guide (1x.02) from
nozzle with nozzle- / gas guide
puller (61.01)
5. pull out the cathode (1x.01) resp.
the cathode (1x.01) along with the
distance ring (1x.07) (HiFocus F-
Technology) by using the cathode
puller (61.01)
6. the cooling tube (01.09) has to be
inspected for damages, take it by a
cross-recessed screwdriver (61.03)

Placement of consumables
1. screw in cooling tube (01.09) with
slot directed to the cathode by a
cross-recessed screwdriver (61.03)
2. insert cathode (1x.01), O-ring 6 x 2
must be placed well (sealing
function)
3. put gas guide (1x.02)
4. slide in nozzle (1x.03)
5. place nozzle cap (1x.04) and
screw it hand tight with socket
wrench (61.02)
6. adjust the swirl gas cap (1x.05)
into the protective cap (1x.06) and
screw both manually to the torch
head fig. 3-4: consumables overview of PerCut 370.1

O-rings only need replacement in case of deformation or damage.

Z 0020 - 01.03.2007 - page 3-6 - Kjellberg Finsterwalde

3.4.2 Plasma Machine Torch PerCut 370.2

fig. 3-5: consumables overview of PerCut 370.2

Removal of used up consumables

1. unscrew the swirl gas cap (3x.12) by hand or by the hook wrench (62.07)
2. unscrew the protection cap (3x.11) together with the swirl gas nozzle (3x.09) by hand (the swirl gas nozzle is pressed out
the protection cap)
3. unscrew the nozzle cap (3x.07) with socket wrench (62.04)
4. take out the nozzle (3x.05)
5. pull out gas guide resp. gas guide cap (3x.03) from nozzle (3x.05) by a gas guide puller (62.03) (only necessary for plasma
gas Air and Oxygen)
6. screw off the cathode (3x.02) with the socket wrench (62.02) – also necessary for a conversion of torch (another plasma
gas - e.g. from Air to Ar/H2) resp. at a damaged cooling tube
7. screw off the cooling tube (3x.01) with the socket wrench (62.01) resp. with hexagon-angle-screwdriver (62.05)

Placement of new consumables

1. screw in cooling tube (01.09) with the socket wrench (62.01) resp. with hexagon-angle-screwdriver (62.05)
2. screw in the cathode (3x.02) with the socket wrench (62.02) tightly
3. put the gas guide resp. the gas guide cap (3x.03) in the nozzle (3x.05) (only necessary for plasma gas Air and Oxygen)
4. insert the nozzle (3x.05)
5. put on the nozzle cap (3x.07) and pull it hand tight with the socket wrench (62.04)
6. put on the swirl gas nozzle (3x.09) and the protection cap (3x.11) and pull it tight by hand
7. screw the swirl gas cap (3x.12) onto the protection cap (3x.11) manually

O-rings only need replacement in case of deformation or damage.

3.4.3 Replacement of current socket in torch shaft

- screw off the defective current socket (00.42) with a screw driver (blade thickness 2.5 mm
maximum, blade width 16 mm maximum)
- screw in the new current socket (00.42) equipped with an o-Ring 14x1 (00.41)
Attention!
Do not twist the current socket resp. do not touch the contact fins inside with
metallic objects.
- check whether the current socket is free of burrs, especially near the transversal slot of socket

Z 0020 - 01.03.2007 - page 3-7 - Kjellberg Finsterwalde

3.4.4 Plasma Cutting Machine

When re-starting the plasma unit after the wear part change, proceed as follows:
1. After pressing the green button S2:
• automatic gas purge activated
• no coolant shall leak from the plasma torch (bide
until the disappearance of the air bubbles in coolant
hoses)
2. Switch over the tumbler switch S5 to gas purge for at
least 20 sec or choose the automatic time of gas purge
on the PGE:
• drain residual coolant from the plasma torch
• coolant drops can damage the torch during ignition
fig.: 3-6: green illuminated button S2 on
front panel of power source
3.5 Hints for use of the quick-change heads
3.5.1 Dismantling the change head

Before opening the torch, the Plasma Power

Source must definitely be switched off and
prevented from being accidentally switched on
again!
1. Safeguard against dropping down (e.g. with
left hand)
2. Left- hand rotation of locking sleeve, than
carefully pulling down torch head out of
securing position, removal by small clockwise
rotation
Attention!
Do not drop the change head, it
could be damaged!
3. Torch head should be placed on a smooth
pad and secured against rolling away. It is
recommended to use the “Station for Torch
head” (Art. No.: .11.846.721.830).

3.5.2 Maintenance of change heads

- check the internal o-rings and if necessary
change damaged or worn-out rings
• take out o-ring 49x2.5 (02.12) – with a
push of air-pressure, if necessary
• put o-ring 7x1.5 (02.13) on current pin fig.: 3-7 station for quick-change head
(art. no.: 11.846.721.830)
(coolant inlet / coolant outlet)
• take out the insulation sleeve (02.19) and put o-ring 7x1.5 (02.13) on it (02.19), use a torque
screwdriver (60.10) for assembly and tighten with 60 cNm
• dismantle the nipple WG/PG (02.17) and put o-ring 7x1.5 (02.13) on it (02.17), use a torque
screwdriver (60.10) with the hexagon insert SW9 (60.13) for assembly and tighten with 60
cNm

- check whether the pilot pin (02.18) has to be exchanged

• dismantling of the PI-insulation sleeve according to the replacement of o-ring
• screw off pilot pin with hexagon insert SW6 (60.14)
• screw in a new pilot pin and thighten it with 20 cNm, use a torque screwdriver (60.10) with
the hexagon insert SW9 (60.14)
• installation as above described
- exchange of control-/ident-gas-nipple (02.20)
• screw off and in of the control-/indent-gas-nipple, use a torque screwdriver (60.10) with the
hexagon insert SW5,5 (60.12) for tightening of nipple and adjust it with 10 cNm

Z 0020 - 01.03.2007 - page 3-8 - Kjellberg Finsterwalde

3.5.3 Installing the change heads

Attention!
Remove the residual coolant from the torch interface (head and shaft) before assembly the
change head, for example through the blowing out with compressed air.

1. Plug the change head onto the torch shaft while slightly turning the change head until the
securing screw fits into the shaft groove.
2. lefthand rotation of change head, until it can be plugged in torch shaft further
Attention!
Do not jam the change head, and plug it on all the way to the limit stop.
3. righthand rotation of sealing sleeve, until it stops in interlock position, supportingly push the torch
head against torch shaft in the same time.

Note!
In case the sealing sleeve cannot be locked, the change tip is not plugged onto the shaft far
enough. It must then be checked whether all inner components are free of foreign matter
and whether all rings are okay. In case of doubt, the contact positions of the torch must be
cleansed with compressed air, and a further attempt is to be made WITHOUT USING FORCE.

3.6 Maintenance and attendance

To prolong the service life of the o-rings, it is recommended to regularly wet the o-rings with an
oxygen-suitable lubricant that can be obtained from Kjellberg. Care must be taken that no lubricant
penetrates into the nipples.

Attention! The use of normal oil or grease leads to the destruction of the change head.

The change head is a high-quality precision part and must therefore be handled with care. To
prevent damages, it is recommended to store the change head not being used in the optionally
available “Station for the change heads”.

Z 0020 - 01.03.2007 - page 3-9 - Kjellberg Finsterwalde

 Instruction Manual

Plasma gas control unit

PGE-360
Article no.: .11.825.113 (version of software: 1.0)
4 Plasma gas control unit PGE-360
4.1 Technical data

PGE-360 - art. No.: .11.825.113

operating voltage:
(magnet solenoids): 24 V AC, 50 / 60 Hz
(Electronic) 230 V AC, 50 / 60 Hz
Dimensions (lxbxh): (551x514x425) mm
Weight: approx. 35 kg
connecting plasma
gases: Air Oxygen Argon Hydrogen Nitrogen Forming gas
(N2/H2)
(free of oil, (99.5%, dry, (99,996 %) (99,95 %) (99,999 %) (95% N2,
dirt, free of dirt, 5% H2)
moisture; use filter /
use filter / fine filter)
fine filter)

Flow rate to connected

torch,max.: 3500 l/h 3500 l/h 3600 l/h 600 l/h 5000 l/h 1800 l/h
maximum pressure: 1,2 MPa 1,2 MPa 1,0 MPa 1,0 MPa 1,0 MPa 1,0 MPa
(12 bar) (12 bar) (10 bar) (10 bar) (10 bar) (10 bar)
3
connection: G ¼“ G ¼“ G ¼“ G /8”-LH G ¼“ G 3/8”-LH
ZG / PG PG / WG1 ZG / PG1 / PG3 ZG / WG1 / PG2
PG2 WG2
connecting Air Oxygen Nitrogen
swirl gases:
(free of oil, connection connection
dirt, via plasma via plasma
moisture; gas gas
use filter /
fine filter)

Flow rate to connected

torch,max.: 5300 l/h
maximum pressure: 1,0 MPa
(10 bar)
connection: G ¼“
WG1 / WG2
Requirements on the Air
air quality
max. size of particles: 0,1 μm (category 1 acc. to ISO 8573)
max. rest oil content: 0,01 mg/m3 (category 1 acc. to ISO 8573)
max. pressure dew point: +3oC (category 4 acc. to ISO 8573)

table 4-1

Z 0026 - 01.03.2007 - page 4-2 - Kjellberg Finsterwalde

4.2 Technical description
Depending on the cutting technology the PGE-360 is required for the adjustment and dosage of the
plasma gases and swirl gases.

The PGE-360 contains the connectors for the gases, the pressure switches, solenoid valves and the
flowmeter for the plasma gases PG, PG1, PG2 and PG3, as well as the connectors for the swirl
gases WG1 and WG2.

With the gas-button on the PGE-360 the “Gas test” can be selected. Thereby the gas flow starts for
all preselected gases.

The cutting technology has to be selected acc. to the respective program at the PGE-360.

4.2.1 Operation of PGE-360

When switching ON the power source the gas control is furnished with the supply voltage. The micro
processor of the PGE-360 initialises itself and begins with gas control of the gas components. The
display shows “PGE-360” at first.

The software version of the micro processor appears approx. 5 seconds after that. The software
version 1.0 is displayed with “Sn 1.0”.

The display of PGE-360 shows “HiFo OFF” if the power source was not switched on by means of the
green button.

When pressing the green button the power source and the gas supply are switched on completely.

The gas supply starts with the gas combination, which was last chosen.

It is possible to choose between 40 different gas combinations according to the following table.

Z 0026 - 01.03.2007 - page 4-3 - Kjellberg Finsterwalde

 Overview of the cutting- and marking- data of PGE 360
stand from 13.03.07 valid from software PGE 1.2

cutting marking
ZG PG WG ZG / PG
WG
display ignition gas cutting gas swirl gas display ignition gas/
swirl gas
marking gas
C- 1 Air O2 O2/---/--- L- 1 Ar ---
C- 2 Air O2 O2/Air/--- L- 2 Ar ----
C- 4 Air O2 Air/---/--- L- 4 Ar ---
C- 5 Air O2 Air/Air/--- L- 5 N2 N2
C- 7 Air O2 Air/Air/Air L- 7 Ar ---
C- 8 Air O2 N2/---/--- L- 8 Ar ---
C- 9 Air O2 N2/N2/--- L- 9 N2 N2
C-11 Air O2 N2/N2/N2 L-11 Ar ---
C-12 Air Air Air/---/--- L-12 Ar ---
C-14 Air Air Air/Air/--- L-14 Ar ---
C-15 Air Air Air/Air/Air L-15 Ar ---
C-16 Air Air N2/---/--- L-16 Ar ---
C-17 Air Air N2/N2/--- L-17 Ar ---
C-19 Air Air N2/N2/N2 L-19 Ar ---
C-20 Ar Ar/---/H2 N2/---/--- L-20 Ar ---
C-21 Ar Ar/---/H2 N2/N2/--- L-21 Ar ---
C-22 Ar Ar/---/H2 N2/N2/--- L-22 Ar N2
C-23 Ar Ar/---/H2 N2/N2/N2 L-23 Ar ---
C-24 Ar Ar/---/H2 N2/N2/N2 L-24 Ar N2
C-28 Ar Ar/Ar/H2 N2/---/--- L-28 Ar ---
C-29 Ar Ar/Ar/H2 N2/N2/--- L-29 Ar N2
C-31 Ar Ar/Ar/H2 N2/N2/N2 L-31 Ar N2
C-32 Ar ---/F5/--- N2/---/--- L-32 Ar ---
C-33 Ar ---/F5/--- N2/N2/--- L-33 Ar ---
C-34 Ar ---/F5/--- N2/N2/N2 L-34 Ar ---
C-35 Ar Ar/F5/H2 N2/---/--- L-35 Ar ---
C-36 Ar Ar/F5/H2 N2/N2/--- L-36 Ar ---
C-37 Ar Ar/F5/H2 N2/N2/N2 L-37 Ar ---
--- --- --- --- L-38 Ar Air
--- --- --- --- L-39 Ar N2
--- --- --- --- L-40 N2 ---
--- --- --- --- L-41 N2 Air
--- --- --- --- L-42 N2 N2
--- --- --- --- L-43 Air ---
--- --- --- --- L-44 Air Air
--- --- --- --- L-45 Air N2
table 4-2

Z 0026 - 01.03.2007 - page 4-4 - Kjellberg Finsterwalde

 Overview of the cutting- and marking- data of PGE 360
stand from 24.04.08 valid from software PGE 1.6

cutting marking
ZG PG WG ZG / PG
WG
display ignition gas cutting gas swirl gas display ignition gas/
swirl gas
marking gas
C- 1 Air O2 O2/---/--- L- 1 Ar ---
C- 2 Air O2 O2/Air/--- L- 2 Ar ----
C- 4 Air O2 Air/---/--- L- 4 Ar ---
C- 5 Air O2 Air/Air/--- L- 5 N2 N2
C- 6 Air O2 Air/Air/--- L- 6 Ar N2
C- 7 Air O2 Air/Air/Air L- 7 Ar ---
C- 8 Air O2 N2/---/--- L- 8 Ar ---
C- 9 Air O2 N2/N2/--- L- 9 N2 N2
C-10 Air O2 N2/N2/--- L-10 Ar N2
C-11 Air O2 N2/N2/N2 L-11 Ar ---
C-12 Air Air Air/---/--- L-12 Ar ---
C-14 Air Air Air/Air/--- L-14 Ar ---
C-15 Air Air Air/Air/Air L-15 Ar ---
C-16 Air Air N2/---/--- L-16 Ar ---
C-17 Air Air N2/N2/--- L-17 Ar ---
C-19 Air Air N2/N2/N2 L-19 Ar ---
C-20 Ar Ar/---/H2 N2/---/--- L-20 Ar ---
C-21 Ar Ar/---/H2 N2/N2/--- L-21 Ar ---
C-22 Ar Ar/---/H2 N2/N2/--- L-22 Ar N2
C-23 Ar Ar/---/H2 N2/N2/N2 L-23 Ar ---
C-24 Ar Ar/---/H2 N2/N2/N2 L-24 Ar N2
C-28 Ar Ar/Ar/H2 N2/---/--- L-28 Ar ---
C-29 Ar Ar/Ar/H2 N2/N2/--- L-29 Ar N2
C-31 Ar Ar/Ar/H2 N2/N2/N2 L-31 Ar N2
C-32 Ar ---/F5/--- N2/---/--- L-32 Ar ---
C-33 Ar ---/F5/--- N2/N2/--- L-33 Ar ---
C-34 Ar ---/F5/--- N2/N2/N2 L-34 Ar ---
C-35 Ar Ar/F5/H2 N2/---/--- L-35 Ar ---
C-36 Ar Ar/F5/H2 N2/N2/--- L-36 Ar ---
C-37 Ar Ar/F5/H2 N2/N2/N2 L-37 Ar ---
--- --- --- --- L-38 Ar Air
--- --- --- --- L-39 Ar N2
--- --- --- --- L-40 N2 ---
--- --- --- --- L-41 N2 Air
--- --- --- --- L-42 N2 N2
--- --- --- --- L-43 Air ---
--- --- --- --- L-44 Air Air
--- --- --- --- L-45 Air N2
Tabelle 4-3

Z 0026 - 01.03.2007 - page 4-5 - Kjellberg Finsterwalde

 designation display 1 (left) display 2 (right)

display of switching on PGE 360

software version Sn 1.0

HiFocus is off HiFo OFF

cutting data set 18 C-18 cutting pressure

marking data set 18 L-18 pressure of the cutting set

test data set t-18 cutting pressure

gas purge of data set 18 Pu18 cutting pressure

error of inlet pressure H2 E1-1 cutting pressure

error of inlet pressure H2/N2 E1-2 cutting pressure

error of inlet pressure Ar E1-3 cutting pressure

error of inlet pressure PG_Air E1-4 cutting pressure

error of inlet pressure O2 E1-5 cutting pressure

error of inlet pressure WG_Air E1-6 cutting pressure

error of inlet pressure N2 E1-7 cutting pressure

error of inlet pressure
E1-8 cutting pressure
- connection of reserve -
error of control gas E1-9 cutting pressure
table 4-3: possibilities of displays

4.3.1 Manual selection of cutting data at the PGE-360

With the manual selection of cutting gases at the PGE-360 the number of gas combination, which is
listed in the cutting tables, is set by the programming switch of the PGE-360.

The toggle switch “gas-set selection” is pressed up and held on and the number of gas combination
is adjusted by means of the rotary switch “gas-set selection”. If the number was achieved, the toggle
switch is let off now.

The gas combination is certain now.

The number of gas combination appears with a preceding C or L on the left display. The gas purge
begins approx. 4 seconds after.

C means: the cutting process was chosen – display “Cutting”

L means: the marking process was chosen – display “Label, Line”

It is dependent on the position (cutting or marking) of the selector switch of PGE-360, which
of the both processes are active. If this selector switch has the position “CNC” the profile-
cutting machine enters the choice over the interface X102 of the power source and the CNC-
control switches the signal 0/1 (cutting/marking = no voltage/voltage).

The respective LEDs of the chosen gas combination shine on the front panel simultaneously with
this left display.

If a cutting set was chosen an automatic gas purge of 25 seconds follows. In the process of marking
the automatic gas purge is 5 seconds. If thhe gas-test switch on the front panel of the PGE-360 is
pressed within this gas purge, the automatic gas purge can be prolonged onto 3 minutes.

In the case of mutual switch-over between “cutting” and “marking”, a gas purge of 5 seconds occurs
after the signal of switch-over.

Z 0026 - 01.03.2007 - page 4-6 - Kjellberg Finsterwalde

4.3.2 Fast data-set selection by using the switch

The fast data-set selection is only possible between the processes “cutting” and “marking”. The
choice occurs by hand over the selector switch “cutting/marking” of the PGC-360 or in switch
position “CNC” by the signal 0/1 of the profile-cutting machine.

Only combinations of cutting and of marking are possible, which are fixed in the operation programm
of the PGE-360.

An arbitrary allocation of the marking gases is not possible.

4.4 Service and display elements of the PGE-360

fig. 4-1: service and display elements of PGE-360

1 input manometer of ignition gas 11 flowmeter of plasma gas 2

2 input manometer of plasma gas 12 flowmeter of plasma gas 1
3 input manometer of plasma gas 1 13 pressure regulator of plasma gas
4 input manometer of plasma gas 2 14 display of plasma-gas pressure
5 input manometer of plasma gas 3 15 toggle of gas test
6 input manometer of swirl gas 1 16 selector switch of cutting/marking/CNC-preselection
7 input manometer of swirl gas 12 17 toggle of gas-set selection
8 flowmeter of swirl gas 2 18 selector switch of gas-set selection
9 flowmeter of swirl gas 1 19 display of gas-set
10 flowmeter of plasma gas 3 20 LED-display of the chosen gases

Z 0026 - 01.03.2007 - page 4-7 - Kjellberg Finsterwalde

4.5 Connection of the plasma gas control unit PGE-360
The PGE-360 is connected by a
25 pole control cable to the socket X110
(placed on the plasma machine). The gas
supply hoses for the plasma gases and
swirl gases are fitted to connectors (1) to
(7).
The supply hoses to the plasma torch
connection unit PBA-360 are connected to
the connectors (13) to (17).
The PGE-360 is fixed at the top of the
plasma machine or another suitable
placement has to be arranged.

fig. 4-2: connections of the plasma gas control unit PGE-360

1 inlet of plasma gas PG3 H2 G3/8“ - lefthand 10 fuse of control circuit 24 V AC
2 inlet of plasma gas PG2 N2/H2 (backing gas) G3/8“ - efthand 11 fuse of control circuit 24 V DC
3 inlet of plasma gas ZG/PG1 Ar G1/4“ 12 earth connection M8
4 inlet of plasma gas ZG/PG Air G1/4“ 13 torch connection of control gas G1/8“
5 inlet of plasma gas PG O2 G1/4“ 14 torch connection of swirl gas M12x1
6 inlet of plasma gas ZG/WG1/WG2 N2 G1/4“ 15 torch connection of plasma gas 3 G3/8“ - lefthand
7 inlet of swirl gas WG1 Air G1/4“ 16 torch connection of plasma gas 2 G1/4“ - lefthand
8 reserve inlet of swirl gas WG2 G1/4“ 17 torch connection of plasma gas 1 G1/4“
9 connection X110A to the plasma cutting machine 25pole plug 18 escape-filter of gas

4.6 Connection of the gas hoses between PGE-360 and PBA-360

The length of the gas hoses for the connection of the components of the Plasma Cutting Complex
has to be arranged according to the system configuration. The following hoses are required:
(1) ignition gas (Air, N2 ,Ar) : Oxyacetylene hose 4x3,5 blue -G1/4“ (marked grey)
(2) cutting gas 2 (Air, O2) : Oxyacetylene hose 4x3,5 blue-G1/4“-lefthand
(3) cutting gas 1 (Ar/H2, N2/H2) : Oxyacetylene hose 4x3,5 red-G3/8“-lefthand
(4) swirl gas (O2, N2, Air) : Oxyacetylene hose 4x3,5 blue- M12x1
(5) control gas (Air, N2, Ar) : Oxyacetylene hose 4x3,5 blue- G1/8“

Z 0026 - 01.03.2007 - page 4-8 - Kjellberg Finsterwalde

4.7 Connection of the gas supply

Attention!
For the gas supply only high- quality, preferable two- step pressure regulators have to be
used, guaranteeing a constant supply pressure. The quality of the pressure reducer influences
the cutting quality and reliability of the complete unit. Pressure reducers that are conform to
the quality requirements are mentioned in the order specifications of Kjellberg.
Furthermore the user has to follow local and national standards.

The connectors for the plasma gas supply hoses are placed on the back of the plasma gas control
unit PGE-360 (fig.4-2):

Ensure the quality of the plasma gases absolutely (see section “Technical data - plasma cutting
unit). Dirty gases can cause double arcing, increased wear of nozzles and cathodes and damage of
torch or inside the PGE-360.

Against coarse dirt all gas connectors of the plasmagas control units, plasmagas connection units
and the plasma torches are equipped with micro filters. They can be unscrewed by a little
screwdriver and if necessary cleaned.
For the gas supply the followng hoses have to be used.
plasma gases 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 4-4

Attention!
The inlet pressure of O2 and Air (ignition/plasma gas) should not exceed 1.2 MPa (12 bar) and
of all other gases not exceed 1.0 MPa (10 bar). Take the adjustable inlet pressures from the
respective cutting tables. Please follow strictly the regulations for handling gas cylinders and
pressure reducers!

Plasma gas AIR, swirl gas AIR

quality requirements:
• size of particles, max. 0,1 μm class 1 acc. to ISO 8573
• remaining oil content, max. 0,01 mg/m3 class 1 acc. to ISO 8573
• dew point, max. +3oC class 4 acc. to ISO 8573
supply from pressure cylinder:
• check the 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 (with
filter/micro filter) and inlet connector “Air” (with filter / micro filter) at the PGE-360
• open the valve and adjust the pressure so the pressure (given in the cutting tables) is shown by
the respective manometer at the gas canisters
supply from the shop line or compressor:
• arrange oil and water separator in the supply line, or dry freezer, to be connected the shop line
and the PGE-360
• the oil separator is not required if the compressor works “oil free”
• adjust the pressure at the compressor so the pressure (given in the cutting tables) is shown by
the respective manometer at the gas cylinders

Z 0026 - 01.03.2007 - page 4-9 - Kjellberg Finsterwalde

 Plasma gas oxygen

Attention!
All components coming in touch with oxygen have to be free of oil and grease! Pressure
reducers for oxygen have to provide with explosion protectors (fire protection). Install micro
filters between gas supply and PGE-360.
• check the cylinder valves (must be free of oil and grease), clean it if required
• open shortly the valve for removing dust
• adjust the pressure reducer with explosion protection to the supply (cylinder, shop line)
• connect the gas hoses (blue marked, G1/4“-G1/4“) between pressure reducer (with filter / micro
filter) and inlet connector “O2” (with filter / micro filter) at the PGE-360
• open the valve and adjust the pressure between min. 10 bar and max 12 bar.

Plasma gases argon, hydrogen, nitrogen and backing gas

• check the 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 respective cylinders
• connect gas hose (black colour, G1/4“-G1/4“) between pressure reducer argon and the inlet
connector „Ar“ at the PGE-360
• connect gas hose (black/green, G1/4”-G1/4”) between pressure reducer nitrogen and the inlet
connector “N2” at the PGE-360
• connect gas hose (red colour, G3/8“ left - G3/8“ left) between pressure reducer hydrogen and the
inlet connector „H2“ of the PGE-360
• open the valve and adjust the pressure so the pressure (given in the cutting tables) is shown by
the respective manometer at the gas cylinders

4.7 Assembly of clamping ring connections

1. Cut back the hose to useful length
2. Put the support sleeve into the end of the hose
3. Complete the connection with clamping ring (consists of 2 parts, take care of right
position!) and nut
4. Put the hose with support sleeve into the connection and firm the nut tightly
5. Tighten the nut by 1 1/4 turns (Hold tight the counter side of the connection!)

Don´t use the support sleeve with tube from metal.

If you change a manometer, please take a new profile packing.

Z 0026 - 01.03.2007 - page 4-10 - Kjellberg Finsterwalde

 Instruction Manual

Plasma Torch Connection Unit

PBA-360
article no.: .11.820.250
5 Plasma Torch Connection Unit PBA-360
5.1 Technical data

Art. no.: .11.820.250

Operating voltage 230 V AC, 50 / 60 Hz
magnet solenoids: see chapter „connection of gas supply“ in the instruction manual of the
plasma gas console
high voltage ignition unit 17 kV
Dimensions (lxbxh): 247 x 252 x 370 mm
Weight: 8 kg
Gases in use: Plasma gas: Air, O2, N2; Ar/H2 (only PGE-360, PGV 3),
Swirl gas: Air, O2, N2;
Control gas: Air, N2; Ar (only PGE-360, PGV 3)

Connection to: PGE 3-360 , PGE-360, PGV 3 with line set PZL

Fig. 1: Technical data

5.2 Technical description

The plasma torch connection unit PBA-360 is the intersection between the plasma torch PerCut 370
and the power source. It is led operated intended by machine.
The PBA-360 contains the high voltage ignition unit. After opening the safety-contact protected cover
plate the connectors for coolant inlet, nozzle, coolant outlet, cathode and control gas as well as ident
gas (gas of identification for torch head) are accessible. The connectors for the plasma gases and
the swirl gases are on the side of the PBA-360.

Fig. 2: Dimension diagram Plasma Torch Connection Unit PBA-360

Z 0022 - 01.04.2006 - page 7-2 - Kjellberg Finsterwalde

5.3 Connection of the PBA-360

The Plasma Torch Connection Unit has to be fixed to the guiding system resp. to a robot, the customer is
using. For the correct fastening the bottom plate of the PBA-360 is furnished with four distance pieces
(with threads M6 inside/outside).
Two attachment variants result:
1. with distance pieces at the supplied condition
2. with turned distance pieces
Afterwards cables of the hose parcel PZL will be inserted into the PBA-360 and fastened there. The
numbered connecting hoses for the gas supply have to be installed gas proof to the respective connectors
1 and 5. The plug of control lines will be plugged in X114A, X121A and X122B and surely locked.

Connect the plasma torch with the output side of the PBA-360; exactly how the connection of hose parcel
PZL with the input side. The plasma gas hoses are screwed according to the outer designations 1, 3 and 4
as well as the inner designations of control gas (G1/8”) and ident gas (G1/8” LH).

After finishing the installation work close the cover, otherwise the door switch avoids starting of plasma
power source!

Z 0022 - 01.04.2006 - page 7-3 - Kjellberg Finsterwalde

 1 Connector of plasma gas 1 of PGE/PGV (G1/4“)
2 Connector of plasma gas 2 of PGE/PGV (G1/4“-LH)
3 Connector of plasma gas 3 of PGE/PGV (G3/8“-LH)
4 Connector of swirl gas of PGE/PGV (M12x1)
5 Connector of control gas of PGE/PGV (G1/8“)
6 Connector of protective conductor(M8)
7 Connector of ignition gas to the torch (G3/8“)
8 Connector of the cutting gas to the torch (G3/8“-LH)
9 Connector of the swirl gas to the torch (M12x1)
10 Ground of the torch (M8)

11 Connector of control cable of PZL at socket X121A

12 Connector of control cable of PZL at socket X122A
13 Connector of control cable of PZL at socket X114A
14 Opening for coolant inlet hose of PZL
15 Connector of the coolant inlet hose of PZL
(M18x1,5)
16 Opening for cathode cables and coolant outlet hose
of PZL
17 Connector of cathode cable of PZL (M12);
cable lugs placed against each other
(see adjoining detail)
18 Connector of coolant outlet hose of PZL (G1/2“)

19 Connector of control cable of torch at socket X121B

of the PBA
20 Opening for coolant inlet hose of torch
21 Connector of the coolant inlet hose of torch
(M18x1,5)
22 Opening for coolant outlet hose of torch
23 Connector of coolant outlet hose of torch
(G1/2“)
24 Opening pilot cable, control and ident gas hose of
torch
25 Connector pilot cable of torch (banana plug)
26 Connector control gas hose of torch (G1/8“)
27 Connector ident gas hose of torch (G1/8“-LH)

Fig. 3: connectors of the PBA-360

Z 0022 - 01.04.2006 - page 7-4 - Kjellberg Finsterwalde

 Instruction Manual

Cooling Unit

KWE 360
article no.: .11.141.102
6 KWE 360
6.1 Technical data
primary side
input voltage U1: 3x 400 V, +/-10 %, 50 Hz
connecting load, max: 1750 VA (100 % ED)
fuse, slow / switch: T 10 A
2
cross section, Cu: 4 x 1,5 mm
weight: 103 kg
dimensions (lxwxh): 670 x 680 x 1060 mm (with undercarriage, steering rolls and wheels)
protection class: IP 22
insulation class: F
cooling: by fan
o
coolant: coolant mixture „Kjellfrost -15“ (freezing protection up to -15 C) or „Kjellfrost -25“
o
(up to -25 C) with integrated corrosion protection
pressure: max. 0,9 MPa (9,0 bar)

table 6-1

6.2 Technical description

The cooling unit consists of a screwed sheet metal housing and the main components: cooler,
coolant tank and coolant pump with hoses.

The mains switch S1, a socket for the connection of control cable, the blocking valve for coolant
inlet/outlet and the ventilation slots for cooling air input are located on the front wall. The cooling air
output takes place through a large surface on the back. The connectors of the power and of the
potential equalisation are also located on the back.

Fixed and steering rolls are under the bottom for manual transport and ring eyelets are on upper
plate for crane transport.

The opening (diameter 150 mm) for the filling of coolant tank is also on the upper side of the cooling
unit.

6.3 Ranges of application

The KWE 360 is used as external recooling unit for the torch cooling of the Kjellberg plasma cutting
units HiFocus without integrated closed circuit cooling.

6.4 Putting into operation

After the 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.

6.4.1 Check out, placement and installation

The Cooling Unit is designed for a service in explosion-proofed rooms or in the free air by using a
roofing under following conditions:
• ambient temperature: -10°C up to +40°C
• relative moisture: max. 90% at 20oC
Place the unit so that the air flow is not blocked. The cooling air is drawn in through the front and is
exhausted through the rear wall. A free distance of at least 250 mm should be kept around the unit.

Z 0023 - 01.04.2006 - page 6-2 - Kjellberg Finsterwalde

 The Cooling Unit is designed acc. to the requirements of the protection class IP 22 (DIN EN 60529),
that means:
• protection against penetration of solid parts above 12 mm size
• drip-proof protection against straight dropping water (without negative influence up to 15o
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 cooling unit will be influenced.

The KWE 360 is movable by hand. When transporting by forklift the unit has to be taken from the
side.

Attention!
The centre point is near to the back of the unit! Danger of
tilting exists!
Ring eyelets are provided for crane transport.
Attention!
For crane transport all four ring eyelets have to be used!
The angle between the ropes or chains should not exceed
45o! Pay attention for the weight of the unit (fig. 6-1)!
fig. 6-1: crane transport
Achtung!
Beim Verfahren der Anlage mit Hand, ist die Gefahr durch Berührung mit den freistehenden
Rädern zu beachten!

6.4.2 Mains connection

The cooling unit is supplied with the ready installed mains cable (4 x 1.5 mm2, 5 m long) and mains
plug (CEE- 16A). The connection to the mains has to be carried out through a wall-mounted power
switch with a suitable wall socket for the power cable plug. Arrange the mains fuses before the
power switch (according to chapter “Technical data of cooling unit").

6.5 Filling up the coolant

The filler neck is placed on the upper side of the KWE 360. Screw off the filler cap by lefthand turn.
The tank capacity amounts at least 20 l up to maximum 50 l. The filling level can be checked visually
and must be at least over the swimming switch. Close the tank with the filler cap after that.

The coolant has to be filled up before the plasma torch is connected (air extraction of the pump).

For operation at temperatures below 0oC the use of antifreezer “Kjellfrost -15” (resists freezing up to
-15oC) or “Kjellfrost -25” (resists freezing up to -25oC) is recommended. These coolants are
protecting the life time of pump, packings and increasing of the useful life the cooling channels of the
plasma torch additionally.

Attention! No water should be added to those coolants (formation of acid)!

When using the hose parcel PZL-H 360 for the extension of the operation radius, it is necessary that
the coolant is checked before the unit is put into operation. Perhaps the missing coolant must be
refilled.

It comes to loss of coolant during the replacement of consumables or torches. Therefor the coolant
has to be refilled up to the end of the fluid level display weekly. After 12 month the complete coolant
has to be replaced (depending on the working conditions).

Z 0023 - 01.04.2006 - page 6-3 - Kjellberg Finsterwalde

6.5.1 Connection of the cooling unit with the plasma machine of Kjellberg

The coolant hoses and the 4pole control cable, which are included in delivery, connect the cooling
unit with the plasma machine. Pay attention, that the connections are straight and are free of kink.

The control cable is plugged in the installed socket at the cooling unit and locked. The other end is
plugged in the socket X133 at the plasma machine.

The blue marked hose has to be linked with the blue outlet (SYMBOL) of the cooling unit and with
the blue inlet (SYMBOL) of the plasma machine.

The red marked hose has to be linked with the red inlet (SYMBOL) of the cooling unit and with the
red outlet (SYMBOL) of the plasma machine.

Then the ball stop valves have to be opened (locking bolt is adjusted in flow direction).

X133 signal remark

OUTPUTS
1 input of control for KWE 48 V ~
2 input of control for KWE 48 V ~
3 swimming switch
4 swimming switch
5 free
table 6-2: signals of interface

6.5.2 Switching ON of cooling unit

Turn the mains switch S1, which is on the front panel, to “1”. The cooling unit is ready. All further
switching actions and controlling functions are taken by the plasma machine.

6.5.3 Switching OFF of cooling unit

The switching off happens through the adjusting of mains switch S1 to 0. Thereby all function
elements of the cooling unit are switched off.

6.6 Protective facilities

• coolant flow control

- the flow rate of coolant is monitored by the plasma machine:
switches off at a flow rate < 1.6 l/min (little torch head PerCut 370.1) and)
< 3.5 l/min (big torch head PerCut 370.2)
- the pressure of pump is monitored – switching off occurs at < 2 bar
- green LED „cooling circuit o.k.“ OFF (if long extensions are in the circuit it can take 1 min to
have the cooling circuit activated)

• motor circuit breaker

- switches off at overload of the pump
- is again turned on by activating on the back wall (behind the door)

• protection circuit
- the pump is switched off, if the pressure of pump does not exist within 20 seconds or if the
volume flow does not pour after 60 seconds
- the plasma machine must turned off and switched on again, so that the pump can be again
switched on

Z 0023 - 01.04.2006 - page 6-4 - Kjellberg Finsterwalde

6.7 Trouble shooting
If the cooling unit does not work right, the work has to be stopped immediately and the reason has to
be found out.

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 a licensed electrician the unit should be opened (see VDE 0105 or
follow national instructions)!

Attention!
• direction of rotation of the pump
- if the pump turns backward because of wrong phase connection, the current display (19)
of plasma machine shows the error ER41 and the LED signal lamp green “cooling circuit
o.k.” (7)is OFF
- Es müssen zwei Phasen am Netzanschluss getauscht werden.

• protective circuit against dry running condition

- the pump is switched off, if the pressure of pump does not exist within 20 seconds or if the
volume flow does not pour after 60 seconds
- the plasma machine must turned off and switched on again, so that the pump can be
again switched on.

Z 0023 - 01.04.2006 - page 6-5 - Kjellberg Finsterwalde

 Cutting data

for

Plasma cutting machines HiFocus 280i; 360i and 440i

with PGE-360
Torch Technology Material Current Thickness Page

PerCut 370.1 HiFocus mild steel 20 - 50 A 0,5 up to 6 mm A1-2

plus mild steel 60 - 160 A 4 up to 20 mm
HiFocus A1-3
data version 2 HiFinox CrNi-steel 35 - 60 A 1 up to 6 mm A1-4
HiFinox CrNiTi-steel 60 A 1 up to 4 mm A1-5
valid from:
HiFocus F CrNi-steel 130 - 160 A 6 up to 20 mm A1-6
Software-
Version HiFocus Fplus CrNi-steel 130 - 160 A 6 up to 20 mm A1-7
1.6 PGE-360 HiFocus F CrNiTi-steel 130 - 160 A 5 up to 15 mm A1-8
plus CrNiTi-steel 130 - 160 A 5 up to 15 mm
HiFocus F A1-9
HiFocus aluminium 35 - 50 A 1 up to 8 mm A1-10
HiFocus F aluminium 130 - 160 A 6 up to 25 mm A1-11
marking mild steel + CrNi-steel A1-12
Consumables of PerCut 370.1 A1-13

PerCut 370.2 HiFocus plus mild steel 120 - 360 A 3 up to 75 mm A1-14

HiFocus F CrNi-steel 230 - 280 A 15 up to 70 mm A1-15
data version 2 HiFocusplus CrNi-steel 360 - 440 A 20 up to 100 mm A1-16
HiFocus F CrNiTi-steel 280 A 15 up to 40 mm A1-17
valid from: plus
HiFocus CrNiTi-steel 360 - 440 A 20 up to 40 mm A1-18
Software-
Version HiFocus F Aluminium 250 - 280 A 16 up to 80 mm A1-19
plus
1.6 PGE-360 HiFocus Aluminium 360 - 440 A 20 up to 100 mm A1-20
marking mild steel + CrNi- steel A1-21
marking CrNi-steel A1-22
Consumables of PerCut 370.2 A1-23

- page A1-1 -
torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 1.0330 / St-12 (up to 3,0 mm) HiFocus - mild steel (0,5 up to 5 mm) (20-50 A) data version: 2

material: 1.0037 / St-37 (up to 4,0 mm) plasma gas O2 with swirl gas O2 and Air
swirl ZG PG WG1 WG 2 cutting down
gas cutting nozzle gas nozzle ignition cutting gas swirl gas ignition pierce pierce cutting cutting cutting speed kerf slope
thickness set current cap cap gas: Air O2 O2 Air height height time height voltage quality speed maximum quality in
[mm] [A] [ bar ] [ bar/scales division [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [m/min] [mm] [ms]
0,5 C-1 20 S2006X Z4015 S3004 5,2 5,0 / 10 ---- 2,5 2,5 0 2,0 108 4,00 5,00 6,00 1,2 4
1 C-1 20 S2006X Z4015 S3004 5,2 5,0 / 10 ---- 2,5 2,5 0 2,0 110 3,50 4,50 5,50 1,3 4
1,5 C-1 25 S2006X Z4020 S3004 5,3 5,0 / 10 ---- 3,0 3,0 0 2,0 116 3,00 3,80 4,50 1,4 4
marking L-1 5 S2006X Z4020 S 3004 ---- ---- ---- 2,5 2,5 0 2,0 72 4,00 ---- ---- 0,0 4
1 C-2 35 S2007X Z4020 S 3004 5,0 5,0 / 15 5,0 / 5 2,5 2,5 0 2,0 108 2,00 ---- ---- 1,2 30
1,5 C-2 35 S2007X Z4020 S 3004 5,0 5,0 / 15 5,0 / 5 3,0 3,0 0 2,0 112 1,60 ---- ---- 1,5 30

adjusted internaly
2 C-2 35 S2007X Z4020 S 3004 5,0 5,0 / 17 5,0 / 5 3,0 3,0 0,1 2,0 114 1,50 ---- ---- 1,6 30
3 C-2 35 S2007X Z4020 S 3004 5,0 5,0 / 18 5,0 / 5 3,5 3,5 0,1 2,0 113 1,20 ---- ---- 1,7 30
4 C-2 35 S2007X Z4020 S 3004 5,0 5,0 / 18 5,0 / 5 4,0 4,0 0,1 2,5 119 0,90 ---- ---- 1,8 30
5 C-2 35 S2007X Z4020 S 3004 5,0 5,0 / 18 5,0 / 5 4,0 5,0 0,2 2,5 120 0,80 ---- ---- 1,9 30
marking L-2 5 S2007X Z4020 S 3004 ---- ---- ---- 2,5 2,5 0 2,0 72 3,00 ---- ---- 0,0 4
3 C-2 50 S2008X Z4020 S3004 5,0 5,0 / 18 5,0 / 5 3,5 3,5 0,1 2,5 116 1,80 2.20 ---- 1,7 50
4 C-2 50 S2008X Z4020 S3004 5,0 5,0 / 18 5,0 / 5 4,0 4,0 0,1 2,5 119 1,30 1,50 ---- 1,9 50
5 C-2 50 S2008X Z4020 S3004 5,0 5,0 / 18 5,0 / 5 4,0 4,0 0,2 2,5 120 1,00 1,20 ---- 2,0 50
6 C-2 50 S2008X Z4020 S3004 5,0 5,0 / 18 5,0 / 5 4,0 4,0 0,2 3,5 125 0,75 ---- ---- 2,1 50
marking L-2 5 S2008X Z4020 S 3004 ---- ---- ---- 2,5 2,5 0 2,0 72 2,50 ---- ---- 0,0 4

torch parts: hints:

- adjust inlet pressure:
11.01 cathode S 002Y .11.843.021.320 ZG - Air / 8,5 bar
11.02 gas guide Z 101 .11.835.221.153 PG - O2 / 11 up to 12 bar
11.03 nozzle S 2006X .11.843.021.406 WG - Air / 5,0 bar
S 2007X .11.843.021.407 - adjust outlet pressure and technology data acc. to table
S 2008X .11.843.021.408 - press the switch "gas test" for adjusting of the volume flow
11.04 nozzle cap DK S 3004 .11.842.401.160 - adjust the pierce delay at the profile cutting machine
11.05 swirl gas cap Z 4015 .11.835.201.1561 - beard appendix is possible at speed reduction in contours and in dependence of material
(WGK) Z 4020 .11.835.201.1571 - cutting parameters and results may differ because of material composition, material
11.06 protection cap Z501 .11.835.201.081 surface and shape of workpiece.
- the compliance of the determined cutting distance is very important. The set cutting
voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
position of selector switch - the best cutting qualities (referring to beard appendix, cutting angles, cutting edges) are
on frontage of HiFocus
achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
consequence of cutting angle displacements and beard appendix.
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.
3 4
2
1

up-slope

- page A1- 2 - Kjellberg Finsterwalde

torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 1.0037 / St-37 HiFocus PLUS - mild steel (4 up to 20 mm) (60-160 A) data version: 2

Plasmagas O2 with swirl gas N2

swirl ZG PG WG1 WG 2 cutting down
gas cutting nozzle gas nozzle ignition cutting gas swirl gas ignition pierce pierce cutting cutting cutting speed kerf slope
thickness set current cap cap gas: Air O2 N2 height height time height voltage quality speed maximum quality in
[mm] [A] [ bar ] [ bar/scales division ] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [m/min] [mm] [ms]
4 C-8 60 S2008X Z4020 S3028 8,0 5,0 / 60 ---- 3,5 3,5 0,2 2 - 2,5 125 2,60 3,20 4,00 1,6 50
5 C-8 60 S2008X Z4020 S3028 8,0 5,0 / 45 ---- 4,0 4,0 0,3 2,5 - 3 126 2,40 3,00 3,50 1,6 50
6 C-8 60 S2008X Z4020 S3028 8,0 5,0 / 45 ---- 4,5 4,5 0,4 2,5 - 3 130 2,00 2,40 3,00 1,7 50
8 C-8 60 S2008X Z4020 S3028 8,0 5,0 / 45 ---- 4,5 4,5 0,6 3,0 132 1,60 1,90 2,20 1,8 50
marking L-8 5 S2008X Z4020 S3028 ---- ---- ---- 2,5 2,5 0,0 2,0 72 2,50 ---- ---- 0,0 4
6 C-8 90 S2010X Z4022 S3028 9,5 6,0 / 65 ---- 4,0 4,0 0,2 2,0 125 3,00 3,40 4,50 1,7 100
8 C-8 90 S2010X Z4022 S3028 9,3 6,0 / 60 ---- 4,5 4,5 0,3 2,5 127 2,70 3,10 4,00 1,9 100

adjusted internaly
10 C-8 90 S2010X Z4022 S3028 9,3 6,0 / 55 ---- 5,0 5,0 0,4 2,5 128 2,10 2,50 3,00 2,0 100
12 C-8 90 S2010X Z4022 S3028 8,5 6,0 / 45 ---- 5,0 5,0 0,4 3,0 130 1,50 1,80 2,40 2,1 100
marking L-8 6 S2010X Z4022 S3028 ---- ---- ---- 3,0 3,0 0,0 2,0 66 3,00 ---- ---- 0,0 4
6 C-8 130 S2012X Z4025 S3028 9,5 6,0 / 90 ---- 4,0 4,0 0,2 2,0 125 3,60 4,50 5,50 1,9 150
8 C-8 130 S2012X Z4025 S3028 9,5 6,0 / 75 ---- 5,0 5,0 0,3 2,0 126 3,20 3,70 4,50 2,0 150
10 C-8 130 S2012X Z4025 S3028 9,3 6,0 / 65 ---- 5,0 5,0 0,4 2,0 127 2,80 3,20 4,00 2,1 150
12 C-8 130 S2014X Z4025 S3028 9,0 6,0 / 70 ---- 5,0 5,0 0,4 2,5 128 2,10 2,60 3,20 2,2 150
15 C-8 130 S2014X Z4025 S3028 9,0 6,0 / 60 ---- 6,0 6,0 0,5 3,0 129 1,60 1,90 2,30 2,3 150
marking L-8 12 S2014X Z4025 S3028 ---- ---- ---- 3,0 3,5 2,0 0,0 60 3,6 ---- ---- 0,0 4
12 C-8 160 S2016X Z4025 S3028 8,0 5,0 / 60 ---- 5,0 5,0 0.4 3,0 124 2,40 2,80 ---- 2,4 200
15 C-8 160 S2016X Z4025 S3028 10,0 5,0 / 45 ---- 5,0 5,0 0,5 3,5 130 2,00 2,40 ---- 2,6 200
20 C-8 160 S2016X Z4025 S3028 10,0 5,0 / 90 ---- 6,5 9,0 0,6 3,5 144 1,40 1,50 ---- 2,9 200
marking L-8 14 S2016X Z4025 S3028 ---- ---- ---- 3,0 3,0 0,0 2,0 51 3,6 ---- ---- 0,0 4

torch parts: ZG PG PG1 PG2 PG3 WG1 WG2

hints:
12.01 cathode S 002Y .11.843.021.320 - adjust inlet pressure:
12.02 gas guide Z 102 .11.835.221.154
ZG - Air / 8,5 bar
PG - O2 / 11 up to 12 bar
12.03 nozzle S 2008X .11.843.021.408
WG - N2 / 5,0 or 6,0 bar
S 2010X .11.843.021.410
- adjust outlet pressure and technology data acc. to table
S 2012X .11.843.021.412
- press the switch "gas test" for adjusting of the volume flow
S 2014X .11.843.021.414
- adjust the pierce delay at the profile cutting machine
S 2016X .11.843.021.416
- beard appendix is possible at speed reduction in contours and in dependence of material
12.04 nozzle cap DK S 3028 .11.842.401.1624 - cutting parameters and results may differ because of material composition, material
12.05 swirl gas cap Z 4020 .11.835.201.1571 surface and shape of workpiece.
(WGK) Z 4022 .11.835.201.1551 - the compliance of the determined cutting distance is very important. The set cutting
Z 4025 .11.835.201.1581 voltages are approximate values only, because they depend on other conditions too,
12.06 protection cap Z501 .11.835.201.081 for example contact between workpiece and cutting table or length of the hose parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges) are
position of selector switch achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
on frontage of HiFocus
consequence of cutting angle displacements and beard appendix.
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.

2 3 4
1

up-slope

- page A1-3- Kjellberg Finsterwalde

torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 1.4301 CrNi HiFinox - CrNi-steel (1 up to 6 mm) (35-60A) data version: 2

Plasma gas N2H2 with swirl gas N2

ZG PG 2 WG1 (+) WG2 cutting down
gas cutting nozzle swirl nozzle ignition cutting gas swirl gas swirl gas ignition pierce pierce cutting cutting cutting kerf slope
thickness set current gas cap cap Ar N2H2 (95/5)1) N2 N2 height height time height voltage speed quality in
[mm] [A] [ bar / Skt. ] [ bar / Skt. ] [scales division] [mm] [mm] [ sec ] [mm] [V] [m/min] [mm] [ms]
1 C-34 35 S 2007x Z4020 S3008 6,0 / 40 6,0 / 100 100 3,0 3,0 0,0 2,5 125 7,0 1,0 4

adjusted internaly
2 C-33 55 S 2008x Z4020 S3008 8,0 / 50 6,0 / 100 60 3,0 3,0 0,1 2,5 124 4,0 1,4 4
3 C-33 60 S 2008x Z4020 S3008 8,0 / 50 6,0 / 100 60 3,0 3,0 0,1 2,5 138 2,8 2,0 4
4 C-33 60 S 2008x Z4020 S3008 8,0 / 50 6,0 / 100 60 3,0 3,0 0,1 2,5 128 2,6 2,2 4
5 C-33 60 S 2008x Z4020 S3008 9,0 / 52 6,0 / 80 50 3,5 3,5 0,1 2,5 128 2,0 2,4 4
6 C-33 60 S 2008x Z4020 S3008 9,0 / 52 6,0 / 80 50 4,0 4,0 0,2 3,0 134 1,6 2,5 4
marking L-33 6 S 2008x Z4020 S3008 ---- ---- ---- 2,5 2,5 0 2,0 64 0,0 3,0 4
1) forming gas: 95 % N2 and 5 % H2

torch parts:

14.01 cathode S042 .11.842.411.510

14.02 gas guide 0,4 (3x cw) Z101 .11.835.221.153
14.03 nozzle S2007X .11.843.021.407
hints:
- adjust inlet pressure:
S2008X .11.843.021.408
ZG - Ar / 8,0 bar
14.04 nozzle cap / DK S3008 .11.842.401.162
PG2 - N2H2 / 6,0 up to 9,0 bar
14.05 swirl gas cap / WGK Z4020 .11.835.201.1571
WG - N2 / 6,0 bar
14.06 protection cap Z501 .11.835.201.081
- adjust outlet pressure and technology data acc. to table
- press the switch "gas test" for adjusting of the volume flow
- adjust the pierce delay at the profile cutting machine
- beard appendix is possible at speed reduction in contours and in
dependence of material
position of selector switch - cutting parameters and results may differ because of material composition,
on frontage of HiFocus material surface and shape of workpiece.
- the compliance of the determined cutting distance is very important. The set
cutting voltages are approximate values only, because they depend on
other conditions too, for example contact between workpiece and cutting
table or length of the hose parcel.
2 3 4 - the best cutting qualities (referring to beard appendix, cutting angles,
1 cutting edges) are achieved by the cutting speed "quality". Cutting speed
"Speed" and "Max" have the consequence of cutting angle displacements
and beard appendix.
- the designation "Distance" (i.e.: cutting distance) gives the range between
up-slope
workpiece surface and bottom edge of torch.

- page A1-4 - Kjellberg Finsterwalde

torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 1.4571 CrNiTi HiFinox - CrNiTi-steel (1 up to 4 mm) (60A) data version: 2

Plasma gas N2H2 with swirl gas N2

swirl ZG PG 2 WG1 WG2 cutting down
gas cutting nozzle gas nozzle ignition cutting gas swirl gas ignition pierce pierce cutting cutting cutting kerf slope
thickness set current cap cap gas: Ar N2H2 (95/5)1) N2 N2 height height time height voltage speed quality in
[mm] [A] [ bar/scales division ] [scales division] [mm] [mm] [ sec ] [mm] [V] [m/min] [mm] [ms]
1 C-33 60 S 2009x Z4020 S3008 9,5 / 45 8,0 / 90 70 3,0 3,0 0,0 2,0 141 5,0 1,0 4

adjusted internaly
1,5 C-33 60 S 2009x Z4020 S3008 9,5 / 45 8,0 / 90 70 3,0 3,0 0,1 2,0 142 4,5 1,1 4
2 C-33 60 S 2009x Z4020 S3008 9,5 / 45 8,0 / 90 70 3,0 3,0 0,1 2,0 143 4,0 1,2 4
3 C-33 60 S 2009x Z4020 S3008 9,5 / 45 8,0 / 90 70 3,5 3,5 0,2 2,5 144 3,6 1,3 4
4 C-33 60 S 2009x Z4020 S3008 9,5 / 45 8,0 / 90 70 4,0 4,0 0,2 3,0 152 3,4 1,5 4
marking L-33 6 S 2009x Z4020 S3008 ---- ---- ---- 2,5 2,5 0,0 2,0 61 3,0 0,0 4
1) forming gas: 95 % N2 and 5 % H2

torch parts: hints:

- adjust inlet pressure:
14.01 cathode S042 .11.842.411.510 ZG - Ar / 8,0 bar
14.02 gas guide Z101 .11.835.221.153 PG2 - N2H2 / 9,0 bar
14.03 nozzle S2009X .11.843.021.409 WG - N2 / 6,0 bar
- adjust outlet pressure and technology data acc. to table
14.04 nozzle cap / DK S3008 .11.842.401.162
- press the switch "gas test" for adjusting of the volume flow
14.05 swirl gas cap / WGK Z4020 .11.835.201.1571
- adjust the pierce delay at the profile cutting machine
14.06 protection cap Z501 .11.835.201.081
- beard appendix is possible at speed reduction in contours and in
dependence of material
- cutting parameters and results may differ because of material
position of selector switch
on frontage of HiFocus composition, material surface and shape of workpiece.
- the compliance of the determined cutting distance is very important. The
set cutting voltages are approximate values only, because they depend
on other conditions too, for example contact between workpiece and
cutting table or length of the hose parcel.
2 3 4 - the best cutting qualities (referring to beard appendix, cutting angles,
1 cutting edges) are achieved by the cutting speed "quality". Cutting
speed "Speed" and "Max" have the consequence of cutting angle
displacements and beard appendix.
up-slope - the designation "Distance" (i.e.: cutting distance) gives the range
between workpiece surface and bottom edge of torch.

- page A1-5 - Kjellberg Finsterwalde

torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 1.4301 CrNi HiFocus F - CrNi-steel (6 up to 20 mm) (130-160A) data version: 2

Plasmagas Ar/H2 with swirl gas N2

swirl ZG PG1 PG3 WG1 (+) WG2 cutting down
gas cutting nozzle gas nozzle ignition cutting gas swirl gas ignition pierce pierce cutting cutting cutting kerf slope
thickness set current cap cap gas: Ar Ar H2 N2 N2 height height time height voltage speed quality in
[mm] [A] [ bar/scales division ] [scales division] [mm] [mm] [ sec ] [mm] [V] [m/min] [mm] [ms]
6 C-23 130 S 2516x Z4530 S3008 8,0 / 73 8,0 / 15 6,0 / 100 100 4,0 4,0 0,2 3,0 108 2,00 2,8 4
8 130 S 2516x Z4530 S3008 8,0 / 73 8,0 / 15 6,0 / 100 100 4,0 4,0 0,3 3,0 110 1,60 3,0 4

adjusted internaly
C-23
10 C-23 130 S 2516x Z4530 S3008 8,0 / 73 8,0 / 15 6,0 / 100 100 4,0 4,0 0,4 3,0 114 1,20 3,3 4
12 C-23 130 S 2516x Z4530 S3008 8,0 / 73 8,0 / 15 6,0 / 100 100 4,0 5,0 0,5 3,0 116 1,00 3,4 4
12 C-21 160 S 2518x Z4530 S3008 8,0 / 75 8,0 / 15 6,0 / 100 100 4,0 5,0 0,3 4,0 110 1,10 2,8 4
15 C-21 160 S 2518x Z4530 S3008 8,0 / 75 8,0 / 15 6,0 / 100 100 4,0 6,0 0,4 4,0 116 0,95 3,0 4
18 C-21 160 S 2518x Z4530 S3008 8,0 / 75 8,0 / 15 6,0 / 100 100 5,0 8,0 0,5 4,0 118 0,85 3,3 4
20 C-21 160 S 2518x Z4530 S3008 8,0 / 75 8,0 / 15 6,0 / 100 100 5,0 10,0 0,6 4,0 122 0,70 3,4 4

torch parts:
ZG PG PG1 PG2 PG3 WG1 WG2
hints:
15.01 cathode S052 .11.842.511.510 - adjust inlet pressure:
15.02 gas guide Z111 .11.834.321.153 ZG - Ar / 8,0 bar
15.03 nozzle S2516x .11.843.111.616 PG1 - Ar / 8,0 bar
S2518x .11.843.111.618 PG3 - H2 / 8,0 bar
15.04 nozzle cap / DK S3008 .11.842.401.162 WG - N2 / 6,0 bar
15.05 swirl gas cap / WGK Z4530 .11.835.411.1581
- adjust outlet pressure and technology data acc. to table
- press the switch "gas test" for adjusting of the volume flow
15.06 protection cap Z501 .11.835.201.081
- adjust the pierce delay at the profile cutting machine
- beard appendix is possible at speed reduction in contours and in dependence of
material
position of selector switch - cutting parameters and results may differ because of material composition, material
on frontage of HiFocus surface and shape of workpiece.
- the compliance of the determined cutting distance is very important. The set cutting
voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges)
are achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have
3 4
2 the consequence of cutting angle displacements and beard appendix.
1 - the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.

up-slope

- page A1-6 - Kjellberg Finsterwalde

torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008

material: 1.4301 CrNi HiFocus F PLUS - CrNi-steel (6 up to 20 mm) (130-160A) data version: 2

Plasma gas Ar/H2 with swirl gas N2

swirl ZG PG1 PG3 WG1 WG2 cutting cutting down
thickness gas cutting nozzle
gas nozzleignition gas cutting gas cutting gas swirl gas swirl gas ignition pierce pierce cutting cutting speed kerf slope
set currrent cap cap Ar Ar H2 N2 N2 height height time height voltage quality max quality in
[mm] [A] [ bar / Skt. ] [ bar / Skt. ] [ bar / Skt. ][ scale division. [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [mm] [ms]
6 C-23 130 S 2516x Z4530 S3028 8,0 / 70 8,0 / 10 6,0 / 90 / + 60 4,0 4,0 0,2 2,5 107 1,50 2,00 2,40 4
8 C-23 130 S 2516x Z4530 S3028 8,0 / 70 8,0 / 10 6,0 / 90 / + 30 4,0 4,0 0,3 2,5 109 1,30 1,80 2,50 4
10 130 S 2516x Z4530 S3028 8,0 / 70 8,0 / 10 6,0 / 90 / + 30 4,5 4,5 0,4 2,5 112 1,15 2,00 2,80 4

adjusted internaly
C-23
12 C-21 130 S 2516x Z4535 S3018 8,0 / 60 8,0 / 60 6,0 / 90 60 4,5 4,5 0,5 3,0 140 1,00 1,60 3,00 4
marking L-23 14 S 2516x Z4530 S3008 ---- ---- ---- ---- 3,5 3,5 0,0 2,5 54 3,00 ---- 0,00 4
12 C-21 160 S 2518x Z4535 S3028 8,0 / 60 8,0 / 50 6,0 / 90 70 5,0 6,0 0,4 4,0 133 1,20 1,90 3,20 4
15 C-21 160 S 2518x Z4545 S3018 8,0 / 75 8,0 / 35 6,0 / 90 80 5,0 6,0 0,5 4,0 121 1,05 1,40 3,30 4
18 C-21 160 S 2518x Z4545 S3018 8,0 / 75 8,0 / 35 6,0 / 90 70 5,0 8,0 0,6 4,5 123 0,90 1,10 3,40 4
20 C-21 160 S 2518X Z4545 S3018 8,0 / 75 8,0 / 35 6,0 / 90 70 5,0 10,0 0,7 5,0 128 0,78 0,90 3,50 4
marking L-21 16 S 2518X Z4530 S3008 ---- ---- ---- ---- 3,5 3,5 0,0 2,5 52 3,00 ---- 0,00 4

torch parts: ZG PG PG1 PG2 PG3 WG1 WG2

hints:
- adjust inlet pressure:
16.01 cathode S052 .11.842.511.510 ZG - Ar / 8,0 bar
16.02 gas guide Z111 .11.834.321.153 PG1 - Ar / 8,0 bar
16.03 nozzle S2516x .11.843.111.616 PG3 - H2 / 7,7 up to 8,0 bar
S2518x .11.843.111.618 WG - N2 / 6,0 bar
- adjust outlet pressure and technology data acc. to table
16.04 nozzle cap/ DK S3008 .11.842.401.162
- press the switch "gas test" for adjusting of the volume flow
S3018 .11.842.401.1621
- adjust the pierce delay at the profile cutting machine
S3028 .11.842.401.1622
- beard appendix is possible at speed reduction in contours and in dependence of
16.05 swirl gas cap/ WGK Z4530 .11.835.411.1581
material
Z4535 .11.835.411.1580 - cutting parameters and results may differ because of material composition, material
Z4540 .11.835.411.1591 surface and shape of workpiece.
Z4545 .11.835.411.1590 - the compliance of the determined cutting distance is very important. The set cutting
16.06 protection cap Z501 .11.835.201.081 voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
position of selector switch - the best cutting qualities (referring to beard appendix, cutting angles, cutting edges) are
on frontage of HiFocus achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
consequence of cutting angle displacements and beard appendix.
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.

3 4
2
1

up-slope

- page A1-7 - Kjellberg Finsterwalde

torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i gültig ab: 01.04.2008

material: 1.4571 CrNiTi HiFocus F - CrNiTi-steel (5 up to 15 mm) (130-160A) Datenversion: 1

plasma gas Ar/H 2 with swirl gas N 2

swirl ZG PG1 PG3 WG1 WG2 cutting speed cutting down
thickness gas cutting nozzle gas nozzle ignition gas cutting gas cutting gas swirl gas swirl gas ignition pierce pierce cutting cutting kerf slope
set currrent cap cap Ar Ar H2 N2 N2 height height time height voltage quality max quality in
[mm] [A] [ bar / Skt. ] [ bar / Skt. ] [ bar / Skt. ] [ Skt. ] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [mm] [ms]
5 C-21 130 S 2516x Z4530 S3008 8,0 / 40 8,0 / 30 6,0 / 90 60 3,5 3,5 0,2 2,0 120 2,50 3,70 2,30 4
6 C-21 130 S 2516x Z4530 S3008 8,0 / 40 8,0 / 30 6,0 / 90 60 4,0 4,0 0,2 2,0 122 2,00 3,00 2,50 4
8 C-21 130 S 2516x Z4530 S3008 8,0 / 40 8,0 / 30 6,0 / 90 60 4,0 4,0 0,3 2,0 124 1,60 2,50 2,60 4

adjusted internaly
10 C-21 130 S 2516x Z4535 S3008 8,0 / 40 8,0 / 40 6,0 / 90 60 4,0 4,0 0,3 2,5 128 1,20 2,10 2,70 4
12 C-21 130 S 2516x Z4535 S3008 8,0 / 40 8,0 / 40 6,0 / 90 50 4,0 4,0 0,3 2,5 131 1,00 1,50 2,80 4
15 C-21 130 S 2516x Z4540 S3008 8,0 / 40 8,0 / 40 6,0 / 90 50 4,0 5,0 0,4 2,5 134 0,85 1,10 3,20 4
marking L-21 14 S 2516x Z4530 S3008 ---- ---- ---- ---- 3,5 3,5 0,0 2,5 54 3,00 ---- 0,00 4
10 C-21 160 S 2518x Z4530 S3008 8,0 / 65 8,0 / 40 6,0 / 90 90 4,0 6,0 0,5 4,0 120 1,50 2,30 2,90 4
12 C-21 160 S 2518x Z4530 S3008 8,0 / 65 8,0 / 40 6,0 / 90 70 4,0 4,0 0,2 4,0 123 1,25 1,80 3,10 4
15 C-21 160 S 2518x Z4530 S3008 8,0 / 65 8,0 / 40 6,0 / 90 50 5,0 8,0 0,4 4,0 127 1,00 1,35 3,30 4
marking L-21 16 S 2518x Z4530 S3008 ---- ---- ---- ---- 3,5 3,5 0,0 2,5 52 3,00 ---- 0,00 4

hints:
torch parts: - adjust inlet pressure:
ZG - Ar / 8,0 bar
15.01 cathode S052 .11.842.511.510 ZG PG PG1 PG2 PG3 WG1 WG2 PG1 - Ar / 8,0 bar
15.02 gas guide Z111 .11.834.321.153 PG3 - H2 / 8,0 bar
15.03 nozzle S2516x .11.843.111.616 WG - N2 / 6,0 bar
S2518x .11.843.111.618 - adjust outlet pressure and technology data acc. to table
15.04 nozzle cap / DK S3008 .11.842.401.162 - press the switch "gas test" for adjusting of the volume flow
15.05 swirl gas cap /WGK Z4530 .11.835.411.1581 - adjust the pierce delay at the profile cutting machine
Z4535 .11.835.411.1580 - beard appendix is possible at speed reduction in contours and in dependence of material
- cutting parameters and results may differ because of material composition, material
Z4540 .11.835.411.1581
surface and shape of workpiece.
15.06 protection cap Z501 .11.835.201.081
- the compliance of the determined cutting distance is very important. The set cutting
voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges) are
position of selector switch achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
on frontage of HiFocus consequence of cutting angle displacements and beard appendix.
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.

2 3 4
1

up-slope

- page A1-8 - Kjellberg Finsterwalde

torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 1.4571 CrNiTi HiFocus F - CrNiTi-steel (5 up to 25 mm) (130-160A) data version: 2

Plasma gas Ar/H2 with swirl gas N2

swirl ZG PG1 PG3 WG1 WG2 cutting speed cutting down
thickness gas cutting nozzle gas nozzle ignition gas cutting gas cutting gas swirl gas swirl gas ignition pierce pierce cutting cutting kerf slope
set currrent cap cap Ar Ar H2 N2 N2 height height time height voltage quality max quality in
[mm] [A] [ bar / Skt. ] [ bar / Skt. ] [ bar / Skt. ] [ Skt. ] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [mm] [ms]
5 C-21 130 S 2516x Z4530 S3028 8,0 / 40 8,0 / 30 6,0 / 70 30 3,5 3,5 0,2 2,0 116 2,00 3,70 2,60 4
6 C-21 130 S 2516x Z4530 S3028 8,0 / 40 8,0 / 30 6,0 / 70 20 4,0 4,0 0,2 2,0 118 1,80 3,00 2,70 4
8 C-21 130 S 2516x Z4530 S3028 8,0 / 40 8,0 / 30 6,0 / 70 20 4,0 4,0 0,3 2,0 120 1,55 2,40 2,70 4

adjusted internaly
10 C-21 130 S 2516x Z4535 S3028 8,0 / 40 8,0 / 40 6,0 / 70 30 4,0 4,0 0,3 2,5 128 1,20 2,10 2,80 4
12 C-21 130 S 2516x Z4535 S3028 8,0 / 45 8,0 / 50 6,0 / 80 30 4,0 5,0 0,4 2,5 132 1,10 1,60 2,90 4
marking L-21 14 S 2516x Z4530 S3008 ---- ---- ---- ---- 3,5 3,5 0,0 2,5 54 3,00 ---- 0,00 4
8 C-21 160 S 2516x Z4535 S3028 8,0 / 65 8,0 / 40 6,0 / 90 90 4,0 6,0 0,5 3,0 120 0,90 2,60 2,70 4
10 C-21 160 S 2518x Z4535 S3028 8,0 / 65 8,0 / 40 6,0 / 90 80 4,0 4,0 0,2 3,5 123 1,20 2,30 2,90 4
12 C-21 160 S 2518x Z4535 S3028 8,0 / 65 8,0 / 40 6,0 / 90 70 4,0 5,0 0,3 3,5 125 1,00 1,80 3,10 4
15 C-21 160 S 2518x Z4535 S3028 8,0 / 65 8,0 / 40 6,0 / 90 60 5,0 8,0 0,4 3,5 127 0,75 1,35 3,30 4
marking L-21 16 S 2518x Z4530 S3008 ---- ---- ---- ---- 3,5 3,5 0,0 2,5 52 3,00 ---- 0,00 4

torch parts:

15.01 cathode S052 .11.842.511.510

15.02 gas guide Z111 .11.834.321.153 ZG PG PG1 PG2 PG3 WG1 WG2
hints:
15.03 nozzle S2516x .11.843.111.616 - adjust inlet pressure:
S2518x .11.843.111.618
ZG - Ar / 8,0 bar
PG1 - Ar / 8,0 bar
15.04 nozzle cap / DK S3028 .11.842.401.1622
PG3 - H2 / 8,0 bar
15.05 swirl gas cap /WGK Z4530 .11.835.411.1581
WG - N2 / 6,0 bar
Z4535 .11.835.411.1580
- adjust outlet pressure and technology data acc. to table
15.06 protection cap Z501 .11.835.201.081
- press the switch "gas test" for adjusting of the volume flow
- adjust the pierce delay at the profile cutting machine
position of selector switch - beard appendix is possible at speed reduction in contours and in dependence of material
on frontage of HiFocus - cutting parameters and results may differ because of material composition, material
surface and shape of workpiece.
- the compliance of the determined cutting distance is very important. The set cutting
voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges) are
3 achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
2 4
consequence of cutting angle displacements and beard appendix.
1
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.

up-slope

- page A1-9 - Kjellberg Finsterwalde

torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 3.3536 AlMg HiFocus - Aluminium (1 up to 8 mm) (35-50A) data version: 2

Plasma gas Air with swirl gas N2

swirl ZG PG WG1 WG2 cutting down
gas cutting nozzle gas nozzle ignition cutting gas swirl gas ignition pierce pierce cutting cutting cutting kerf slope
thickness set current cap cap gas: Air Air N2 N2 height height time height voltage speed quality in
[mm] [A] [ bar ] [ bar / scales division ] [mm] [mm] [ sec ] [mm] [V] [m/min] [mm] [ms]
1 C-16 35 S2007x Z 4020 S3004 5,5 6,0 / 95 ----- 3,0 3,0 0,1 2,0 135 3,9 1,6 30
2 C-16 35 S2007x Z 4020 S3004 5,5 6,0 / 95 ----- 3,0 3,0 0,1 2,0 136 2,6 1,8 30

adjusted internaly
3 C-16 35 S2007x Z 4020 S3004 5,5 6,0 / 95 ----- 3,0 3,0 0,1 2,0 138 2,4 1,8 30
4 C-16 35 S2007x Z 4020 S3004 5,5 6,0 / 95 ----- 3,5 3,5 0,1 2,0 140 1,8 1,8 30
4 C-16 45 S2008x Z 4020 S3004 5,5 6,0 / 95 ----- 3,5 3,5 0,1 2,0 140 2,0 2,2 50
5 C-16 50 S2008x Z 4020 S3004 6,0 6,0 / 85 ----- 3,5 3,5 0,2 2,0 142 1,6 2,2 50
6 C-16 50 S2008x Z 4020 S3004 6,0 6,0 / 85 ----- 3,5 3,5 0,2 2,0 142 1,3 2,2 50
8 C-16 50 S2008x Z 4020 S3004 6,5 6,0 / 85 ----- 3,5 3,5 0,2 2,0 146 1,1 2,5 50

torch parts:
11.01 cathode S 002Y .11.843.021.320 hints:
11.02 gas guide Z101 .11.835.221.153 - adjust inlet pressure:
11.03 nozzle S2007x .11.843.021.407 ZG - Air / 8,5 bar
S2008x .11.843.021.408 PG - Air / 8,0 bar
11.04 nozzle cap / DK S3004 .11.842.401.160 WG1 - N2 / 6,0 bar
11.05 swirl gas cap /WGK Z4020 .11.835.201.1571 - adjust outlet pressure and technology data acc. to table
11.06 protection cap Z501 .11.835.201.081 - press the switch "gas test" for adjusting of the volume flow
- adjust the pierce delay at the profile cutting machine
- beard appendix is possible at speed reduction in contours and in dependence of
material
- cutting parameters and results may differ because of material composition, material
surface and shape of workpiece.
position of selector switch - the compliance of the determined cutting distance is very important. The set cutting
on frontage of HiFocus voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges)
are achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have
3 the consequence of cutting angle displacements and beard appendix.
2 4
1
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.

up-slope

- page A1-10 - Kjellberg Finsterwalde

torch: PerCut 370.1 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 3.3536 AlMg HiFocus F - Aluminium (6 up to 25 mm) (130-160A) data version: 2

Plasma gas Ar/H2 with swirl gas N2

swirl ZG PG1 PG3 WG1 WG2 cutting down
gas cutting nozzle gas nozzle ignition cutting gas swirl gas ignition pierce pierce cutting cutting cutting speed * kerf slope
thickness set current cap cap gas: Ar Ar H2 N2 N2 height height time height voltage quality speed max quality
[mm] [A] [ bar / scales division ] [scale div.] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [m/min] [mm] [ms]
6 C-21 130 S 2516x Z4530 S3008 8,0 / 70 8,0 / 40 6,0 / 90 70 4,0 4,0 0,1 2,0 121 3,20 4,50 6,50 2,30 4
8 C-21 130 S 2516x Z4530 S3008 8,0 / 70 8,0 / 40 6,0 / 90 70 4,0 4,0 0,2 2,0 124 2,20 3,50 5,50 2,40 4

adjusted internaly
10 C-21 130 S 2516x Z4530 S3008 8,0 / 70 8,0 / 40 6,0 / 90 60 4,5 6,0 0,3 2,5 127 1,60 3,00 4,50 2,70 4
12 C-21 130 S 2516x Z4530 S3008 8,0 / 70 8,0 / 40 6,0 / 90 60 4,5 6,0 0,4 3,0 131 1,40 2,50 4,00 2,80 4
16 C-21 130 S 2516x Z4530 S3008 8,0 / 70 8,0 / 40 6,0 / 90 50 4,5 8,0 0,5 3,0 133 1,00 1,80 2,70 3,00 4
12 C-21 160 S 2518x Z4530 S3008 8,0 / 75 8,0 / 45 6,0 / 90 60 5,0 7,0 0,3 4,0 129 1,90 2,40 3,30 2,40 4
15 C-21 160 S 2518x Z4535 S3008 8,0 / 75 8,0 / 45 6,0 / 90 90 5,0 8,0 0,4 4,0 131 1,40 2,00 2,80 2,80 4
20 C-21 160 S 2518XZ4535 S3008 8,0 / 75 8,0 / 45 6,0 / 90 80 5,0 10,0 0,5 4,0 134 1,10 1,70 2,30 3,00 4
25 C-21 160 S 2518x Z4540 S3008 8,0 / 75 8,0 / 45 6,0 / 90 80 5,0 12,0 0,6 4,5 137 0,80 1,10 1,50 3,30 4

hints:
torch parts: ZG PG PG1 PG2 PG3 WG1 WG2 - adjust inlet pressure:
ZG - Ar / 8,0 bar
15.01 cathode S052 .11.842.511.510 PG1 - Ar / 8,0 bar
15.02 gas guide Z111 .11.834.321.153 PG3 - H2 / 8,0 bar
15.03 nozzle S2516x .11.843.111.616 WG - N2 / 6,0 bar
S2518x .11.843.111.618 - adjust outlet pressure and technology data acc. to table
15.04 nozzle cap / DK S3008 .11.842.401.162 - press the switch "gas test" for adjusting of the volume flow
15.05 swirl gas cap / WGK Z4530 .11.835.411.1581 - adjust the pierce delay at the profile cutting machine
Z4535 .11.835.411.1580 - beard appendix is possible at speed reduction in contours and in dependence of
Z4540 .11.835.411.1591 material
15.06 protection cap Z501 .11.835.201.081
- cutting parameters and results may differ because of material composition, material
surface and shape of workpiece.
- the compliance of the determined cutting distance is very important. The set cutting
position of selector switch voltages are approximate values only, because they depend on other conditions too,
on frontage of HiFocus for example contact between workpiece and cutting table or length of the hose
parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges)
are
achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
consequence of cutting angle displacements and beard appendix.
3 4 - the designation "Distance" (i.e.: cutting distance) gives the range between
2
1 workpiece
surface and bottom edge of torch.

up-slope

- page A1-11 - Kjellberg Finsterwalde

 Marking data HiFocus 280i, 360i and 440i
torch: PerCut 370.1 Marking of mild steel and CrNi-steel valid from: 21.04.2008
Marking gas Argon data version: 2

WG1 ( bar / scales division )

Upslope / switch position

material thickness (mm)

cutting speed (mm/min)

ignition height (mm)
range of technology

cutting height (mm)

pierce height (mm)

cutting current (A)

cutting voltage (V)

cutting kerf (mm)

ZG (ignition gas)
swirl gas nozzle

downslope (ms)
protection cap

pierce time (s)

swirl gas cap
cooling tube

nozzle cap
gas guide

comment
material

cathode
gas set

nozzle

L-1 1.0037 St37 0 5 S901 S002 Z101 S2006X S3004 Z4020 Z501 1 marking Ar --- 2,5 2,0 2,5 0 72 4000 0 1 4
L-2 1.0037 St37 0 5 S901 S002 Z101 S2007X S3004 Z4020 Z501 1 marking Ar --- 2,5 2,0 2,5 0 72 3000 0 1 4
L-2 1.0037 St37 0 5 S901 S002 Z101 S2008X S3004 Z4020 Z501 1 marking Ar --- 2,5 2,0 2,5 0 72 2500 0 1 4
L-8 1.0037 St37 0 5 S901 S002 Z102 S2008X S3028 Z4020 Z501 1 marking Ar --- 2,5 2,0 2,5 0 72 2500 0 1 4
L-8 1.0037 St37 0 6 S901 S002 Z102 S2010X S3028 Z4022 Z501 1 marking Ar --- 3,0 2,0 3,0 0 66 3000 0 1 4
L-8 1.0037 St37 0 12 S901 S002 Z102 S2014X S3028 Z4030 Z501 2 marking Ar --- 3,0 2,0 3,5 0 60 3600 0 1 4
L-8 1.0037 St37 0 14 S901 S002 Z102 S2016X S3028 Z4025 Z501 2 marking Ar --- 3,0 2,0 3,5 0 51 3600 0 1 4
L-34 1.4301 CrNi 0 6 S901 S042 Z101 S2007X S3008 Z4025 Z501 1 marking Ar --- 2,5 2,0 2,5 0 65 3600 0 1 4
L-33 1.4301 CrNi 0 6 S901 S042 Z101 S2008X S3008 Z4020 Z501 1 marking Ar --- 2,5 2,0 2,5 0 64 3000 0 1 4
L-33 1.4571 CrNiTi 0 6 S901 S042 Z101 S2009X S3008 Z4020 Z501 1 marking Ar --- 2,5 2,0 2,5 0 61 3000 0 1 4
L-23 1.4301 CrNi 0 14 S901 S052 Z111 S2516X S3008 Z4530 Z501 2 marking Ar --- 3,5 2,5 3,5 0 54 3000 0 1 4
L-21 1.4571 CrNiTi 0 14 S901 S052 Z111 S2516 S3008 Z4530 Z501 2 Markieren Ar --- 3,5 2,5 3,5 0 54 3000 0 1 4
L-21 1.4301 CrNi 0 16 S901 S052 Z111 S2518X S3008 Z4530 Z501 2 marking Ar --- 3,5 2,5 3,5 0 52 3000 0 1 4

position of selector
switch on frontage of HiFocus

3 4
2
1

up-slope
2)

1)

1) change from the CUTTING to the MARKING at the PGE-360

2) Then the display 'gas set' changes from the cutting-set C-** to the marking-set L-**.

Note:
- piercing delay is adjusted at the profile-cutting-machine
- don't enlarge the ignition distance
- the parameters for marking vary depending on material and kind of surface.
- the compliance of the determined cutting distance is very important.
- the set cutting voltages are approximate values only, because they depend on other conditions too, for example contact between workpiece and
cutting table or length of the hose parcel.

- page A1-12 - Kjellberg Finsterwalde

consumable overview of the PerCut 370.1

Allocation of thr item numbers (for example 31.02)

to the designations (types) see spare parts list

- page A1-13 - Kjellberg Finsterwalde

 torch: PerCut 370.2 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008

material: 1.0037 / St-37 HiFocus PLUS - mild steel (3 up to 75 mm) (120-360 A) data version: 2

Plasma gas O2 with swirl gas Air und N2

ignition PG WG 1 WG 2 WG 1 WG 2 cutting cutting down
thickness gas cutting gas nozzle nozzle swirl gas cutting gas swirl gas ignition pierce pierce cutting cutting speed kerf slope
set current guide cap gas Air O2 Air Air N2 N2 height height time height voltage quality speed max. quality in
[mm] [A] cap [ bar ] [ 6,0 bar/ Skt. ] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [m/min] [mm] [ms]
3 C-10 120 T 104 T2115 T3030 V 4335 5,0 ---- ---- 90 20 3,0 5,0 0,2 2,0 119 6,00 7,00 8,00 1,6 150
4 C-10 120 T 104 T2115 T3030 V 4335 5,5 ---- ---- 90 50 4,0 6,0 0,2 2,0 122 5,00 6,00 7,50 1,7 150

Air
5 C10 120 T 104 T2115 T3030 V 4335 5,5 ---- ---- 90 50 4,0 6,0 0,3 2,0 124 4,00 5,00 6,00 1,8 150
6 C10 120 T 104 T2115 T3030 V 4335 5,5 ---- ---- 90 50 5,0 6,0 0,3 2,0 126 3,50 4,30 5,00 1,9 150
8 C-10 120 T 104 T2115 T3030 V 4330 6,5 ---- ---- 70 30 6,0 8,0 0.4 2,0 129 3,00 3,50 4,00 2,1 150
10 C-10 120 T 104 T2115 T3030 V 4330 6,5 ---- ---- 70 20 6,0 8,0 0,4 2,0 132 2,50 3,00 3,50 2,3 150
marking L-10 10 T 104 T2115 T3030 V 4335 Ar ----- ----- ----- 10 ----- 2,0 2,0 0,0 2,0 74 3,00 ----- ----- 0,8 4
10 C- 6 200 T 102 T2120 T3045 V 4335 4,8 90 30 ---- ---- 5,0 5,0 0,4 2,5 124 2,70 3,50 4,50 3,3 300
12 C- 6 200 T 102 T2120 T3045 V 4345 5,5 90 30 ---- ---- 6,0 6,0 0,6 3,0 127 2,10 3,00 4,00 3,4 300

Air
15 C- 6 200 T 102 T2120 T3045 V 4345 5,5 90 40 ---- ---- 7,0 15,0 0,8 3,0 131 1,60 2,50 3,00 3,6 300
20 C- 6 200 T 102 T2120 T3045 V 4345 5,5 90 50 ---- ---- 7,0 20,0 1,2 4,0 136 1,35 1,60 2,00 3,8 300
25 C- 6 200 T 102 T2120 T3045 V 4345 5,5 90 50 ---- ---- 8,0 25,0 1,5 5,0 141 1,00 1,30 1,50 4,1 300
marking L- 6 20 T 102 T2120 T3045 V 4335 Ar ----- ----- ----- 20 ----- 2,0 2,0 0,0 2,0 57 3,00 ----- ----- 1,3 4
15 C-10 280 T 101 T2125 T3045 V 4345 5,5 ---- ---- 90 50 6,0 6,0 0,8 3,5 127 2,80 3,60 3,90 3,6 400
20 C-10 280 T 101 T2125 T3045 V 4345 5,5 ---- ---- 90 50 7,0 15,0 1,0 4,0 133 1,80 2,20 2,40 4,1 400
25 C- 6 280 T 101 T2125 T3045 V 4345 5,5 90 50 ---- ---- 7,0 20,0 1,2 4,5 136 1,50 1,70 1,90 4,2 400
HiFocus 280i

Air
30 C- 6 280 T 101 T2125 T3045 V 4345 6,0 90 50 ---- ---- 8,0 25,0 1,5 5,0 144 1,00 1,10 1,20 4,9 400
35 C- 6 280 T 101 T2125 T3045 V 4345 6,5 90 50 ---- ---- 8,0 30,0 2,0 5,5 156 0,70 0,85 0,95 5,0 400
40 C- 6 280 T 101 T2125 T3045 V 4345 6,5 90 50 ---- ---- 8,0 ---- ---- 6,0 164 0,50 0,65 0,75 5,2 400
50 C- 6 280 T 101 T2125 T3045 V 4345 6,5 90 50 ---- ---- 9,0 ---- ---- 7,0 167 0,40 0,45 0,50 5,6 400
60 C- 6 280 T 101 T2125 T3045 V 4350 6,5 90 50 ---- ---- 9,0 ---- ---- 8,0 178 0,20 0,25 0,25 6,1 400
marking L- 6 35 T 101 T2125 T3045 V 4345 Ar ----- ----- ----- 20 ----- 2,0 2,0 0,0 2,0 60 4,00 ----- ----- 1,8 4
20 C- 6 300 T 101 T2127 T3045 V 4345 6,0 90 60 ---- ---- 7,0 20,0 0,9 4,0 130 2,00 2,50 2,80 4,1 500
25 C- 6 300 T 101 T2127 T3045 V 4350 6,0 90 50 ---- ---- 7,0 25,0 1,1 5,0 134 1,50 1,90 2,20 4,4 500
Air
30 C- 6 300 T 101 T2127 T3045 V 4350 6,0 90 50 ---- ---- 8,0 25,0 1,3 5,5 139 1,20 1,40 1,50 5,0 500
40 C- 6 300 T 101 T2127 T3045 V 4350 6,0 90 50 ---- ---- 8,0 30,0 2,0 6,5 147 0,70 0,90 1,10 5,8 500
50 C- 6 300 T 101 T2127 T3045 V 4350 6,0 90 50 ---- ---- 9,0 ---- ---- 7,0 156 0,45 0,50 0,60 6,5 500
60 C- 6 300 T 101 T2127 T3045 V 4350 6,0 90 40 ---- ---- 9,0 ---- ---- 8,0 168 0,27 0,30 0,35 6,7 500
HiFocus 360i

marking L- 6 35 T 101 T2127 T3045 V 4345 Ar ----- ----- ----- 10 ----- 2,0 2,0 0,0 2,0 53 3,50 ----- ----- 1,6 4
40 C- 6 360 T 101 T2130 T3045 V 4345 7,0 90 30 ---- ---- 7,5 30,0 2,0 6,0 146 0,95 1,10 1,20 5,5 500
50 C- 6 360 T 101 T2130 T3045 V 4345 7,0 90 30 ---- ---- 8,0 ---- ---- 6,5 156 0,60 0,70 0,75 6,3 500
Air

60 C- 6 360 T 101 T2130 T3045 V 4350 7,0 90 30 ---- ---- 9,0 ---- ---- 7,0 167 0,35 0,40 0,43 6,9 500
70 C- 6 360 T 101 T2130 T3045 V 4350 7,0 90 50 ---- ---- 9,0 ---- ---- 8,0 185 0,20 0,20 0,25 7,6 500
75 C- 6 360 T 101 T2130 T3045 V 4350 7,0 90 50 ---- ---- 9,0 ---- ---- 8,0 192 ---- ---- 0,15 8,0 500
torch parts: position of selector switch hints:
ZG PG PG1 PG2 PG3 WG1 WG2

31.01 cooling tube T 901 .11.836.901.152 on the frontage of HiFocus - adjust inlet pressure:
31.02 cathode T 012 .11.836.921.300 ZG - Air / 8,5 bar
31.03 gas guide T 101 .11.836.921.153 PG - O2 / 8,5 up to 9,5 bar
T 102 .11.836.921.154 WG - Air / 6,0 bar
3
T 104 .11.836.921.1542 2 4
WG - N2 / 6,0 bar
31.05 nozzle T2115 / 120 A .11.836.921.415 1
T2120 / 200 A .11.836.921.420
- adjust outlet pressure and technology data acc. to table
T2125 / 280 A .11.836.921.425 - press the switch "gas test" for adjusting of the volume flow
T2127 / 300 A .11.836.921.427 - adjust the pierce delay at the profile cutting machine
up-slope
T2130 / 360 A .11.836.921.430 - beard appendix is possible at speed reduction in contours and in dependence of material
31.07 nozzle cap / DK T3030 .11.836.901.163 - cutting parameters and results may differ because of material composition, material
T3045 .11.836.901.164
surface and shape of workpiece.
31.09 swirl gas nozzle T522 .11.836.921.271
31.11 protection cap T502 .11.841.721.081 - the compliance of the determined cutting distance is very important. The set cutting
31.12 swirl gas cap / V4335 .11.833.101.155 voltages are approximate values only, because they depend on other conditions too,
(WGK) V4345 .11.833.101.157 for example contact between workpiece and cutting table or length of the hose parcel.
V4350 .11.833.101.159 - the best cutting qualities (referring to beard appendix, cutting angles, cutting edges) are
achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
consequence of cutting angle displacements and beard appendix.
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.
- page A1-14 - Kjellberg Finsterwalde
 torch: PerCut 370.2 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 1.4301 HiFocus F - CrNi-steel (15 up to 70 mm) (230-280A) data version: 2

Plasma gas ArH2 with swirl gas N2

swirl ignition cutting gas swirl gas cutting cutting
material gas cutting nozzle nozzle gas cap gas PG1 PG2 PG3 WG1+ WG2 ignition pierce pierce cutting cutting speed kerf down
thickness set current cap Ar Ar Ar H2 N2 N2 height height time height voltage quality max. quality slope
[mm] [A] [ bar / Skt. ] [scale div.] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [mm] [ms]
15 C-24 230 T2523 T3000 V 4340 8,0 / 75 ----- 8,0 / 40 8,0 / 90 70 6 15,0 0,8 4,5 132 1,40 1,70 3,6 250
20 C-24 250 T2523 T3000 V 4340 8,0 / 85 ----- 8,0 / 50 8,0 / 90 70 6 20,0 1,2 5,0 141 1,05 1,30 4,0 250
25 C-24 250 T2523 T3000 V 4340 8,0 / 85 ----- 8,0 / 50 8,0 / 90 50 7 25,0 1,5 5,0 144 0,90 1,10 4,1 250
30 C-24 250 T2523 T3000 V 4340 8,0 / 85 ----- 8,0 / 50 8,0 / 90 30 7 30,0 2,0 5,5 147 0,80 0,85 4,2 250
40 C-24 250 T2523 T3000 V 4340 8,0 / 85 ----- 8,0 / 50 8,0 / 90 70 8 ---- ---- 5,5 151 0,55 0,60 4,4 250

adjusted internaly
50 C-24 250 T2523 T3000 V 4350 8,0 / 85 ----- 8,0 / 50 8,0 / 90 70 8 ---- ---- 6,0 158 0,40 0,48 4,8 250
60 C-24 250 T2523 T3000 V 4350 8,0 / 85 ----- 8,0 / 50 8,0 / 90 70 8 ---- ---- 6,5 162 0,28 0,32 5,0 250
70 C-24 250 T2523 T3000 V 4350 8,0 / 85 ----- 8,0 / 50 8,0 / 90 70 8 ---- ---- 7,0 173 ---- 0,15 5,5 250
marking L-24 15 T2523 T3000 V 4340 ----- ----- ----- 8,0 / 30 ----- 4 4,0 0,0 4,0 59 3,50 ----- 1,5 4
20 C-24 280 T2525 T3000 V 4340 8,0 / 90 ----- 8,0 / 50 8,0 / 90 30 6 20,0 1,2 4,5 137 1,20 1,50 3,9 300
25 C-24 280 T2525 T3000 V 4340 8,0 / 90 ----- 8,0 / 50 8,0 / 90 30 6 25,0 1,5 4,5 142 1,00 1,20 4,2 300
HiFocus 280i

30 C-24 280 T2525 T3000 V 4340 8,0 / 90 ----- 8,0 / 50 8,0 / 90 30 7 30,0 2,0 5,0 145 0,82 1,00 4,3 300
40 C-24 280 T2525 T3000 V 4345 8,0 / 90 ----- 8,0 / 50 8,0 / 90 70 8 30,0 2,3 5,5 149 0,58 0,65 4,6 300
50 C-24 280 T2525 T3000 V 4345 8,0 / 90 ----- 8,0 / 50 8,0 / 90 70 8 ---- ---- 6,0 151 0,43 0,48 5,0 300
60 C-24 280 T2525 T3000 V 4350 8,0 / 90 ----- 8,0 / 50 8,0 / 90 70 8 ---- ---- 6,5 161 0,30 0,35 5,2 300
70 C-24 280 T2525 T3000 V 4350 8,0 / 90 ----- 8,0 / 50 8,0 / 90 70 8 ---- ---- 7,5 172 ---- 0,20 5,7 300
marking L-24 18 T2525 T3000 V 4340 ----- ----- ----- 8,0 / 30 ----- 5 5,0 0,0 5,0 57 3,50 ----- 1,6 4

torch parts:
36.01 cooling tube V951 .11.828.911.230 hints:
36.02 cathode T051 .11.836.911.500 - adjust inlet pressure:
36.05 nozzle T2523 .11.836.911.623 ZG - Ar / 8,0 bar
T2525 .11.836.911.625 PG1 - Ar / 8,0 bar
36.07 nozzle cap T3000 .11.836.901.160 PG3 - H2 / 8,0 bar
36.09 swirl gas nozzle T522 .11.836.921.271
WG1 - N2 / 6,0 bar
36.11 protection cap T502 .11.841.721.081
36.12 swirl gas cap / V4340 .11.833.101.156 - adjust outlet pressure and technology data acc. to table
(WGK) V4345 .11.833.101.157 - press the switch "gas test" for adjusting of the volume flow
V4350 .11.833.101.158 - adjust the pierce delay at the profile cutting machine
- beard appendix is possible at speed reduction in contours and in dependence of material
- cutting parameters and results may differ because of material composition, material
position of selector switch surface and shape of workpiece.
on frontage HiFocus
- the compliance of the determined cutting distance is very important. The set cutting
voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges) are
2 3 4
* flying cutting achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
is possible 1
on switch consequence of cutting angle displacements and beard appendix.
position 3
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.
up-slope

- page A1-15 - Kjellberg Finsterwalde

 torch: PerCut 370.2 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008

material: 1.4301 HiFocus Plus - CrNi-steel (20 up to 100 mm) (360-440A) data version: 2

Plasmagas ArH2 with swirl gas N2

swirl ignition cutting gas swirl gas cutting cutting
gas cutting nozzle nozzle gas gas PG1 PG2 PG3 WG1+ WG2 ignition pierce pierce cutting cutting speed kerf down
thickness set current cap cap Ar Ar Ar H2 N2 N2 height height time height voltage quality max. quality slope
[mm] [A] [ bar / Skt. ] [ Skt. ] [ bar / Skt. ] [ Skt. ] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [mm] [ms]
20 C-31 360 T2427 T3219 T4040 8,0 / 60 30 8,0 / 85 6,0 / 90 / + 90 6 15,0 1,2 5,0 142 1,40 1,60 4,3 400
25 C-31 360 T2427 T3219 T4040 8,0 / 70 30 8,0 / 85 6,0 / 90 / + 90 7 20,0 1,5 5,5 144 1,20 1,40 4,5 400
HiFocus 360i

30 C-31 360 T2427 T3219 T4040 8,0 / 70 30 8,0 / 85 6,0 / 90 / + 80 8 25,0 2,0 6,0 150 1,00 1,20 4,7 400
40 C-31 360 T2427 T3219 T4040 8,0 / 70 30 8,0 / 80 6,0 / 90 / + 70 8 30,0 2,5 7,0 154 0,72 0,85 5,3 400
50 C-31 360 T2427 T3209 T4045 8,5 / 70 30 8,0 / 80 6,0 / 90 / + 70 8 ---- ---- 7,0 156 0,52 0,65 5,4 400

adjusted internaly
60 C-31 360 T2427 T3209 T4045 8,5 / 70 35 8,0 / 75 6,0 / 90 / + 70 8 ---- ---- 8,0 159 0,45 0,50 5,7 400
70 C-31 360 T2427 T3209 T4045 8,5 / 70 35 8,0 / 75 6,0 / 90 / + 70 8 ---- ---- 8,0 168 0,30 0,40 6,3 400
80 C-31 360 T2427 T3209 T4045 8,5 / 70 35 8,0 / 70 6,0 / 90 / + 70 8 ---- ---- 8,0 170 0,28 0,32 6,5 400
marking L-31 32 T2427 T3209 T4040 ----- ----- ----- 8,0 / 80 ----- 6 6,0 0,0 6,0 49 4,00 ----- 1,8 4
30 C-31 440 T2429 T3219 T4040 8,5 / 60 30 8,0 / 90 7,0 / 90 / + 90 8 30,0 1,7 8,0 163 1,10 1,30 5,5 400
40 C-31 440 T2429 T3228 T4045 8,5 / 70 35 8,0 / 90 6,0 / 90 / + 50 8 30,0 2,2 8,0 158 0,90 1,00 5,6 400
HiFocus 440i

50 C-31 440 T2429 T3228 T4045 8,5 / 70 35 8,0 / 90 6,0 / 90 / + 70 8 ---- ---- 8,5 160 0,70 0,80 5,7 400
60 C-29 440 T2429 T3208 T4045 8,5 / 70 35 8,0 / 90 6,0 / 90 70 8 ---- ---- 9,0 163 0,55 0,65 5,9 400
70 C-29 440 T2429 T3208 T4050 8,7 / 70 40 8,0 / 80 6,0 / 90 70 8 ---- ---- 10,0 166 0,40 0,45 6,8 400
80 C-29 440 T2429 T3208 T4050 8,7 / 70 40 8,0 / 80 6,0 / 90 70 8 ---- ---- 10,0 170 0,34 0,38 7,3 400
100 C-31 440 T2429 T3208 T4050 8,7 / 70 40 8,0 / 70 6,0 / 90 / + 90 8 ---- ---- 10,0 184 ---- 0,19 7,9 400
marking L-31 35 T2429 T3208 T4040 ----- ----- ----- 8,0 / 90 ----- 7 7,0 0,0 7,0 48 4,50 ----- 1,9 4

torch parts: hints:

37.01 cooling tube V951 .11.828.911.230 - adjust inlet pressure:
37.02 cathode T051 .11.836.911.500 ZG PG PG1 PG2 PG3 WG1 WG2 ZG - Ar / 8,0 bar
37.05 nozzle T2427 .11.846.911.627
PG1 - Ar / 8,0 bar
T2429 .11.846.911.629
PG2 - Ar scale division acc. to table
37.07 nozzle cap / DK T3208 .11.846.901.1608
T3209 .11.846.901.1609 PG3 - H2 / 8,0 bar
T3219 .11.846.901.1619 WG - N2 / 8,0 bar
T3228 .11.846.901.1628 - adjust outlet pressure and technology data acc. to table
37.10 protection cap T503 .11.846.901.081 - press the switch "gas test" for adjusting of the volume flow
37.12 swirl gas cap / WGK T4040 .11.846.901.1540
- adjust the pierce delay at the profile cutting machine
T4045 .11.846.901.1545
- beard appendix is possible at speed reduction in contours and in dependence of
T4050 .11.846.901.1550
material
- cutting parameters and results may differ because of material composition, material
position of selector switch
on the frontage of HiFocus surface and shape of workpiece.
- the compliance of the determined cutting distance is very important. The set cutting
voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
2 3 4 - the best cutting qualities (referring to beard appendix, cutting angles, cutting edges)
1 are achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
consequence of cutting angle displacements and beard appendix.
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.
up-slope

- page A1-16 - Kjellberg Finsterwalde

 torch: PerCut 370.2 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: 1.4571 HiFocus F - CrNiTi-steel (15 up to 40 mm) (280A) data version: 2

Plasma gas ArH2 with swirl gas N2

swirl ignition cutting gas swirl gas cutting cutting
gas cutting nozzle nozzle gas cap gas PG1 PG2 PG3 WG1+ WG2 ignition pierce pierce cutting cutting speed kerf down
thickness set current cap Ar Ar Ar H2 N2 N2 height height time height voltage quality max. quality slope
[mm] [A] [ bar / Skt. ] [ Skt. ] [ bar / Skt. ] [ Skt. ] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [mm] [ms]
HiFocus 280i

15 C-31 280 T2525 T3000 V4340 8,5 / 65 25 8,0 / 90 8,0 / 90 / + 40 6 15,0 0,8 5,0 140 1,70 2,10 4,0 300
20 C-31 280 T2525 T3000 V4340 8,5 / 65 25 8,0 / 90 8,0 / 90 / + 40 6 20,0 1,2 5,0 142 1,40 1,70 4,1 300

internaly
adjusted
25 C-31 280 T2525 T3000 V4345 8,5 / 65 25 8,0 / 90 8,0 / 90 / + 40 6 25,0 1,5 5,5 144 1,10 1,30 4,4 300
30 C-31 280 T2525 T3000 V4345 8,5 / 60 20 8,0 / 100 8,0 / 90 / + 40 7 30,0 2,0 6,0 149 0,90 1,10 4,9 300
40 C-31 280 T2525 T3000 V4345 8,5 / 65 25 8,0 / 80 8,0 / 90 / + 90 8 ----- ----- 7,0 152 0,65 0,78 5,1 300
marking L-31 27 T2525 T3000 V4340 ----- ----- ----- 8,0 / 50 ----- 4 4,0 0,0 4,0 52 3,50 ----- 1,9 4

hints:
torch parts - adjust inlet pressure:
36.01 cooling tube V951 .11.828.911.230 ZG PG PG1 PG2 PG3 WG1 WG2
ZG - Ar / 8,5 bar
36.02 cathode T051 .11.836.911.500
PG1 - Ar / 8,5 bar
36.05 nozzle T2523 .11.836.911.623
T2525 .11.836.911.625 PG2 - Ar scale division acc. to table
36.07 nozzle cap T3000 .11.836.901.160 PG3 - H2 / 8,0 bar
36.09 swirl gas nozzle T522 .11.836.921.271 WG - N2 / 8,0 bar
36.11 protection cap T502 .11.841.721.081 - adjust outlet pressure and technology data acc. to table
36.12 swirl gas cap / V4340 .11.833.101.156
- press the switch "gas test" for adjusting of the volume flow
(WGK) V4345 .11.833.101.157
- adjust the pierce delay at the profile cutting machine
V4350 .11.833.101.158
- beard appendix is possible at speed reduction in contours and in dependence of material
- cutting parameters and results may differ because of material composition, material
position of selector switch surface and shape of workpiece.
on frontage HiFocus - the compliance of the determined cutting distance is very important. The set cutting
voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges) are
2 3 4 achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
* flying cutting
is possible 1 consequence of cutting angle displacements and beard appendix.
on switch
position 3 - the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.

up-slope

- page A1-17 - Kjellberg Finsterwalde

 torch: PerCut 370.2 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008

material: 1.4571 HiFocus Plus - CrNiTi-steel (20 up to 40 mm) (360-440A) data version: 2

Plasma gas ArH2 with swirl gas N2

swirl ignition cutting gas swirl gas cutting cutting
gas cutting nozzle nozzle gas gas PG1 PG2 PG3 WG1+ WG2 ignition pierce pierce cutting cutting speed kerf down
thickness set current cap cap Ar Ar Ar H2 N2 N2 height height time height voltage quality max. quality slope
HiFocus 360i

[mm] [A] [ bar / Skt. ] [ Skt. ] [ bar / Skt. ] [ Skt. ] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [mm] [ms]
20 C-31 360 T2427 T3209 T4040 8,5 / 65 25 8,0 / 100 8,0 / 90 / + 90 6 15,0 1,2 5,0 147 1,50 1,70 4,5 400
25 C-31 360 T2427 T3209 T4045 8,5 / 65 25 8,0 / 100 8,0 / 90 / + 90 7 20,0 1,5 5,0 149 1,30 1,55 4,6 400

adjusted internaly
30 C-31 360 T2427 T3209 T4050 8,5 / 65 25 8,0 / 100 8,0 / 90 / + 90 8 25,0 2,0 6,0 152 1,10 1,40 4,7 400
40 C-31 360 T2427 T3209 T4050 8,5 / 65 25 8,0 / 100 8,0 / 90 / + 90 8 30,0 2,5 7,0 156 0,84 0,97 5,3 400
HiFocus 440i

marking L-31 30 T2427 T3209 T 4040 ----- ----- ----- 8,0 / 80 ----- 4 4,0 0,0 4,0 45 4,00 ----- 2,0 4
20 C-31 440 T2429 T3209 T4040 8,5 / 60 20 8,0 / 100 8,0 / 90 / + 40 6 15,0 1,2 6,0 149 1,70 2,10 5,0 400
25 C-31 440 T2429 T3209 T4040 8,5 / 60 20 8,0 / 100 8,0 / 90 / + 40 7 20,0 1,5 6,0 151 1,45 1,70 5,1 400
30 C-31 440 T2429 T3219 T4045 8,5 / 65 25 8,0 / 100 8,0 / 90 / + 90 8 25,0 2,0 7,0 155 1,20 1,35 5,4 400
40 C-31 440 T2429 T3219 T4050 8,5 / 65 25 8,0 / 100 8,0 / 90 / + 90 8 30,0 2,5 8,0 160 0,90 1,00 6,0 400
marking L-31 35 T2429 T3209 T 4040 ----- ----- ----- 8,0 / 90 ----- 4 4,0 0,0 4,0 44 4,50 ----- 2,0 4

torch parts:
hints:
37.01 cooling tube V951 .11.828.911.230
ZG PG PG1 PG2 PG3 WG1 WG2
37.02 cathode T051 .11.836.911.500 - adjust inlet pressure:
37.05 nozzle T2427 .11.846.911.627 ZG - Ar / 8,5 bar
T2429 .11.846.911.629 PG1 - Ar / 8,5 bar
37.07 nozzle cap / DK T3209 .11.846.901.1609 PG2 - Ar scale division acc. to table
T3219 .11.846.901.1619 PG3 - H2 / 8,0 bar
37.10 protection cap T503 .11.846.901.081
WG - N2 / 8,0 bar
37.12 swirl gas cap / WGK T4040 .11.846.901.1540
T4045 .11.846.901.1545 - adjust outlet pressure and technology data acc. to table
T4050 .11.846.901.1550 - press the switch "gas test" for adjusting of the volume flow
- adjust the pierce delay at the profile cutting machine
- beard appendix is possible at speed reduction in contours and in dependence of
material
- cutting parameters and results may differ because of material composition, material
surface and shape of workpiece.
position of selector switch - the compliance of the determined cutting distance is very important. The set cutting
on the frontage of HiFocus voltages are approximate values only, because they depend on other conditions too,
for example contact between workpiece and cutting table or length of the hose parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges)
are achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have
2 3 4
the consequence of cutting angle displacements and beard appendix.
1 - the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
surface and bottom edge of torch.

up-slope

- page A1-18- Kjellberg Finsterwalde

 torch: PerCut 370.2 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008
material: AlMg3 HiFocus F - Aluminium (16 up to 80 mm)(250-280A) data version: 2

Plasmagas ArH2 with swirl gas N2

swirl ignition cutting gas swirl gas cutting cutting
gas cutting nozzlenozzle gas gas PG1 PG2 PG3 WG1 WG2 ignition pierce pierce cutting cutting speed kerf down
thickness set current cap cap Ar Ar Ar H2 N2 N2 height height time height voltage quality max. quality slope
[mm] [A] [ bar/Skt. ] [Skt. ] [ bar/Skt. ] [ bar/Skt. ] [ Skt. ] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [mm] [ms]
16 C-22 250 T2523 T3000 V 4340 8,0 / 85 ----- 8,5 / 60 8,0 / 90 80 6 15,0 0,6 3 130 3,00 4,50 3,9 250
20 C-22 250 T2523 T3000 V 4340 8,0 / 85 ----- 8,5 / 60 8,0 / 90 70 7 20,0 1,0 3 132 2,50 3,70 4,0 250
25 C-22 250 T2523 T3000 V 4345 8,0 / 85 ----- 8,5 / 60 8,0 / 90 70 7 25,0 1,3 3,5 135 2,00 2,70 4,1 250
30 C-22 250 T2523 T3000 V 4345 8,0 / 85 ----- 8,5 / 60 8,0 / 90 70 7 25,0 1,8 4 138 1,50 2,20 4,2 250

adjusted internaly
40 C-22 250 T2523 T3000 V 4350 8,0 / 85 ----- 8,5 / 60 8,0 / 90 80 8 30,0 2,3 4 140 1,10 1,40 4,4 250
50 C-22 250 T2523 T3000 V 4350 8,0 / 85 ----- 8,5 / 60 8,0 / 90 80 8 ---- ---- 5 149 0,70 1,20 4,6 250
60 C-22 250 T2523 T3000 V 4350 8,0 / 85 ----- 8,5 / 60 8,0 / 90 80 8 ---- ---- 5 155 0,50 0,80 5,5 250
20 C-29 280 T2525 T3000 V 4340 8,0 / 70 50 8,0 / 60 8,0 / 90 70 7 12,0 0,6 4 129 2,80 3,80 4,2 300
HiFocus 280i

25 C-29 280 T2525 T3000 V 4345 8,0 / 70 50 8,0 / 60 8,0 / 90 70 7 15,0 0,8 4 131 2,30 3,00 4,3 300
30 C-29 280 T2525 T3000 V 4345 8,0 / 70 50 8,0 / 60 8,0 / 90 70 7 15,0 1,0 4 133 1,80 2,20 4,4 300
40 C-29 280 T2525 T3000 V 4350 8,0 / 70 50 8,0 / 60 8,0 / 90 80 8 20,0 1,5 4 135 1,20 1,55 4,6 300
60 C-29 280 T2525 T3000 V 4350 8,0 / 70 50 8,0 / 60 8,0 / 90 80 8 ---- ---- 5 148 0,55 0,80 5,7 300
80 C-29 280 T2525 T3000 V 4350 8,0 / 70 50 8,0 / 60 8,0 / 90 80 8 ---- ---- 7 188 ---- 0,15 7,0 300
torch parts: hints:
- adjust inlet pressure:
36.01 cooling tube V951 .11.828.911.230
ZG PG PG1 PG2 PG3 WG1 WG2 ZG - Ar / 8,0 bar
36.02 cathode T051 .11.836.911.500
PG1 - Ar / 8,0 bar
36.05 nozzle T2523 .11.836.911.623
PG2 - Ar scale division acc. to table
T2525 .11.836.911.625
PG3 - H2 / 8,0 or 8,5 bar
36.07 nozzle cap T3000 .11.836.901.160
WG - N2 / 8,0 bar
36.09 swirl gas nozzle T522 .11.836.921.271
36.11 protection cap T502 .11.841.721.081 - adjust outlet pressure and technology data acc. to table
36.12 swirl gas cap / V4340 .11.833.101.156 - press the switch "gas test" for adjusting of the volume flow
(WGK) V4345 .11.833.101.157 - adjust the pierce delay at the profile cutting machine
V4350 .11.833.101.158 - beard appendix is possible at speed reduction in contours and in dependence of material
- cutting parameters and results may differ because of material composition, material
surface and shape of workpiece.
- the compliance of the determined cutting distance is very important. The set cutting
voltages are approximate values only, because they depend on other conditions too,
position of selector switch
on frontage HiFocus for example contact between workpiece and cutting table or length of the hose parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting edges) are
achieved by the cutting speed "quality". Cutting speed "Speed" and "Max" have the
consequence of cutting angle displacements and beard appendix.
3
- the designation "Distance" (i.e.: cutting distance) gives the range between workpiece
2 4
* flying cutting surface and bottom edge of torch.
is possible 1
on switch
position 3

up-slope

- page A1-19 - Kjellberg Finsterwalde

 torch: PerCut 370.2 Cutting data HiFocus 280i, 360i and 440i valid from: 21.04.2008

material: AlMg3 HiFocus Plus - Aluminium (20 up to 90 mm)(360-440A) data version: 2

Plasma gas ArH2 with swirl gas N2

swirl ignition cutting gas swirl gas cutting cutting
gas cutting nozzle nozzle gas cap gas PG1 PG2 PG3 WG1+ WG2 ignition pierce pierce cutting cutting speed kerf down
thickness set current cap Ar Ar Ar H2 N2 N2 height height time height voltage quality max. quality slope
[mm] [A] [ bar / Skt. ] [ Skt. ] [ bar / Skt. ] [ Skt. ] [mm] [mm] [ sec ] [mm] [V] [m/min] [m/min] [mm] [ms]
20 C-29 360 T2427 T3208 T4040 8,5 / 70 40 8,0 / 65 8,0 / 90 80 7 12,0 0,6 4,0 127 3,20 4,00 4,0 400
25 C-29 360 T2427 T3208 T4045 8,5 / 70 40 8,0 / 65 8,0 / 90 80 7 15,0 0,8 5,0 130 2,60 3,50 4,2 400
30 C-29 360 T2427 T3208 T4045 8,0 / 70 40 8,0 / 65 8,0 / 90 80 7 15,0 1,0 5,0 134 2,00 2,80 4,5 400
HiFocus 360i

40 C-29 360 T2427 T3208 T4050 8,0 / 70 40 8,0 / 65 8,0 / 90 80 7 20,0 1,5 6,0 142 1,40 1,80 4,7 400
50 C-29 360 T2427 T3209 T4050 8,0 / 70 40 8,0 / 65 8,0 / 90 80 7 ---- ---- 6,0 145 1,00 1,50 5,1 400
60 C-29 360 T2427 T3209 T4050 8,0 / 70 40 8,0 / 65 8,0 / 90 80 7 ---- ---- 7,0 153 0,80 1,30 5,5 400

adjusted internaly
70 C-29 360 T2427 T3209 T4050 8,0 / 70 40 8,0 / 65 8,0 / 90 80 7 ---- ---- 7,0 158 0,70 0,90 5,7 400
80 C-29 360 T2427 T3209 T4050 8,0 / 70 40 8,0 / 65 8,0 / 90 90 7 ---- ---- 6,0 162 0,60 0,75 5,6 400
90 C-29 360 T2427 T3209 T4050 8,0 / 70 40 8,0 / 65 8,0 / 90 90 7 ---- ---- 6,0 167 ---- 0,30 6,6 400
20 C-29 440 T2429 T3208 T4040 8,5 / 70 40 8,0 / 65 8,0 / 90 70 7 12,0 0,6 4,5 130 3,50 4,50 4,4 400
25 C-29 440 T2429 T3208 T4040 8,5 / 70 40 8,0 / 65 8,0 / 90 70 7 15,0 0,8 5,0 132 2,90 3,60 4,6 400
30 C-29 440 T2429 T3208 T4040 8,5 / 70 40 8,0 / 65 8,0 / 90 50 7 15,0 1,0 6,0 138 2,20 2,80 4,8 400
HiFocus 440i

40 C-29 440 T2429 T3208 T4045 8,5 / 70 40 8,0 / 65 8,0 / 90 80 7 20,0 1,5 6,0 140 1,80 2,40 5,4 400
50 C-29 440 T2429 T3209 T4050 8,5 / 70 40 8,0 / 65 8,0 / 90 80 7 ---- ---- 6,0 146 1,30 1,70 5,6 400
60 C-29 440 T2429 T3209 T4050 8,5 / 70 40 8,0 / 65 8,0 / 90 80 7 ---- ---- 7,0 155 1,00 1,30 5,8 400
70 C-29 440 T2429 T3209 T4050 8,5 / 70 40 8,0 / 65 8,0 / 90 80 7 ---- ---- 7,0 159 0,80 1,00 6,1 400
80 C-29 440 T2429 T3209 T4050 8,5 / 70 40 8,0 / 65 8,0 / 90 90 7 ---- ---- 6,0 162 0,70 0,85 6,2 400
90 C-29 440 T2429 T3209 T4050 8,5 / 70 40 8,0 / 65 8,0 / 90 90 7 ---- ---- 6,0 168 ---- 0,40 6,3 400

hints:
torch parts: - adjust inlet pressure:
ZG - Ar / 8,0 or 8,5 bar
37.01 cooling tube V951 .11.828.911.230 ZG PG PG1 PG2 PG3 WG1 WG2
PG1 - Ar / 8,0 or 8,5 bar
37.02 cathode T051 .11.836.911.500
PG2 - Ar scale division acc. to table
37.05 nozzle T2427 .11.846.911.627
PG3 - H2 / 8,0 bar
T2429 .11.846.911.629
WG - N2 / 8,0 bar
37.07 nozzle cap / DK T3208 .11.846.901.1608
- adjust outlet pressure and technology data acc. to table
T3209 .11.846.901.1609
- press the switch "gas test" for adjusting of the volume flow
37.10 protection cap T503 .11.846.901.081
- adjust the pierce delay at the profile cutting machine
37.12 swirl gas cap / WGK T4040 .11.846.901.1540
- beard appendix is possible at speed reduction in contours and in dependence of
T4045 .11.846.901.1545
material
T4050 .11.846.901.1550
- cutting parameters and results may differ because of material composition, material
surface and shape of workpiece.
position of selector switch - the compliance of the determined cutting distance is very important. The set cutting
voltages are approximate values only, because they depend on other conditions
on frontage of HiFocus
too, for example contact between workpiece and cutting table or length of the hose
parcel.
- the best cutting qualities (referring to beard appendix, cutting angles, cutting
edges) are achieved by the cutting speed "quality". Cutting speed "Speed" and
"Max" have the consequence of cutting angle displacements and beard appendix.
- the designation "Distance" (i.e.: cutting distance) gives the range between
3
2 4 workpiece surface and bottom edge of torch.
1

up-slope

- page A1-20 - Kjellberg Finsterwalde

 Marking data HiFocus 280i, 360i and 440i valid from: 21.04.2008
torch:PerCut 370.2 Marking of mild steel and CrNi-steel data version: 2

Marking gas Air

up slope / switch position

WG1 - N2 ( bar / Skt.)

ignition height (mm)

cutting height (mm)
pierce height (mm)
cutting current (A)

cutting voltage (V)

technology range

down slope (ms)

swirl gas nozzle
thickness (mm)

protection cap

pierce time (s)

cutting speed
swirl gas cap
nozzle cap
gas guide

kerf (mm)
(mm/min)
comment
material

cathode
gas set

nozzle

ZG
Air
L-38 1.0037 St37 0 10 T012 T104 T2115 T3030 T522 V4335 T502 1 marking Ar 8,0/30 2 2 2 0 78 2000 1,2 2 4
L-44 1.0037 St37 0 10 T012 T104 T2115 T3030 T522 V4335 T502 1 marking Air 8,0/ 8 2 2 2 0 178 7000 1,5 2 4
L-38 1.0037 St37 0 10 T012 T102 T2115 T3030 T522 V4340 T502 1 marking Ar 8,0/30 2 2 2 0 78 2000 1,2 2 4
L-44 1.0037 St37 0 10 T012 T102 T2115 T3030 T522 V4335 T502 1 marking Air 8,0/40 2 2 2 0 194 7000 1,7 2 4
L-44 1.0037 St37 0 23 T012 T102 T2120 T3045 T522 V4335 T502 1 marking Air 8,0/ 8 2 2 2 0 128 5600 2,0 2 4
L-44 1.0037 St37 0 35 T012 T101 T2125 T3045 T522 V4345 T502 1 marking Air 8,0/ 8 2 2 2 0 117 8000 2,0 2 4
L-44 1.0037 St37 0 35 T012 T101 T2127 T3045 T522 V4345 T502 1 marking Air 8,0/ 8 2 2 2 0 102 8000 1,8 2 4
L-44 1.0037 St37 0 35 T012 T101 T2130 T3045 T522 V4345 T502 1 marking Air 8,0/60 3 3 3 0 93 4000 1,8 2 4
N2
L-39 1.0037 St37 0 10 T012 T104 T2115 T3030 T522 V4335 T502 1 marking Ar 8,0/10 2 2 2 0 74 3000 0,8 2 4
L-45 1.0037 St37 0 10 T012 T104 T2115 T3030 T522 V4335 T502 1 marking Air 8,0/10 2 2 2 0 180 7000 1,5 2 4
L-39 1.0037 St37 0 10 T012 T102 T2115 T3030 T522 V4330 T502 1 marking Ar 8,0/20 2 2 2 0 73 3000 0,8 2 4
L-39 1.0037 St37 0 10 T012 T102 T2115 T3030 T522 V4335 T502 1 marking Ar 8,0/20 2 2 2 0 78 3000 1,0 2 4
L-39 1.0037 St37 0 10 T012 T102 T2115 T3030 T522 V4340 T502 1 marking Ar 8,0/20 2 2 2 0 83 3000 1,0 2 4
L-45 1.0037 St37 0 10 T012 T102 T2115 T3030 T522 V4335 T502 1 marking Air 8,0/40 2 2 2 0 195 7000 1,7 2 4
L-39 1.0037 St37 0 20 T012 T102 T2120 T3045 T522 V4335 T502 1 marking Ar 8,0/20 2 2 2 0 57 3000 1,3 2 4
L-42 1.0037 St37 0 23 T012 T102 T2120 T3045 T522 V4335 T502 1 marking N2 8,0/ 8 2 2 2 0 119 6000 1,5 2 4
L-39 1.0037 St37 0 35 T012 T101 T2125 T3045 T522 V4345 T502 1 marking Ar 8,0/20 2 2 2 0 60 4000 1,8 2 4
L-42 1.0037 St37 0 35 T012 T101 T2125 T3045 T522 V4345 T502 1 marking N2 8,0/ 8 2 2 2 0 101 7500 1,5 2 4
L-39 1.0037 St37 0 35 T012 T101 T2127 T3045 T522 V4345 T502 1 marking Ar 8,0/10 2 2 2 0 53 3500 1,6 2 4
L-45 1.0037 St37 0 35 T012 T101 T2127 T3045 T522 V4345 T502 1 marking Air 8,0/40 2 2 2 0 102 9000 1,7 2 4
L-42 1.0037 St37 0 35 T012 T101 T2127 T3045 T522 V4345 T502 1 marking N2 8,0/ 8 2 2 2 0 93 5500 1,6 2 4
L-39 1.0037 St37 0 35 T012 T101 T2130 T3045 T522 V4345 T502 1 marking Ar 8,0/20 3 3 3 0 48 2000 2,0 2 4

ZG PG PG1 PG2 PG3 WG1 WG2

position of selector switch

on frontage of HiFocus

2)

2 3 4
1

up-slope
1)

1) change from the CUTTING to the MARKING at the PGE-360

2) Then the display 'gas set' changes from the cutting-set C-** to the marking-set L-**.

Note:
- piercing delay is adjusted at the profile-cutting-machine
- don't enlarge the ignition distance
- the parameters for marking vary depending on material and kind of surface.
- the compliance of the determined cutting distance is very important.
- the set cutting voltages are approximate values only, because they depend on other conditions too, for example contact between workpiece and
cutting table or length of the hose parcel.

- page A1-21 - Kjellberg Finsterwalde

 Marking data HiFocus 280i, 360i and 440i valid from: 21.04.2008
torch: PerCut 370.2 marking of CrNi-steel data version: 2

marking gas Argon

up slope / switch position

WG1 - N2 ( bar / Skt.)

ignition height (mm)

cutting height (mm)
pierce height (mm)
cutting current (A)

cutting voltage (V)

technology range

down slope (ms)

swirl gas nozzle
thickness (mm)

protection cap

pierce time (s)

cutting speed
swirl gas cap
nozzle cap
gas guide

kerf (mm)
(mm/min)
comment
material

cathode
gas set

nozzle

ZG
L-24 1.4301CrNi 0 20 T051 ----- T2523 T3000 T522 V4340 T502 1 HiFocusF Ar 8,0 / 50 4,0 4,0 4,0 0 56 3500 1,5 2 4
L-24 1.4301CrNi 0 20 T051 ----- T2523 T3000 T522 V4345 T502 1 HiFocusF Ar 8,0 / 50 4,0 4,0 4,0 0 56 3500 1,5 2 4
L-24 1.4301CrNi 0 20 T051 ----- T2523 T3000 T522 V4350 T502 1 HiFocusF Ar 8,0 / 50 4,0 4,0 4,0 0 56 3500 1,5 2 4
L-24 1.4301CrNi 0 27 T051 ----- T2525 T3000 T522 V4340 T502 1 HiFocusF Ar 8,0 / 50 4,0 4,0 4,0 0 52 3500 1,9 2 4
L-24 1.4301CrNi 0 27 T051 ----- T2525 T3000 T522 V4345 T502 1 HiFocusF Ar 8,0 / 50 4,0 4,0 4,0 0 52 3500 1,9 2 4
L-24 1.4301CrNi 0 27 T051 ----- T2525 T3000 T522 V4350 T502 1 HiFocusF Ar 8,0 / 50 4,0 4,0 4,0 0 52 3500 1,9 2 4
Plus
L-31 1.4301CrNi 0 30 T051 ----- T2427 T3209 ----- T4040 T503 1 HiFocus Ar 8,0 / 80 4,0 4,0 4,0 0 45 4000 2,0 2 4
L-31 1.4301CrNi 0 30 T051 ----- T2427 T3209 ----- T4045 T503 1 HiFocusPlus Ar 8,0 / 80 4,0 4,0 4,0 0 45 4000 2,0 2 4
L-31 1.4301CrNi 0 30 T051 ----- T2427 T3209 ----- T4050 T503 1 HiFocusPlus Ar 8,0 / 80 4,0 4,0 4,0 0 45 4000 2,0 2 4
Plus
L-31 1.4301CrNi 0 35 T051 ----- T2429 T3208 ----- T4040 T503 1 HiFocus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4
L-31 1.4301CrNi 0 35 T051 ----- T2429 T3208 ----- T4045 T503 1 HiFocusPlus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4
L-31 1.4301CrNi 0 35 T051 ----- T2429 T3208 ----- T4050 T503 1 HiFocusPlus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4
Plus
L-31 1.4301CrNi 0 30 T051 ----- T2427 T3219 ----- T4040 T503 1 HiFocus Ar 8,0 / 80 4,0 4,0 4,0 0 45 4000 2,0 2 4
L-31 1.4301CrNi 0 35 T051 ----- T2429 T3219 ----- T4040 T503 1 HiFocusPlus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4
L-31 1.4301CrNi 0 35 T051 ----- T2429 T3228 ----- T4045 T503 1 HiFocusPlus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4
L-31 1.4571CrNiTi 0 35 T051 ----- T2429 T3209 ----- T4040 T503 1 HiFocusPlus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4
L-31 1.4571CrNiTi 0 35 T051 ----- T2429 T3209 ----- T4045 T503 1 HiFocusPlus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4
L-31 1.4571CrNiTi 0 35 T051 ----- T2429 T3209 ----- T4050 T503 1 HiFocusPlus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4
L-31 1.4571CrNiTi 0 35 T051 ----- T2429 T3219 ----- T4045 T503 1 HiFocusPlus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4
L-31 1.4571CrNiTi 0 35 T051 ----- T2429 T3219 ----- T4050 T503 1 HiFocusPlus Ar 8,0 / 90 4,0 4,0 4,0 0 44 4500 2,0 2 4

position of selector switch

on frontage of HiFocus

2 3 4
1

up-slope

1) change from the CUTTING to the MARKING at the PGE-360

2) Then the display 'gas set' changes from the cutting-set C-** to the marking-set L-**.

Note:
- piercing delay is adjusted at the profile-cutting-machine
- don't enlarge the ignition distance
- the parameters for marking vary depending on material and kind of surface.
- the compliance of the determined cutting distance is very important.
- the set cutting voltages are approximate values only, because they depend on other conditions too, for example contact between workpiece and
cutting table or length of the hose parcel.

- page A1-22 - Kjellberg Finsterwalde

consumables overview of the PerCut 370.2

Allocation of thr item numbers (for example 31.02)

to the designations (types) see spare parts list

page A1-23 Kjellberg Finsterwalde

 Wiring diagrams
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Wiring diagrams
for the Plasma cutting unit HiFocus 280i

Wiring diagram of the power source .11.034.302.SP1

.11.034.306.SP1 g
Legend for the wiring diagram of the power source .11.034.302.SP1
.11.034.306.SP1 g

Wiring diagram of the CNC-interface .11.034.30x.SP2

.11.034.40x.SP2 e
.11.034.60x.SP2

Wiring diagram inverter module 11.412.002CSP a

with gas console according to delivery variant:

PGE-360
Wiring diagram for the complete unit .11.034.302 SP81 d
.11.034.402 SP81 d
.11.034.602.SP81 d
Wiring diagram PGE-360 .11.825.113.SP_b
gas plan PGE-360 .11.825.113.GP_c

or:
PGE3-360
Wiring diagram for the complete unit .11.034.302 SP83 g
incl. wiring and gas plan PGE3-360 .11.034.402 SP83 g
.11.034.602.SP83 g

or:
FlowControl 3 (PGC3 + PGV3)
Wiring diagram for the complete unit .11.034.302 SP82 d
.11.034.402 SP82 d
.11.034.602.SP82 d
Circuit diagram PGC .11.420.00x.SP d
Wiring diagram PGV3 .11.825.155.SP_f
gas plan PGV3 .11.825.155.GP_d

Cooling unit for Plasma Machine Torch

KWE 360
Wiring diagram KWE 360 .11.141.102 e SP
Wiring diagrams
Wiring diagrams
Wiring diagrams
Wiring diagrams
Wiring diagrams
Wiring diagrams
Wiring diagrams
 Wiring diagrams

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 Order information and connecting diagrams

Order information and connecting diagrams

for the plasma cutting unit HiFocus 280i

with the plasma torches PerCut 370.1 and PerCut 370.1M,

PerCut 370.1M Rotator, 4 mm head reduction
PerCut 370.1M Rotator, 6 mm head reduction
PerCut 370.2 and PerCut 370.2M

.11.034.402.K80 .11.034.302.S83 PGE 3-360

.11.034.302.S85A-PGE-360
.11.034.302.S85B-PFC
.11.034.302.S93 PGE 3-360
.11.034.302.S95A-PGE-360
.11.034.302.S95B-PFC

Torch connection: with plasma torch connection unit

Plasma gases: oxygen; forming gas F5; argon; hydrogen; air
Swirl gases: oxygen; nitrogen; air
plasma machine torch PerCut 370/PerCut 370M with swirl
Torch:
gas
Order information and connecting diagrams
01.09.2008
pos. article-no. designation pcs.
1.11 .11.034.302 HiFocus 280i 400V/50Hz 1,00
1.51 .11.573.007.005 Primary cable 4x35qmm, 5m w/o plug 1,00
1.53 .12.54870 Workpiece cable 70 qmm, 5m 1,00
1.61 .11.141.102 KWE 360 400 V water cooler 1,00
1.62 .11.570.008.005 Control cable, 5m KWE360 1,00
1.63 .11.501.500.325 Cooling Hose 5m 1,00
1.64 .11.501.500.320 Cooling Hose 5m 1,00

2.00 .16.500.380 Control cables power source - PGE

2.00 .16.500.455 Gas supply - gas control
2.02 .11.500.700.468 Control cable 25pol., 2m 1,00
2.03 .11.570.003.0018 Control cable/RS485 PA -PGC 1,8m 1,00
2.04 .11.501.500.059 Gas hose Air G1/4" 6m 1,00
2.05 .11.501.500.060 Gas hose O2 G1/4" 6m 1,00
2.06 .11.501.500.058 Gas hose Ar G1/4" 6m 1,00
2.07 .11.501.500.057 Gas hose H2 G3/8" Left, 6m 1,00
2.08 .11.501.500.094 Gas hose N2 G1/4" 6m 1,00
2.09 .11.501.500.267 Gas hose N2/H2 G3/8" LEFT 6m 1,00
2.13 .11.570.003.010 Control cable/RS485 PA -PGC 10m 1,00
2.14 .11.501.500.065 Gas hose AIR G1/4" 10m 1,00
2.15 .11.501.500.061 Gas hose O2 G1/4" 10m 1,00
2.16 .11.501.500.069 Gas hose Ar G1/4" 10m 1,00
2.17 .11.501.500.073 Gas hose H2 G3/8" Left 10m 1,00
2.18 .11.501.500.095 Gas hose N2 G1/4" 10 m 1,00
2.19 .11.501.500.268 Gas hose N2/H2 G3/8" Left 10m 1,00
2.22 .11.500.700.396 Control cable PA-PGE/PGV 25 pol. 20m 1,00
2.23 .11.570.003.020 Control cable/RS485 PA -PGC 20m 1,00
2.24 .11.501.500.066 Gas hose Air G1/4" 20 m 1,00
2.25 .11.501.500.062 Gas hose O2 G1/4" 20m 1,00
2.26 .11.501.500.070 Gas hose Ar G1/4" 20m 1,00
2.27 .11.501.500.074 Gas hose H2 G3/8" Left 20m 1,00
2.28 .11.501.500.096 Gas hose N2 G1/4" 20m 1,00
2.29 .11.501.500.269 Gas hose N2/H2 G3/8" LEFT 20m 1,00
2.32 .11.570.009.030 Control cable PA-PGE/PGV 25+1pol. 30m 1,00
2.33 .11.570.003.030 Control cable/RS485 PA -PGC 30m 1,00
2.34 .11.501.500.067 Gas hose Air G1/4" 30m 1,00
 Order information and connecting diagrams
01.09.2008
pos. article-no. designation pcs.
2.35 .11.501.500.063 Gas hose O2 G1/4" 30m 1,00
2.36 .11.501.500.071 Gas hose Ar G1/4" 30m 1,00
2.37 .11.501.500.075 Gas hose H2 3/8" Left 30m 1,00
2.38 .11.501.500.097 Gas hose N2 G1/4" 30m 1,00
2.39 .11.501.500.270 Gas hose N2/H2 G3/8" LEFT 30m 1,00
2.42 .11.570.009.040 Control cable PA-PGE/PGV 25+1 pol. 40m 1,00
2.43 .11.570.003.040 Control cable/RS485 PA -PGC 40m 1,00
2.44 .11.501.500.068 Gas hose Air G1/4" 40m 1,00
2.45 .11.501.500.064 Gas hose O2 G1/4" 40m 1,00
2.46 .11.501.500.072 Gas hose Ar G1/4" 40m 1,00
2.47 .11.501.500.076 Gas hose H2 G3/8" Left 40m 1,00
2.48 .11.501.500.098 Gas hose N2 G1/4" 40m 1,00
2.49 .11.501.500.271 Gas hose N2/H2 G3/8" LEFT 40m 1,00
2.52 .11.570.009.050 Control cable PA-PGE/PGV 25+1pol. 50m 1,00
2.53 .11.570.003.050 Control cable/RS485 PA-PGC 50m 1,00
2.54 .11.501.500.100 Gas hose Air G1/4" 50m 1,00
2.55 .11.501.500.099 Gas hose O2 G1/4" 50m 1,00
2.56 .11.501.500.101 Gas hose Ar G1/4" 50m 1,00
2.57 .11.501.500.102 Gas hose H2 G3/8" Left 50m 1,00
2.58 .11.501.500.103 Gas hose N2 G1/4" 50m 1,00
2.59 .11.501.500.279 Gas hose N2/H2 G3/8" LEFT 50m 1,00

3.00 .16.500.456 Gas supply - manual

3.10 .11.825.103 PGE 3-360 Plasma gas controller (O2) 1,00
3.20 .11.825.113 PGE -360 Plasma gas controller all gases 1,00
3.30 .16.500.457 Gas control automatic - flowcontrol
3.31 .11.420.003 PGC Control unit for PGV 3 1,00
3.31 .11.420.001.900 Power Supply PGC 1 1.5m 1,00
3.32 .11.825.155 PGV 3 Plasma gas controller 1,00
3.40 .11.570.001.0018 Control cable/CAN1 PGV-PGC 1,8m 1,00
3.41 .11.570.001.005 Control cable/CAN1 PGV/PGC 5m 1,00
3.42 .11.570.001.010 Control cable/CAN1 PGV-PGC 10m 1,00
3.43 .11.570.001.020 Control cable /CAN1 PGV-PGC 20m 1,00
3.44 .11.570.001.030 Control cable /CAN1 PGV-PGC 30m 1,00
3.45 .11.570.001.040 Control cable /CAN1 PGV-PGC 40m 1,00
3.50 .11.570.002.0018 Control cable/24VAC PGV-PGC 1,8m 1,00
Order information and connecting diagrams
01.09.2008
pos. article-no. designation pcs.
3.51 .11.570.002.005 Control cable/24VAC PGV-PGC 5m 1,00
3.52 .11.570.002.010 Control cable/24VAC PGV-PGC 10m 1,00
3.53 .11.570.002.020 Control cable/24VAC PGV-PGC 20m 1,00
3.54 .11.570.002.030 Control cable /24VDC PGV-PGC 30m 1,00
3.55 .11.570.002.040 Control cable/24VAC PGV-PGC 40m 1,00

6.00 .11.820.250 PBA-360 Plasma torch connection block 1,00

6.01 .16.500.531 Hose parcel extension PA-PGE/PGV
6.01 .11.580.007.005 Gas hose PG1 AIR/N2 G1/4"-G1/4" 5m 1,00
6.02 .11.580.008.005 Gas hose PG2 O2/N2 G1/4"L-G1/4"L 5m 1,00
6.03 .11.580.015.005 Gas hose PG3 H2 G3/8"-G3/8" 5m 1,00
6.08 .11.580.009.005 Gas hose WG M12x1-M12x1 5m 1,00
6.09 .11.580.010.005 Gas hose KG Air/N2 G1/8"-G1/8" 5m 1,00
6.10 .11.825.810 PZL-360 Hose and cable set 10m 1,00
6.11 .11.580.007.010 Gas hose PG1 AIR/N2 G1/4"-G1/4" 10m 1,00
6.12 .11.580.008.010 Gas hose PG2 O2/N2 G1/4"L-G1/4"L 10m 1,00
6.13 .11.580.015.010 Gas hose PG3 H2 G3/8"-G3/8" 10m 1,00
6.18 .11.580.009.010 Gas hose WG M12x1-M12x1 10m 1,00
6.19 .11.580.010.010 Gas hose KG Air/N2 G1/8"-G1/8" 10m 1,00
6.20 .11.825.815 PZL-360 Hose and cable set 15m 1,00
6.21 .11.580.007.015 Gas hose PG1 AIR/N2 G1/4"-G1/4" 15m 1,00
6.22 .11.580.008.015 Gas hose PG2 O2/N2 G1/4"L-G1/4"L 15m 1,00
6.23 .11.580.015.015 Gas hose PG3 H2 G3/8"-G3/8" 15m 1,00
6.28 .11.580.009.015 Gas hose WG M12x1-M12x1 15m 1,00
6.29 .11.580.010.015 Gas hose KG Air/N2 G1/8"-G1/8" 15m 1,00
6.30 .11.825.825 PZL-360 Hose and cable set 25m 1,00
6.40 .11.825.835 PZL-360 Hose and cable set 35m 1,00
6.50 .11.825.845 PZL-360 Hose and cable set 45m 1,00
6.60 .11.825.855 PZL-360 Hose and cable set 55m 1,00

7.10 .11.824.800.010 FB - Remote Control 10m 1,00

8.00 .16.500.233 Plasma machine torches:

8.52 .11.846.921.9015 Torch Shaft 1,5m 360A/C - PerCut 370 M 1,00
8.53 .11.846.821.100 Quick change head PerCut 370.1M 160A 1,00
 Order information and connecting diagrams
01.09.2008
pos. article-no. designation pcs.
8.58 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1,00
8.95 .11.822.571 Torch Holder, Compl. PB-S76/150 W 1,00

9.00 .16.500.513 Torch tools 160A:

9.01 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1,00
9.02 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1,00
9.20 .16.500.514 Torch tools 360A:
9.21 .11.840.301.824 Nozzle Puller PB-S70/75/76/77 1,00
9.22 .12.38190 Socket Spanner for Nozzle Cap 1,00
9.23 .12.38170 Socket Spanner for Cathode 1,00
9.24 .12.38180 Socket Spanner for Cooling Tube 1,00
9.25 .10.712.536 Hexagonal Wrench 4.0 mm 1,00
9.26 .10.710.560 Pin Spanner With Hinge For DIA. 4 1,00
9.27 .12.40320 Cap puller 1,00
9.30 .11.846.921.830 Station for quick change head PerCut 370M 1,00
9.31 .11.846.921.840 Tool for Quick-Change Head PerCut 370M 1,00
9.40 .36.000.015 Cathode dial indicator 1,00
9.50 .16.500.257 Options gas / water supply:
9.51 .12.62320 Coolant Kjellfrost -15° C / 10l 1,00
9.52 .12.62330 Coolant Kjellfrost -15°C / 20l 1,00
9.53 .12.62340 Coolant Kjellfrost -25°C / 10l 1,00
9.54 .12.62350 Coolant Kjellfrost -25°C/ 20l 1,00

10.00 .16.500.004 Consumables:

10.01 .11.846.721.880 Consumables kit PerCut 370 Mild steel 1,00
10.02 .11.846.711.880 Consumables kit PerCut 370M CrNi <300A 1,00

11.00 .16.500.515 Consumables up to 160A:

12.00 .16.500.465 Consumables HiFocus CrNi-steel

12.10 .16.500.254 Consumables category A
12.11 .11.842.411.510 Cathode A S042 HiFinox 1,00
12.11 .11.842.511.510 Cathode A S052 FineFocus 1,00
12.13 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
Order information and connecting diagrams
01.09.2008
pos. article-no. designation pcs.
12.13 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1,00
12.13 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1,00
12.13 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1,00
12.15 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
12.15 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1,00
12.15 .11.835.411.1580 Swirl Gas Cap 3,5 Z4535 1,00
12.15 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1,00
12.15 .11.835.411.1590 Swirl Gas Cap 4,5 Z4545 1,00
12.20 .16.500.255 Consumables category B
12.22 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
12.22 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
12.24 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
12.24 .11.842.401.1621 Nozzle cap complete 0,8 S3018 1,00
12.26 .11.835.201.081 Protection Cap Z501 1,00

14.00 .16.500.464 Consumables HiFocus mild steel

14.10 .16.500.254 Consumables category A
14.11 .11.843.021.320 Cathode O2 S002Y complete 1,00
14.11 .11.843.121.310 Cathode 02 XL S012X 1,00
14.13 .11.843.021.406 Nozzle 0,6 S2006X 25A 1,00
14.13 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
14.13 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
14.13 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1,00
14.13 .11.843.021.410 Nozzle 1,0 S2010X 80/90A 1,00
14.13 .11.843.021.411 Nozzle 1,1 S2011X 90/100A 1,00
14.13 .11.843.021.412 Nozzle 1,2 S2012X 100/130A 1,00
14.13 .11.843.021.414 Nozzle 1,4 S2014X 130/160A 1,00
14.13 .11.843.021.416 Nozzle 1,6 S2016X 160A 1,00
14.13 .11.843.121.412 Nozzle 1,2 S2112X 100A 1,00
14.13 .11.843.121.414 Nozzle 1,4 S2114X 130A 1,00
14.13 .11.843.121.416 Nozzle 1,6 S2116X 160A 1,00
14.15 .11.835.201.1561 Swirl Gas Cap 1,5 Z4015 1,00
14.15 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
14.15 .11.835.201.1551 Swirl Gas Cap 2,2 Z4022 1,00
14.15 .11.835.201.1581 Swirl Gas Cap 2,5 Z4025 1,00
 Order information and connecting diagrams
01.09.2008
pos. article-no. designation pcs.
14.15 .11.835.401.1571 Swirl Gas Cap 4,0 Z4140 1,00
14.20 .16.500.255 Consumables category B
14.22 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
14.22 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1,00
14.22 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
14.23 .11.835.421.303 Spacer Z111A 1,00
14.24 .11.842.401.160 Nozzle cap complete 0,4 S3004 1,00
14.24 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
14.24 .11.842.401.1622 Nozzle cap complete 0,8 S3028 1,00
14.26 .11.835.201.081 Protection Cap Z501 1,00

15.00 .16.500.516 Consumables up to 360A:

17.00 .16.500.465 Consumables HiFocus CrNi-steel

17.10 .16.500.254 Consumables category A
17.11 .11.836.911.500 Cathode T051 ArH2 1,00
17.13 .11.836.911.623 Nozzle T2523 ArH2 250A 2,3mm 1,00
17.13 .11.836.911.625 Nozzle T2525 ArH2 280A 2,5mm 1,00
17.15 .11.833.101.156 Swirl Gas Cap 4,0 dry V4340 1,00
17.15 .11.833.101.157 Swirl Gas Cap 4,5 dry V4345 1,00
17.15 .11.833.101.158 Swirl Gas Cap 5 dry V4350 1,00
17.20 .16.500.255 Consumables category B
17.21 .11.828.911.230 Cooling tube PB-S75 ArH2 1,00
17.23 .10.505.908 O-ring 18.2 X 1.9 VMQ ISO 1629 70SHSW 1,00
17.23 .10.505.923 O-ring 28 X 2.0 VMQ ISO 1629 70 shore 1,00
17.23 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1,00
17.27 .11.836.901.160 Nozzle cap T3000 1,00
17.38 .11.841.721.081 Protective cap T502 1,00
17.39 .11.836.921.271 Swirl gas nozzle T522 1,00

18.00 .16.500.187 Consumables (oxygen):

18.10 .16.500.254 Consumables category A
18.11 .11.836.921.300 Cathode T012 O2/Air 1,00
18.13 .11.836.921.415 Nozzle T2115 O2 120A 1,5mm 1,00
18.13 .11.836.921.420 Nozzle T2120 O2 200A 2,0mm 1,00
Order information and connecting diagrams
01.09.2008
pos. article-no. designation pcs.
18.15 .11.833.101.155 Swirl Gas Cap 3,5 dry V4335 1,00
18.15 .11.833.101.157 Swirl Gas Cap 4,5 dry V4345 1,00
18.20 .16.500.255 Consumables category B
18.21 .11.836.901.152 Cooling Tube T901 1,00
18.22 .11.836.921.153 Gas guide T101 (6x0,8 cw) 1,00
18.22 .11.836.921.1531 Gas guide T111 (6x0,8 ccw) 1,00
18.22 .11.836.921.154 Gas guide T102 (3x0,6 cw) 1,00
18.22 .11.836.921.1541 Gas guide T112 (3x0,6 ccw) 1,00
18.22 .11.836.921.1542 Gas guide T104 (3x0,4 cw) 1,00
18.23 .10.505.908 O-ring 18.2 X 1.9 VMQ ISO 1629 70SHSW 1,00
18.24 .10.505.923 O-ring 28 X 2.0 VMQ ISO 1629 70 shore 1,00
18.25 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1,00
18.26 .10.505.961 O-ring 48x2 VMQ ISO 1629 70 shore 1,00
18.27 .11.836.901.163 Nozzle cap T3030 (12x1,5 30° cw) 1,00
18.27 .11.836.901.164 Nozzle cap T3045 (12x1,5 45° cw) 1,00
18.27 .11.836.901.1641 Nozzle cap T3145 (12x1,5 45° ccw) 1,00
18.27 .11.836.901.165 Nozzle cap T3060 (12x1,5 60° cw) 1,00
18.27 .11.836.901.1651 Nozzle cap T3160 (12x1,5 60° ccw) 1,00
18.38 .11.841.721.081 Protective cap T502 1,00
18.39 .11.836.921.271 Swirl gas nozzle T522 1,00

25.00 .16.500.257 Options gas / water supply:

25.00 .16.500.400 Safety instructions!
25.00 .16.500.426 Gas from cylinders
25.10 .10.500.205 Explosion Protection 1,00
25.11 .11.822.618 Micro filter O2 25/0,01ym 1,00
25.12 .11.822.621 Micro filter O2 0,01ym 1,00
25.15 .11.822.619 Micro filter air 5/0,01ym 14bar 1,00
25.16 .11.822.623 Micro filter air 5/0,1ym 1,00
25.19 .11.822.633 Filter SG 5ym 1,00
25.21 .10.639.312 Pressure reducer air 20 bar 1,00
25.21 .10.639.322 Pressure reducer air 10 bar 1,00
25.22 .10.639.309 Pressure reducer Ar/Co2 20 bar 1,00
25.22 .10.639.319 Pressure reducer Ar 10 bar 1,00
25.23 .10.639.310 Pressure reducer H2 20 bar 1,00
 Order information and connecting diagrams
01.09.2008
pos. article-no. designation pcs.
25.24 .10.639.311 Pressure reducer N2 20 bar 1,00
25.24 .10.639.321 Pressure reducer N2 10 bar 1,00
25.25 .10.639.313 Pressure reducer O2 20 bar 1,00
25.25 .10.639.323 Pressure reducer O2 10 bar 1,00

30.00 .16.500.439 Plasma cutting unit - CNC

30.10 .16.500.441 Plug X102
30.11 .11.822.200 Interface 25 pol Plug 1,00
30.20 .16.500.481 Plug X104 for interface
30.21 .11.822.203 Interface 4pol. plug 1,00
30.31 .11.820.101.205 Strapping plug cable set 1600 (X121) 1,00
Order information and connecting diagrams
Order information and connecting diagrams
Order information and connecting diagrams
 Spare parts lists

Spare parts lists

for the Plasma Cutting Machine

with Gas Console according to the delivery option:

Plasma Gas Control Unit PGE 3-360

or
Plasma Gas Control Unit PGE-360
or
Plasma Gas Valve Unit PGV 3

Plasma Machine Torch

PerCut 370.1 PerCut 370.1M

PerCut 370.1M Rotator, 4 mm head reduction
PerCut 370.1M Rotator, 6 mm head reduction
PerCut 370.2 PerCut 370.2M

Plasma Torch Connection Unit PBA-360

Cooling Unit KWE 360

Dear customer,

with the plasma cutting system you have purchased a quality product from
the Kjellberg Finsterwalde Plasma und Maschinen GmbH.

When ordering spare parts, please mention the complete article no. of the torch and also the complete
designation with article no. of the spare parts according to this list.
This information is required to be able to fulfil your wishes at short notice.

We reserve ourselves for technical reasons conditioned changes in the quantity production.

Claims of whatever kind can’t be derived from this spare parts list. Please direct your order straight to us or
to your contractor.

For more information we are always at your disposal.

Spare parts lists

Spare parts list HiFocus 280i

.11.034.302.E 05.09.2008
pos article no. designation code pcs.
01.00 .16.500.368 Front wall
01.01 .10.110.310 Emergency stop switch S3 1
01.02 .10.108.409 Contact part (S2,S3) 2
01.03 .10.108.412 Contact, opener (S3) 2
01.04 .10.145.011 Cam switch with key S1 1
01.05 .10.110.306 Illuminated push button switch S2 1
01.06 .10.108.411 Contact, closer (S2) 2
01.07 .10.110.311 Light-emitting diode green H1 1
01.08 .12.LP066520 PBC 066520A S5 1
01.09 .10.187.202 Knob 28mm black with line (S5,P5) 2
01.10 .10.187.203 Cover 28mm black with line (S5) 2
01.11 .10.187.204 Arrow ring 28mm black (S5,P5) 2
01.12 .10.800.208 Pin Logo Kjellberg Finsterwalde 1
01.13 .10.105.671 Frame for LCD display (A3) 2
01.14 .10.187.205 Knob 15mm black with line (A3) 3
01.15 .10.187.206 Cover 15mm black with line (A3) 3
01.16 .10.187.207 Arrow ring 15mm black (A3) 3
01.17 .12.LP066504 PCB 066504A A3 1

02.00 .16.500.369 Rear wall

02.03 .10.189.300 Fuseholder 6,3X32 mm 11
02.04 .10.189.302 Fuse cap 6,3 x 32 mm 11
02.06 .10.189.309 Fuse 6,25A 6,3x32mm 1
02.07 .10.189.305 Fuse T 2A, 6,3X32 mm 7
02.08 .10.189.311 Fuse T 500 mA 3
02.09 .10.164.174 Plug Insert, Female 7 Poles X121 1
02.10 .10.164.200 Body Part 3
02.11 .10.164.201 Crimp Contact, Female 0,75-1,5 qmm 41
(X102,X110,X121,X132,X122)
02.12 .10.603.008R Cable gland M63x1.5 27-48mm 1
02.13 .10.603.017 Nut M 63x1.5 1
02.14 023.763.000 DIX TBE 35-70 Mounting jack 1
02.15 .10.164.065 Socket insert 4 poles + PE X104 1
02.17 .10.164.197 Plug Insert, Female 8 Poles X132,X122 2
02.18 .10.164.110 Plug Insert, Female, 25-Pol. X102,X110 2
 Spare parts lists
11.034.302.E 05.09.2008
pos article no. designation code pcs.
02.19 .10.164.113 Plug Base (X102,X110) 2
02.20 .10.164.176 Plug Insert, Female 10 Poles X114 1
02.21 .10.164.179 Plug Base (X114) 1
02.22 .10.164.702 SUB-D socket 9pol/insert/soldered conn. X4.2 1
02.23 .10.164.701 SUB-D plug 9pol./insert/soldered connect. X4.1 1
02.24 .10.164.704.1 SUB-D clamping bolt short 8 mm 4
02.25 .10.164.714 SUB-D cover plate for socket red 1
02.26 .10.164.715 SUB-D Cover plate for plug blue 1
02.27 .10.164.198 Plug Insert X130 1
02.28 .10.580.139 Clamp 1
02.29 .10.274.024 Knurled nut M6 2
02.30 .10.639.575 Filter housing F5CL 3/8" 1
02.31 .10.639.576 Mounting angle F5/F10SL 1
02.32 .10.639.577 Filter element Type SE (100my) 1
02.33 .10.504.563 Handle part PA black 2
02.34 .11.034.402.755 Handle 595 lg 1
02.35 .10.109.519 Micro switch A1 S4 1
02.36 .11.822.204 Jumper 8pol (X132) X132 1

03.00 .16.500.505 Power source, left side

03.01 .10.269.566 Lifting eye M 10 4
03.02 .10.140.696 Fan dia. 300 M3 1
03.03 .11.036.112.100 Transformer complete T2 1
03.04 .11.034.402.450 Choke HiFocus 360i L2 1
03.05 .10.129.104 Resistor 6 OHM 5A 400W 29x300 R2,R5 2
03.06 .11.035.002.510 Choke coil L1 1
03.07 .11.500.700.467 Mains Cable 4x50qmm; 5m Without Plug 1
03.08 .10.502.246 Steering toller PL-CK 160x50 2
03.09 .11.035.002.590 Rectifier unit B6C 380/505-150 2
03.10 .12.58200 Fan Switch S4 1
03.11 .11.033.902.450 HF-Choke 80A L4 1
03.12 .10.502.262 WHEEL PB-CK 160x50 2
03.13 .10.184.763 Spring catch 2
03.14 .10.190.031 Filter 3x470n/10n 1
03.15 671.100.008 Capacitor B - 8 MFD - VIS M8 1
03.16 .10.129.107 Fixed resistor 12 OHM 5A 400W 29x300 R1 1
Spare parts lists
.11.034.302.E 05.09.2008
pos article no. designation code pcs.
03.17 .11.412.002B2 Inverter module 3 80A 1
03.20 .11.034.402.460 Main current relay K 31 K3 1
03.21 .10.161.730.230 Contactor B145 00 220-240V 50/60HZ Q1 1
03.22 .10.101.869 Shunt 150mV/400A Form B R6N 1
03.23 .10.164.300 Protective terminal 35qmm small 1
03.24 .10.164.078 Protective terminal 70qmm 1
03.25 .10.164.079 Terminal strip 70 qmm 3
03.26 .11.034.402.360 Coolant measuring unit 360i new P2 1
03.27 .10.133.360 CAPACITOR MKP 400,3 8,33 kVA 3x55,2uF 2
03.28 .10.190.035 ring core choke R102 3x1,5mH/ 200A L5 1
03.29 .10.148.283 TUMBLER SWITCH, 1-POLE S6 1
03.30 .10.147.814 circuit breaker MBN325 F7 1

04.00 .16.500.371 Control Unit

04.01 .10.164.189 Terminal strip 9700A/8 S35 T3 2
04.02 671.100.012 Capacitor B - 12 MFD - VIS M8 C4 1
04.03 .10.161.703 Contact G481 02 for type CF/BF (K4) 2
04.04 .10.101.603 Operating hours counter 24V AC 50/60Hz P1 1
04.06 .10.161.710.24 Contactor BG0040A024 50/60 Hz K6 1
04.07 .10.161.722.24 Contactor BF25 10 A024 50/60Hz K4 1
04.08 .10.190.364 Transformer T1 1
04.09 .10.190.029 Suppressor choke L3 1
04.10 .101.20.031 Resistor 100K 4,50 W 5% TK 200 R7 1
04.11 671.100.025 Capacitor B - 25 MFD - VIS M8 C3 1
04.12 .101.30.056 Resistor 47R 7,00 W 5% TK 200 R6 1
04.13 .10.535.603 Fan Boxer 119x119x25 M4 1
04.14 .10.140.724 Filter Medium125 x 125 x 8 mm F100S 1
04.17 .11.033.702.470 Current relais K2 1
04.18 .11.033.702.460 Current relais K1,K7 4
04.19 .10.164.170 Plug Insert, Female 3 Poles X103 1
04.20 .10.164.200.1 Case Base Plastic (X103) 1
04.21 .12.LP077785 Thyristor control A6 1
04.22 .12.LP067101 PCB-MR-control 2 A1 1
04.23 .10.164.283 Distribution Strip X50 1
04.24 .12.LP067201 PCB-067201 B adaptation HF 360i A2 1
 Spare parts lists
.11.034.302.E 05.09.2008
pos article no. designation code pcs.
04.25 .16.003.945 Converter RS-232 to RS-485 A8 1
04.26 .12.LP070320 PCB 070320 a mains adapter 4 A10 1
04.27 .10.110.467 Socket for relay (K12,K13) 2
04.28 .10.110.469 Frame for relay (K12,K13) 2
04.30 .10.110.480 Relay 24 VAC SPU.2 5A 250 VA K5,K11 2
04.31 .10.110.975 Relay K10 1
04.32 .10.110.977 Socket (K10) 1

05.00 .16.500.506 Power module

05.01 .10.535.601 Fan Type W2S130-AA03-44 Dm.150 M1,M2 2
05.02 .10.100.042 IGBT Module FF100R12KS4 Tr1-Tr4 2
05.03 .10.105.846 Module DSEP 2X91-06 A FRED Miniblock V1-V4 4
05.04 .10.105.868 Module SKD 62/16 B1 1
05.05 .10.123.261 PTC Resistor 60°C PTC 3
05.06 .11.412.002.450 Choke module 80 A L4 2
05.07 .10.535.605 Fan Boxer 135x135x38 230VAC 50/60Hz M3 1
05.08 .11.412.002.490 Choke L3 Module L3 1
05.09 .11.412.002.100 Transformer module plasma 80 A T1 1
05.10 .11.412.002.480 Choke L2 Module L2 1
05.11 .11.412.002.470 Choke L1 Module L1 1
05.12 .10.132.937 Capacitor 9uF 10% 700 VDC, STYLE SP C1 2
05.13 .10.164.097 Terminal strip 2.5qmm/8pole X3 1
05.14 .12.LP068311 PCB 068311C E-INLE A2 1
05.15 .10.164.189 Terminal strip 9700A/8 S35 3
05.16 .10.164.190 Protective terminal 10qmm 9700 A 2
05.17 .10.190.032 Toroidal choke R63 3x3mH/40A/6qmm L6 1
05.18 .10.190.031 Filter 3x470n/10n A1 1
05.19 .10.190.021 Mains transformer 400V/42V 0,8A, 50/60 Hz T2 1
05.20 .12.LP068320 PCB 068320 a A-INLE A4 1
05.21 .12.LP067000 PCB 067000 t INST2 A5 1
05.22 .12.LP068210 PCB 068210 c IGBT-INLE A3 1
Spare parts lists

fig. 1: frontage of the HiFocus

 Spare parts lists

Fig. 2:rear panel of the HiFocus

Spare parts lists

Fig. 3: side view of the HiFocus

 Spare parts lists

Fig. 4: mounting plate of the HiFocus

Spare parts lists

Fig. 5: power module of the HiFocus

 Spare parts lists

Spare parts lists PGE-360

.11.825.113 09.09.2008
pos article no. designation code pcs.

01.01 .10.148.902 Pressure switch 804-10-213 1/4" S1-S8, S10 9

01.02 .10.148.909 pressure transformer 0-10 BAR, G1/4" P1 1
01.03 .10.148.912 pressure transformer 0-16 BAR, G1/4" P2 1
01.04 .10.501.007 non-return valve G1/4" 2
01.05 .10.501.008 non-return valve G1/8" 11
01.06 .10.639.005 pressure reducer G 1/4" 8 BAR DR1 1
01.07 .11.825.102.816 Solenoid valve 24V AC w. orifice Ø1,1 Y27 1
01.08 .11.825.155.816 pressure reducer for PGV 3 ZG-section DR2 1
01.09 .11.825.155.817 pressure reducer for PGV 3 WG-bypass DR3 1
01.10 .12.250.000 SV with 2xDGN M13x1 O2 Y5, Y20 2
01.11 .12.250.002 SV with DGN M13x1 and HyLok 6M O2 Y1-4,Y7-16,Y22 14
01.12 .12.250.006 SV with HyLok 6M and DGN M13x1 O2 (Y22), Y24, Y25 3
01.13 .12.250.106.50 DR 2xM13x1A 5 bar DR5 1
01.14 .12.250.302 SV 3/2 with DGN M13x1 and HyLok 6M Y26 1
01.15 .12.250.303 SV 3/2 with M13x1A and HyLok 6M Y6 1
01.16 .12.250.304 SV 3/2 with M13x1 A/I (Y21), Y23 2
01.17 .10.101.985 power supply 230 VAC, 24 VDC, 2A controlled A3 1
01.18 .10.130.002 RC-link, 250V AC/DC 0,2uF 47 Ohm RC1 1
01.19 .10.164.111 Plug Insert, Male, 25-POL. X110A 1
01.20 .10.164.113 Plug Base X110A 1
01.21 .10.189.300 Fuse holder 6,3X32 mm F1, F2 2
01.22 .10.189.302 Fuse cap 6,3 x 32 mm F1, F2 2
01.23 .10.189.305 Fuse T 2A, 6,3X32 mm F1 1
01.24 .10.189.309 Fuse 6,25A 6,3x32mm F2 1
01.25 .10.535.605 Fan Boxer 135x135x38 230VAC 50/60Hz M1 1
01.26 .12.LP068620 PCB_068620_d CAN3 ( for PGE-360) A2 LP CAN3 1
01.27 .10.504.590 bar handle form B, L=100 black eloxadized 2
01.28 .10.504.883 rubber buffer 6 x 30 x 30 BLACK 4
01.29 .10.184.838 standoff M6 X 30 , I/A chromated 2
01.30 .10.508.019 Polyamide plastic hose 6/4 mm blue 1
01.31 .10.508.020 Polyamide plastic hose 6/4mm red 1
Spare parts lists
.11.825.113 09.09.2008
pos article no. designation code pcs.

01.32 .10.508.021 Polyamide plastic hose 6/4mm black 1

01.33 .10.508.023 Polyamide plastic hose 6/4mm green 1
01.34 .10.500.057 support sleeve brass 1
01.35 .10.500.058 clamping ring set 6mm brass 1
01.36 .10.500.065 metric tube Dm6 MS 1
01.37 .12.250.300 Solenoid valve Y21 1

02.01 .10.102.097 flow meter Air, O2 4

02.02 .10.102.198 flow meter. H2 PM 4700 8bar 3,5-35Nl/min 1
02.03 .10.187.202 Knob 28mm black with line 2
02.04 .10.187.203 Cover 28mm black with line 2
02.05 .10.187.204 Arrow ring 28mm black 2
02.06 .10.501.004 FLASH BACK Valve G1/8" I/I 0,2-16 BAR 2
02.07 .10.501.007 FLASH BACK Valve G1/4" 3
02.08 .10.575.152 Manometer gasket R1/4", Cu 7
02.09 .10.639.523 Manometer 50mm 1/4" 0-16.0 bar for Oxygen 2
02.10 .10.639.527 Manometer 50mm 1/4" 0-16.0 bar 5
02.11 .11.825.113.830 pressure reducer 12 bar, pre-finished 1
02.12 .12.250.002 SV with DGN M13x1 and HyLok 6M O2 Y28, Y29 2
02.13 .12.LP067401 PCB 067401 b FW_ PGE360, equipped A1 1
02.14 .12.LP067410 PCB 067410 b LED_PGE-360, equipped A4 1
 Spare parts lists

Fig. 6: Inlet unit, Outlet unit,

Details of clamping ring connection, Electrical components
Spare parts lists

Fig. 7: Front panel, rear view of front panel

 Spare parts lists

Spare parts lists PerCut 370.1

.11.846.621.E0 17.04.2008
pos article no. designation code pcs.
00.01 .11.846.721.901 Torch shaft 1,0m 360A/C - PerCut 370 1
00.01 .11.846.721.9015 Torch shaft 1,5m 320A/C - PerCut 370 1
00.01 .11.846.721.902 Torch shaft 2m 360A/C - PerCut 370 1
00.32 .10.505.961 O-ring 48x2 VMQ ISO 1629 70 shore 1
00.33 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1
00.35 .11.841.101.971 Set screw M6 of PB-S80 WS 1
00.36 .11.846.701.971 Threaded pin M6x7 1
00.39 .11.846.701.972 Stop screw M8x1 1
00.40 .10.505.803 O-ring 6x1 VMQ ISO 1629 70 shore 1
00.41 .10.575.036 O-ring 12x1,5 VMQ ISO 1629 70 shore 1
00.42 .10.164.344 sleeve MC BL12, silvered 4WSK7.713.00A 1
00.43 .11.841.101.956 Water inlet application f current socket 1

01.01 .11.846.621.100 Quick-change head PerCut 370.1 160A 1

01.08 .10.505.916 O-ring 26x2 VMQ ISO 1629 70 shore 1
01.09 .11.842.401.152 Cooling Tube PerCut 160 1
01.10 .10.505.917 O-ring 65x3.0 VMQ ISO 1629 red 1
01.11 .10.505.946 O-ring 36x2 VMQ ISO 1692 70 shore 1
01.12 .10.505.964 O-ring 49x2,5 VMQ ISO 1629 70 shore 1
01.13 .10.505.831 O-ring 7x1.5 VMQ ISO 1629 70 shore 5
01.14 .10.505.035 O-ring 8x1.5 VMQ ISO 1629 70 shore 4
01.15 .10.505.034 O-ring 9x1.5 VMQ ISO 1629 70 shore 3
01.16 .10.505.826 O-ring 6 x 1,5 VMQ ISO 1629 70 shore 2
01.17 .11.846.701.179 Connector SG/PG PerCut 370 1
01.18 .11.841.701.178 Pilot pin, complete, of PB-S110 WU 1
01.19 .11.841.701.182 PI-insolating sleeve of PB-S110 WU 1
01.20 .11.846.701.181 Connector CG PerCut 370 2
01.21 .10.505.799 O-ring 3.5x1.5 VMQ ISO 1629 70 shore 6
01.22 .11.841.101.078 Locking screw M6 of PB-S80 WS 3
01.23 .11.841.101.079 Role of locking screw 3
01.24 .11.841.701.079 Washer of locking screw 3
01.27 .11.841.701.179 Nipple -swirl g/plasma g- of PB-S 110 WU 1

11.01 .11.843.021.320 Cathode O2 S002Y complete 1

11.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
11.03 .11.843.021.406 Nozzle 0,6 S2006X 25A 1
Spare parts lists
.11.846.621.E0 17.04.2008
pos article no. designation code pcs.
11.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1
11.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1
11.04 .11.842.401.160 Nozzle cap complete 0,4 S3004 1
11.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1
11.05 .11.835.201.1561 Swirl Gas Cap 1,5 Z4015 1
11.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1
11.06 .11.835.201.081 Protection Cap Z501 1

12.01 .11.843.021.320 Cathode O2 S002Y complete 1

12.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
12.02 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1
12.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1
12.03 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1
12.03 .11.843.021.410 Nozzle 1,0 S2010X 80/90A 1
12.03 .11.843.021.412 Nozzle 1,2 S2012X 100/130A 1
12.03 .11.843.021.416 Nozzle 1,6 S2016X 160A 1
12.03 .11.843.021.414 Nozzle 1,4 S2014X 130/160A 1
12.03 .11.843.021.411 Nozzle 1,1 S2011X 90/100A 1
12.04 .11.842.401.1622 Nozzle cap complete 0,8 S3028 1
12.04 .11.842.401.1624 Nozzle cap complete 0,8 S3048 1
12.05 .11.835.201.1551 Swirl Gas Cap 2,2 Z4022 1
12.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1
12.05 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1
12.05 .11.835.201.1581 Swirl Gas Cap 2,5 Z4025 1
12.06 .11.835.201.081 Protection Cap Z501 1

14.01 .11.842.411.510 Cathode A S042 HiFinox 1

14.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
14.03 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1
14.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1
14.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1
14.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1
14.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1
14.06 .11.835.201.081 Protection Cap Z501 1
 Spare parts lists
.11.846.621.E0 17.04.2008
pos article no. designation code pcs.
15.01 .11.842.511.510 Cathode A S052 FineFocus 1
15.02 .11.834.321.153 Gas guide PB-S4x/Z111 1
15.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1
15.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1
15.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1
15.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1
15.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1
15.05 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1
15.06 .11.835.201.081 Protection Cap Z501 1

16.01 .11.842.511.510 Cathode A S052 FineFocus 1

16.02 .11.834.321.153 Gas guide PB-S4x/Z111 1
16.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1
16.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1
16.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1
16.04 .11.842.401.1621 Nozzle cap complete 0,8 S3018 1
16.05 .11.835.411.1580 Swirl Gas Cap 3,5 Z4535 1
16.05 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1
16.05 .11.835.411.1590 Swirl Gas Cap 4,5 Z4545 1
16.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1
16.06 .11.835.201.081 Protection Cap Z501 1

50.08 .12.29270 Filter M5x22 1

50.09 .12.49050 FILTER M 8X25, 9T2228 1
50.10 .12.49050 FILTER M 8X25, 9T2228 1

60.00 .16.500.006 Torch tools

60.10 .10.615.909 Torque screwdriver 1
60.11 .10.615.909.1 Connecting shaft E 6,3 / 1/4" 1
60.12 .10.615.909.2 Hexagon application, long, 1/4" SW 5,5 1
60.13 .10.615.909.3 Hexagon application, long, 1/4" SW 9 1
60.14 .10.615.909.4 Hexagon application, long, 1/4" SW 6 1
Spare parts lists
.11.846.621.E0 17.04.2008
pos article no. designation code pcs.
61.01 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1
61.02 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1
61.03 .10.716.836 crosstip screwdriver 1

70.00 .16.500.129 Accessories:

70.01 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1
70.10 .11.846.721.830 Station for head PerCut 370 1
Spare parts lists
Spare parts lists

Spare parts lists PerCut 370.1M

.11.846.821.E0 17.04.2008
pos article no. designation code pcs.
00.01 .11.846.921.901 Torch Shaft 1,0m 360A/C - PerCut 370 M 1
00.01 .11.846.921.9015 Torch Shaft 1,5m 360A/C - PerCut 370 M 1
00.01 .11.846.921.902 Torch shaft 2,0m 360A/C - PerCut 370M 1
00.33 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1
00.34 .10.505.972 VMQ ISO 1629 70 Shore RO 1
00.35 .11.846.901.970 locking support of PerCut 370M 1
00.36 .11.846.901.971 threaded pin M6x12 1
00.37 .11.846.901.972 Stop screw of PerCut 370M 1
00.41 .10.575.036 O-ring 12x1,5 VMQ ISO 1629 70 shore 1
00.42 .10.164.344 sleeve MC BL12, silvered 4WSK7.713.00A 1
00.43 .11.841.101.956 Water inlet application f current socket 1

01.01 .11.846.821.100 Quick change head PerCut 370.1M 160A 1

01.08 .10.505.916 O-ring 26x2 VMQ ISO 1629 70 shore 1
01.09 .11.842.401.152 Cooling Tube PerCut 160 1
01.11 .10.505.946 O-ring 36x2 VMQ ISO 1692 70 shore 1
01.12 .10.505.964 O-ring 49x2,5 VMQ ISO 1629 70 shore 1
01.13 .10.505.831 O-ring 7x1.5 VMQ ISO 1629 70 shore 5
01.14 .10.505.035 O-ring 8x1.5 VMQ ISO 1629 70 shore 4
01.15 .10.505.034 O-ring 9x1.5 VMQ ISO 1629 70 shore 3
01.16 .10.505.826 O-ring 6 x 1,5 VMQ ISO 1629 70 shore 2
01.17 .11.846.901.179 Nipple WG/PG PerCut 370 2
01.18 .11.841.701.178 Pilot pin, complete, of PB-S110 WU 1
01.19 .11.841.701.182 PI-insolating sleeve of PB-S110 WU 1
01.20 .11.846.701.181 Connector CG PerCut 370 2
01.21 .10.505.799 O-ring 3.5x1.5 VMQ ISO 1629 70 shore 6
01.22 .11.846.901.078 locking ring of PerCut 370M 1
01.23 .11.846.901.079 Locking sleeve of PerCut 370M 1
01.24 .10.257.543 THREATED PIN M4x4 DIN913 1

11.01 .11.843.021.320 Cathode O2 S002Y complete 1

11.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
11.03 .11.843.021.406 Nozzle 0,6 S2006X 25A 1
11.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1
11.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1
 Spare parts lists
.11.846.721.E0 17.04.2008
pos article no. designation code pcs.
11.04 .11.842.401.160 Nozzle cap complete 0,4 S3004 1
11.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1
11.05 .11.835.201.1561 Swirl Gas Cap 1,5 Z4015 1
11.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1
11.06 .11.835.201.081 Protection Cap Z501 1

12.01 .11.843.021.320 Cathode O2 S002Y complete 1

12.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
12.02 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1
12.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1
12.03 .11.843.021.412 Nozzle 1,2 S2012X 100/130A 1
12.03 .11.843.021.416 Nozzle 1,6 S2016X 160A 1
12.03 .11.843.021.414 Nozzle 1,4 S2014X 130/160A 1
12.03 .11.843.021.411 Nozzle 1,1 S2011X 90/100A 1
12.03 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1
12.03 .11.843.021.410 Nozzle 1,0 S2010X 80/90A 1
12.04 .11.842.401.1622 Nozzle cap complete 0,8 S3028 1
12.04 .11.842.401.1624 Nozzle cap complete 0,8 S3048 1
12.05 .11.835.201.1551 Swirl Gas Cap 2,2 Z4022 1
12.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1
12.05 .11.835.201.1581 Swirl Gas Cap 2,5 Z4025 1
12.05 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1
12.06 .11.835.201.081 Protection Cap Z501 1

14.01 .11.842.411.510 Cathode A S042 HiFinox 1

14.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
14.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1
14.03 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1
14.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1
14.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1
14.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1
14.06 .11.835.201.081 Protection Cap Z501 1

15.01 .11.842.511.510 Cathode A S052 FineFocus 1

15.02 .11.834.321.153 Gas guide PB-S4x/Z111 1
15.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1
15.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1
15.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1
Spare parts lists
.11.846.721.E0 17.04.2008
pos article no. designation code pcs.
15.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1
15.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1
15.05 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1
15.06 .11.835.201.081 Protection Cap Z501 1

16.01 .11.842.511.510 Cathode A S052 FineFocus 1

16.02 .11.834.321.153 Gas guide PB-S4x/Z111 1
16.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1
16.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1
16.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1
16.04 .11.842.401.1621 Nozzle cap complete 0,8 S3018 1
16.05 .11.835.411.1580 Swirl Gas Cap 3,5 Z4535 1
16.05 .11.835.411.1590 Swirl Gas Cap 4,5 Z4545 1
16.05 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1
16.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1
16.06 .11.835.201.081 Protection Cap Z501 1

50.08 .12.29270 Filter M5x22 1

50.09 .12.49050 FILTER M 8X25, 9T2228 1
50.10 .12.49050 FILTER M 8X25, 9T2228 1

60.00 .16.500.006 Torch tools

60.10 .10.615.909 Torque screwdriver 1
60.11 .10.615.909.1 Connecting shaft E 6,3 / 1/4" 1
60.12 .10.615.909.2 Hexagon application, long, 1/4" SW 5,5 1
60.13 .10.615.909.3 Hexagon application, long, 1/4" SW 9 1
60.14 .10.615.909.4 Hexagon application, long, 1/4" SW 6 1

61.01 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1

61.02 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1
61.03 .10.716.836 crosstip screwdriver 1

70.00 .16.500.129 Accessories:

70.01 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1
70.10 .11.846.921.830 Station for quick change head PerCut 370M 1
70.20 .11.846.921.840 Tool for Quick-Change Head PerCut 370M 1
Spare parts lists
Spare parts lists

Spare parts lists PerCut 370.1M Rotator, 4 mm head reduction

.17.212.821.E0 17.04.2008
pos article no. designation code pcs.
01.01 .17.212.821.100 Quick change head PerCut 370.1M Rotator 1
01.08 .10.505.916 O-ring 26x2 VMQ ISO 1629 70 shore 1
01.09 .11.842.601.152 Cooling tube PerCut 160 3D, 66,5 long 1
01.11 .10.505.946 O-ring 36x2 VMQ ISO 1692 70 shore 1
01.12 .10.505.964 O-ring 49x2,5 VMQ ISO 1629 70 shore 1
01.13 .10.505.831 O-ring 7x1.5 VMQ ISO 1629 70 shore 5
01.14 .10.505.035 O-ring 8x1.5 VMQ ISO 1629 70 shore 4
01.15 .10.505.034 O-ring 9x1.5 VMQ ISO 1629 70 shore 3
01.16 .10.505.826 O-ring 6 x 1,5 VMQ ISO 1629 70 shore 2
01.17 .11.846.701.179 Connector SG/PG PerCut 370 2
01.18 .11.841.701.178 Pilot pin, complete, of PB-S110 WU 1
01.19 .11.841.701.182 PI-insolating sleeve of PB-S110 WU 1
01.20 .11.846.701.181 Connector CG PerCut 370 2
01.21 .10.505.799 O-ring 3.5x1.5 VMQ ISO 1629 70 shore 6
01.22 .11.846.901.078 locking ring of PerCut 370M 1
01.23 .11.846.901.079 Locking sleeve of PerCut 370M 1
01.24 .10.257.543 THREATED PIN M4x4 DIN913 1

21.01 .11.842.621.310 Cathode O2 XL R002 (3D) 1

21.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
21.03 .11.842.621.406 Nozzle 0,6 R2006 25A(3D) 1
21.03 .11.842.621.407 Nozzle 0,7 R2007 35A (3D) 1
21.04 .11.842.601.160 Nozzle cap complete 0,4 R3004 (3D) 1
21.05 .11.838.001.1561 Swirl Gas Cap 1,5 Y4015 (3D) 1
21.05 .11.838.001.1571 Swirl Gas Cap 2,0 Y4020 (3D) 1
21.06 .11.835.201.081 Protection Cap Z501 1

22.01 .11.842.621.310 Cathode O2 XL R002 (3D) 1

22.02 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1
22.03 .11.842.621.408 Nozzle 0,8 R2008 50/60A (3D) 1
22.03 .11.842.621.409 Nozzle 0,9 R2009 70/80A (3D) 1
22.03 .11.842.621.411 Nozzle 1,1 R2011 90/100A (3D) 1
22.03 .11.842.621.414 Nozzle 1,4 R2014 130/160A (3D) 1
22.03 .11.842.621.412 Nozzle 1,2 R2012 100/130A (3D) 1
 Spare parts lists
.17.212.821.E0 17.04.2008
pos article no. designation code pcs.
22.03 .11.842.621.410 Nozzle 1,0 R2010 80/90A (3D) 1
22.04 .11.842.601.162 Nozzle cap complete 0,8 R3008 (3D) 1
22.04 .11.842.601.1621 Nozzle cap complete 0,8 R3018 (3D) 1
22.04 .11.842.601.1622 Nozzle cap complete 0,8 R3028 (3D) 1
22.05 .11.842.601.155 Swirl Gas Cap 2,2 R4022 (3D) 1
22.05 .11.842.601.158 Swirl Gas Cap 2,5 R4025 (3D) 1
22.05 .11.842.601.157 Swirl Gas Cap 2,0 R4020 (3D) 1
22.06 .11.835.201.081 Protection Cap Z501 1

23.01 .11.842.721.310 Cathode O2 XL R012 (3D) 1

23.02 .11.834.321.153 Gas guide PB-S4x/Z111 1
23.03 .11.842.721.412 Nozzle 1,2 R2112 100A (3D) 1
23.03 .11.842.721.414 Nozzle 1,4 R2114 130A (3D) 1
23.03 .11.842.721.416 Nozzle 1,6 R2116 160A (3D) 1
23.04 .11.842.601.162 Nozzle cap complete 0,8 R3008 (3D) 1
23.05 .11.842.701.158 Swirl Gas Cap 3,0 R4130 (3D) 1
23.05 .11.842.701.159 Swirl Gas Cap 4,0 R4140 (3D) 1
23.06 .11.835.201.081 Protection Cap Z501 1
23.07 .11.835.421.303 Spacer Z111A 1

24.01 .11.842.611.510 Cathode A R042 HiFinox (3D) 1

24.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
24.03 .11.842.621.407 Nozzle 0,7 R2007 35A (3D) 1
24.03 .11.842.621.408 Nozzle 0,8 R2008 50/60A (3D) 1
24.04 .11.842.601.162 Nozzle cap complete 0,8 R3008 (3D) 1
24.05 .11.842.601.157 Swirl Gas Cap 2,0 R4020 (3D) 1
24.06 .11.835.201.081 Protection Cap Z501 1

25.01 .11.842.711.510 Cathode A R052 (3D) 1

25.02 .11.834.321.153 Gas guide PB-S4x/Z111 1
25.03 .11.842.711.614 Nozzle 1,4 A R2514 120A (3D) 1
25.03 .11.842.711.618 Nozzle 1,8 A R2518 160A (3D) 1
25.03 .11.842.711.616 Nozzle 1,6 A R2516 140A (3D) 1
25.04 .11.842.601.1621 Nozzle cap complete 0,8 R3018 (3D) 1
25.05 .11.842.711.159 Swirl Gas Cap 4,0 R4540 (3D) 1
Spare parts lists
.17.212.821.E0 17.04.2008
pos article no. designation code pcs.
25.05 .11.842.711.157 Swirl Gas Cap 2,5 R4525 (3D) 1
25.05 .11.842.711.158 Swirl Gas Cap 3,0 R4530 (3D) 1
25.06 .11.835.201.081 Protection Cap Z501 1

60.00 .16.500.006 Torch tools

60.10 .10.615.909 Torque screwdriver 1
60.11 .10.615.909.1 Connecting shaft E 6,3 / 1/4" 1
60.12 .10.615.909.2 Hexagon application, long, 1/4" SW 5,5 1
60.13 .10.615.909.3 Hexagon application, long, 1/4" SW 9 1
60.14 .10.615.909.4 Hexagon application, long, 1/4" SW 6 1

61.01 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1

61.02 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1
61.03 .10.716.836 crosstip screwdriver 1

70.00 .16.500.129 Accessories:

70.01 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1
70.10 .11.846.921.830 Station for quick change head PerCut 370M 1
70.20 .11.846.921.840 Tool for Quick-Change Head PerCut 370M 1
Spare parts lists
Spare parts lists

Spare parts lists PerCut 370.1M Rotator, 6 mm head reduction

.17.213.921.E0 17.04.2008
pos article no. designation code pcs.
01.01 .17.213.921.100 Quick change head PerCut 370.1M Rot. 160A 1
01.08 .10.505.916 O-ring 26x2 VMQ ISO 1629 70 shore 1
01.09 .11.842.601.152 Cooling tube PerCut 160 3D, 66,5 long 1
01.11 .10.505.946 O-ring 36x2 VMQ ISO 1692 70 shore 1
01.12 .10.505.964 O-ring 49x2,5 VMQ ISO 1629 70 shore 1
01.13 .10.505.831 O-ring 7x1.5 VMQ ISO 1629 70 shore 5
01.14 .10.505.035 O-ring 8x1.5 VMQ ISO 1629 70 shore 4
01.15 .10.505.034 O-ring 9x1.5 VMQ ISO 1629 70 shore 3
01.16 .10.505.826 O-ring 6 x 1,5 VMQ ISO 1629 70 shore 2
01.17 .11.846.701.179 Connector SG/PG PerCut 370 2
01.18 .11.841.701.178 Pilot pin, complete, of PB-S110 WU 1
01.19 .11.841.701.182 PI-insolating sleeve of PB-S110 WU 1
01.20 .11.846.701.181 Connector CG PerCut 370 2
01.21 .10.505.799 O-ring 3.5x1.5 VMQ ISO 1629 70 shore 6
01.22 .11.846.901.078 locking ring of PerCut 370M 1
01.23 .11.846.901.079 Locking sleeve of PerCut 370M 1
01.24 .10.257.543 THREATED PIN M4x4 DIN913 1

21.01 .11.842.621.310 Cathode O2 XL R002 (3D) 1

21.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
21.03 .11.842.621.406 Nozzle 0,6 R2006 25A(3D) 1
21.03 .11.842.621.407 Nozzle 0,7 R2007 35A (3D) 1
21.04 .11.842.601.160 Nozzle cap complete 0,4 R3004 (3D) 1
21.05 .11.838.001.1561 Swirl Gas Cap 1,5 Y4015 (3D) 1
21.05 .11.838.001.1571 Swirl Gas Cap 2,0 Y4020 (3D) 1
21.06 .11.835.201.081 Protection Cap Z501 1

22.01 .11.842.621.310 Cathode O2 XL R002 (3D) 1

22.02 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1
22.03 .11.842.621.408 Nozzle 0,8 R2008 50/60A (3D) 1
22.03 .11.842.621.411 Nozzle 1,1 R2011 90/100A (3D) 1
22.03 .11.842.621.414 Nozzle 1,4 R2014 130/160A (3D) 1
22.03 .11.842.621.412 Nozzle 1,2 R2012 100/130A (3D) 1
22.03 .11.842.621.410 Nozzle 1,0 R2010 80/90A (3D) 1
22.03 .11.842.621.409 Nozzle 0,9 R2009 70/80A (3D) 1
 Spare parts lists
.17.213.921.E0 17.04.2008
pos article no. designation code pcs.
22.04 .11.842.601.162 Nozzle cap complete 0,8 R3008 (3D) 1
22.04 .11.842.601.1622 Nozzle cap complete 0,8 R3028 (3D) 1
22.04 .11.842.601.1621 Nozzle cap complete 0,8 R3018 (3D) 1
22.05 .11.842.601.155 Swirl Gas Cap 2,2 R4022 (3D) 1
22.05 .11.842.601.157 Swirl Gas Cap 2,0 R4020 (3D) 1
22.05 .11.842.601.158 Swirl Gas Cap 2,5 R4025 (3D) 1
22.06 .11.835.201.081 Protection Cap Z501 1

23.01 .11.842.721.310 Cathode O2 XL R012 (3D) 1

23.02 .11.834.321.153 Gas guide PB-S4x/Z111 1
23.03 .11.842.721.412 Nozzle 1,2 R2112 100A (3D) 1
23.03 .11.842.721.416 Nozzle 1,6 R2116 160A (3D) 1
23.03 .11.842.721.414 Nozzle 1,4 R2114 130A (3D) 1
23.04 .11.842.601.162 Nozzle cap complete 0,8 R3008 (3D) 1
23.05 .11.842.701.158 Swirl Gas Cap 3,0 R4130 (3D) 1
23.05 .11.842.701.159 Swirl Gas Cap 4,0 R4140 (3D) 1
23.06 .11.835.201.081 Protection Cap Z501 1
23.07 .11.835.421.303 Spacer Z111A 1

24.01 .11.842.611.510 Cathode A R042 HiFinox (3D) 1

24.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1
24.03 .11.842.621.407 Nozzle 0,7 R2007 35A (3D) 1
24.03 .11.842.621.408 Nozzle 0,8 R2008 50/60A (3D) 1
24.04 .11.842.601.162 Nozzle cap complete 0,8 R3008 (3D) 1
24.05 .11.842.601.157 Swirl Gas Cap 2,0 R4020 (3D) 1
24.06 .11.835.201.081 Protection Cap Z501 1

25.01 .11.842.711.510 Cathode A R052 (3D) 1

25.02 .11.834.321.153 Gas guide PB-S4x/Z111 1
25.03 .11.842.711.614 Nozzle 1,4 A R2514 120A (3D) 1
25.03 .11.842.711.618 Nozzle 1,8 A R2518 160A (3D) 1
25.03 .11.842.711.616 Nozzle 1,6 A R2516 140A (3D) 1
25.04 .11.842.601.1621 Nozzle cap complete 0,8 R3018 (3D) 1
25.05 .11.842.711.159 Swirl Gas Cap 4,0 R4540 (3D) 1
25.05 .11.842.711.157 Swirl Gas Cap 2,5 R4525 (3D) 1
25.05 .11.842.711.158 Swirl Gas Cap 3,0 R4530 (3D) 1
25.06 .11.835.201.081 Protection Cap Z501 1
Spare parts lists
.17.213.921.E0 17.04.2008
pos article no. designation code pcs.
60.00 .16.500.006 Torch tools
60.10 .10.615.909 Torque screwdriver 1
60.11 .10.615.909.1 Connecting shaft E 6,3 / 1/4" 1
60.12 .10.615.909.2 Hexagon application, long, 1/4" SW 5,5 1
60.13 .10.615.909.3 Hexagon application, long, 1/4" SW 9 1
60.14 .10.615.909.4 Hexagon application, long, 1/4" SW 6 1

61.01 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1

61.02 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1
61.03 .10.716.836 crosstip screwdriver 1

70.00 .16.500.129 Accessories:

70.01 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1
70.10 .11.846.921.830 Station for quick change head PerCut 370M 1
70.20 .11.846.921.840 Tool for Quick-Change Head PerCut 370M 1
Spare parts lists
Spare parts lists

Spare parts lists PerCut 370.2

.11.846.721.E0 08.07.2008
pos article no. designation code pcs.
0.2 .11.846.721.101 PerCut 370.2 1,0m / 360A / C 1
0.2 .11.846.721.1015 PerCut 370.2 1,5m / 360A / C 1
0.2 .11.846.721.102 PerCut 370.2 2m/360A/C 1

00.01 .11.846.721.901 Torch shaft 1,0m 360A/C - PerCut 370 1

00.01 .11.846.721.902 Torch shaft 2m 360A/C - PerCut 370 1
00.01 .11.846.721.9015 Torch shaft 1,5m 320A/C - PerCut 370 1
00.32 .10.505.961 O-ring 48x2 VMQ ISO 1629 70 shore 1
00.33 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1
00.35 .11.841.101.971 Set screw M6 of PB-S80 WS 1
00.36 .11.846.701.971 Threaded pin M6x7 1
00.39 .11.846.701.972 Stop screw M8x1 1
00.40 .10.505.803 O-ring 6x1 VMQ ISO 1629 70 shore 1
00.41 .10.575.036 O-ring 12x1,5 VMQ ISO 1629 70 shore 1
00.42 .10.164.344 sleeve MC BL12, silvered 4WSK7.713.00A 1
00.43 .11.841.101.956 Water inlet application f current socket 1

02.01 .11.846.721.100 Quick-change head PerCut 370.2 360A 1

02.10 .10.505.917 O-ring 65x3.0 VMQ ISO 1629 red 1
02.11 .10.505.961 O-ring 48x2 VMQ ISO 1629 70 shore 1
02.12 .10.505.964 O-ring 49x2,5 VMQ ISO 1629 70 shore 2
02.13 .10.505.831 O-ring 7x1.5 VMQ ISO 1629 70 shore 5
02.14 .10.505.035 O-ring 8x1.5 VMQ ISO 1629 70 shore 4
02.15 .10.505.034 O-ring 9x1.5 VMQ ISO 1629 70 shore 3
02.16 .10.505.826 O-ring 6 x 1,5 VMQ ISO 1629 70 shore 2
02.17 .11.846.701.179 Connector SG/PG PerCut 370 2
02.18 .11.841.701.178 Pilot pin, complete, of PB-S110 WU 1
02.19 .11.841.701.182 PI-insolating sleeve of PB-S110 WU 1
02.20 .11.846.701.181 Connector CG PerCut 370 2
02.21 .10.505.799 O-ring 3.5x1.5 VMQ ISO 1629 70 shore 6
02.22 .11.841.101.078 Locking screw M6 of PB-S80 WS 3
02.23 .11.841.101.079 Role of locking screw 3
02.24 .11.841.701.079 Washer of locking screw 3
 Spare parts lists
.11.846.721.E0 08.07.2008
pos article no. designation code pcs.
31.01 .11.836.901.152 Cooling Tube T901 1
31.02 .11.836.921.300 Cathode T012 O2/Air 1
31.03 .11.836.921.153 Gas guide T101 (6x0,8 cw) 1
31.03 .11.836.921.1531 Gas guide T111 (6x0,8 ccw) 1
31.03 .11.836.921.1542 Gas guide T104 (3x0,4 cw) 1
31.03 .11.836.921.1541 Gas guide T112 (3x0,6 ccw) 1
31.03 .11.836.921.154 Gas guide T102 (3x0,6 cw) 1
31.04 .10.505.908 O-ring 18.2 X 1.9 VMQ ISO 1629 70SHSW 1
31.05 .11.836.921.415 Nozzle T2115 O2 120A 1,5mm 1
31.05 .11.836.921.425 Nozzle T2125 O2 250A 2,5mm 1
31.05 .11.836.921.430 Nozzle T2130 O2 350A 3,0mm 1
31.05 .11.836.921.427 Nozzle T2127 O2 300A 2,7mm 1
31.05 .11.836.921.420 Nozzle T2120 O2 200A 2,0mm 1
31.06 .10.505.923 O-ring 28 X 2.0 VMQ ISO 1629 70 shore 1
31.07 .11.836.901.163 Nozzle cap T3030 (12x1,5 30° cw) 1
31.07 .11.836.901.165 Nozzle cap T3060 (12x1,5 60° cw) 1
31.07 .11.836.901.1651 Nozzle cap T3160 (12x1,5 60° ccw) 1
31.07 .11.836.901.164 Nozzle cap T3045 (12x1,5 45° cw) 1
31.07 .11.836.901.1641 Nozzle cap T3145 (12x1,5 45° ccw) 1
31.08 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1
31.09 .11.836.921.271 Swirl gas nozzle T522 1
31.11 .11.841.721.081 Protective cap T502 1
31.12 .11.833.101.155 Swirl Gas Cap 3,5 dry V4335 1
31.12 .11.833.101.157 Swirl Gas Cap 4,5 dry V4345 1

36.01 .11.828.911.230 Cooling tube PB-S75 ArH2 1

36.02 .11.836.911.500 Cathode T051 ArH2 1
36.02 .11.836.911.520 Cathode T053 ArH2 1
36.04 .10.505.908 O-ring 18.2 X 1.9 VMQ ISO 1629 70SHSW 1
36.05 .11.836.911.623 Nozzle T2523 ArH2 250A 2,3mm 1
36.05 .11.836.911.625 Nozzle T2525 ArH2 280A 2,5mm 1
36.06 .10.505.923 O-ring 28 X 2.0 VMQ ISO 1629 70 shore 1
36.07 .11.836.901.160 Nozzle cap T3000 1
36.08 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1
36.09 .11.836.921.271 Swirl gas nozzle T522 1
Spare parts lists
.11.846.721.E0 08.07.2008
pos article no. designation code pcs.
36.11 .11.841.721.081 Protective cap T502 1
36.12 .11.833.101.1550 Swirl Gas Cap 3,0 dry V4330 1
36.12 .11.833.101.155 Swirl Gas Cap 3,5 dry V4335 1
36.12 .11.833.101.156 Swirl Gas Cap 4,0 dry V4340 1
36.12 .11.833.101.157 Swirl Gas Cap 4,5 dry V4345 1
36.12 .11.833.101.159 Swirl Gas Cap 6 dry V4360 1
36.12 .11.833.101.158 Swirl Gas Cap 5 dry V4350 1

37.01 .11.828.911.230 Cooling tube PB-S75 ArH2 1

37.02 .11.836.911.500 Cathode T051 ArH2 1
37.02 .11.836.911.520 Cathode T053 ArH2 1
37.04 .10.505.908 O-ring 18.2 X 1.9 VMQ ISO 1629 70SHSW 1
37.05 .11.846.911.627 Nozzle T2427 ArH2 360A 2,7mm 1
37.05 .11.846.911.629 Nozzle T2429 ArH2 440A 2,9mm 1
37.07 .11.846.901.1608 Nozzle cap T3208 1
37.07 .11.846.901.1609 Nozzle cap T3209 1
37.07 .11.846.901.1628 Nozzle cap T3228 1
37.07 .11.846.901.1619 Nozzle cap T3219 1
37.09 .11.846.901.1545 Swirl gas cap T4045 1
37.09 .11.846.901.1540 Swirl gas cap T4040 1
37.09 .11.846.901.1550 Swirl gas cap T4050 1
37.10 .11.846.901.081 Protective cap T503 1

50.08 .12.29270 Filter M5x22 1

50.09 .12.49050 FILTER M 8X25, 9T2228 1
50.10 .12.49050 FILTER M 8X25, 9T2228 1

60.00 .16.500.006 Torch tools

60.10 .10.615.909 Torque screwdriver 1
60.11 .10.615.909.1 Connecting shaft E 6,3 / 1/4" 1
60.12 .10.615.909.2 Hexagon application, long, 1/4" SW 5,5 1
60.13 .10.615.909.3 Hexagon application, long, 1/4" SW 9 1
60.14 .10.615.909.4 Hexagon application, long, 1/4" SW 6 1
 Spare parts lists
.11.846.721.E0 08.07.2008
pos article no. designation code pcs.
62.01 .12.38180 Socket Spanner for Cooling Tube 1
62.02 .12.38170 Socket Spanner for Cathode 1
62.03 .12.40320 Cap puller 1
62.04 .12.38190 Socket Spanner for Nozzle Cap 1
62.05 .10.712.536 Hexagonal Wrench 4.0 mm 1
62.06 .12.38540 Test Gauge 1
62.07 .10.710.560 Pin Spanner With Hinge For DIA. 4 1
62.08 .11.840.301.824 Nozzle Puller PB-S70/75/76/77 1

70.00 .16.500.129 Accessories:

70.01 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1
70.10 .11.846.721.830 Station for head PerCut 370 1
Spare parts lists
 Spare parts lists

Spare parts lists PerCut 370.2M

.11.846.921.E0 08.07.2008
pos article no. designation code pcs.
0.2 .11.846.921.101 PerCut 370.2 M 1,0m / 360A / C 1
0.2 .11.846.921.1015 PerCut 370.2 M 1,5m / 360A / C 1
0.2 .11.846.921.102 PerCut 370.2 M 2,0m / 360A / C 1

00.01 .11.846.921.901 Torch Shaft 1,0m 360A/C - PerCut 370 M 1

00.01 .11.846.921.902 Torch shaft 2,0m 360A/C - PerCut 370M 1
00.01 .11.846.921.9015 Torch Shaft 1,5m 360A/C - PerCut 370 M 1
00.33 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1
00.34 .10.505.972 VMQ ISO 1629 70 Shore RO 1
00.35 .11.846.901.970 locking support of PerCut 370M 1
00.36 .11.846.901.971 threaded pin M6x12 1
00.39 .11.846.901.972 Stop screw of PerCut 370M 1
00.41 .10.575.036 O-ring 12x1,5 VMQ ISO 1629 70 shore 1
00.42 .10.164.344 sleeve MC BL12, silvered 4WSK7.713.00A 1
00.43 .11.841.101.956 Water inlet application f current socket 1

02.01 .11.846.921.100 Quick change head PerCut 370.2M 360A 1

02.11 .10.505.961 O-ring 48x2 VMQ ISO 1629 70 shore 1
02.12 .10.505.964 O-ring 49x2,5 VMQ ISO 1629 70 shore 2
02.13 .10.505.831 O-ring 7x1.5 VMQ ISO 1629 70 shore 5
02.14 .10.505.035 O-ring 8x1.5 VMQ ISO 1629 70 shore 4
02.15 .10.505.034 O-ring 9x1.5 VMQ ISO 1629 70 shore 3
02.16 .10.505.826 O-ring 6 x 1,5 VMQ ISO 1629 70 shore 2
02.17 .11.846.701.179 Connector SG/PG PerCut 370 2
02.18 .11.841.701.178 Pilot pin, complete, of PB-S110 WU 1
02.19 .11.841.701.182 PI-insolating sleeve of PB-S110 WU 1
02.20 .11.846.701.181 Connector CG PerCut 370 1
02.21 .10.505.799 O-ring 3.5x1.5 VMQ ISO 1629 70 shore 6
02.22 .11.846.901.078 locking ring of PerCut 370M 1
02.23 .11.846.901.079 Locking sleeve of PerCut 370M 1
02.24 .10.257.543 THREATED PIN M4x4 DIN913 1
Spare parts lists
.11.846.921.E0 08.07.2008
pos article no. designation code pcs.
31.01 .11.836.901.152 Cooling Tube T901 1
31.02 .11.836.921.300 Cathode T012 O2/Air 1
31.03 .11.836.921.153 Gas guide T101 (6x0,8 cw) 1
31.03 .11.836.921.1542 Gas guide T104 (3x0,4 cw) 1
31.03 .11.836.921.1531 Gas guide T111 (6x0,8 ccw) 1
31.03 .11.836.921.1541 Gas guide T112 (3x0,6 ccw) 1
31.03 .11.836.921.154 Gas guide T102 (3x0,6 cw) 1
31.04 .10.505.908 O-ring 18.2 X 1.9 VMQ ISO 1629 70SHSW 1
31.05 .11.836.921.415 Nozzle T2115 O2 120A 1,5mm 1
31.05 .11.836.921.425 Nozzle T2125 O2 250A 2,5mm 1
31.05 .11.836.921.427 Nozzle T2127 O2 300A 2,7mm 1
31.05 .11.836.921.430 Nozzle T2130 O2 350A 3,0mm 1
31.05 .11.836.921.420 Nozzle T2120 O2 200A 2,0mm 1
31.06 .10.505.923 O-ring 28 X 2.0 VMQ ISO 1629 70 shore 1
31.07 .11.836.901.163 Nozzle cap T3030 (12x1,5 30° cw) 1
31.07 .11.836.901.164 Nozzle cap T3045 (12x1,5 45° cw) 1
31.07 .11.836.901.1641 Nozzle cap T3145 (12x1,5 45° ccw) 1
31.07 .11.836.901.165 Nozzle cap T3060 (12x1,5 60° cw) 1
31.07 .11.836.901.1651 Nozzle cap T3160 (12x1,5 60° ccw) 1
31.08 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1
31.09 .11.836.921.271 Swirl gas nozzle T522 1
31.11 .11.841.721.081 Protective cap T502 1
31.12 .11.833.101.155 Swirl Gas Cap 3,5 dry V4335 1
31.12 .11.833.101.157 Swirl Gas Cap 4,5 dry V4345 1

36.01 .11.828.911.230 Cooling tube PB-S75 ArH2 1

36.02 .11.836.911.500 Cathode T051 ArH2 1
36.02 .11.836.911.520 Cathode T053 ArH2 1
36.04 .10.505.908 O-ring 18.2 X 1.9 VMQ ISO 1629 70SHSW 1
36.05 .11.836.911.623 Nozzle T2523 ArH2 250A 2,3mm 1
36.05 .11.836.911.625 Nozzle T2525 ArH2 280A 2,5mm 1
36.06 .10.505.923 O-ring 28 X 2.0 VMQ ISO 1629 70 shore 1
36.07 .11.836.901.160 Nozzle cap T3000 1
36.08 .10.505.958 O-ring 42x2 VMQ ISO 1629 70 shore 1
36.09 .11.836.921.271 Swirl gas nozzle T522 1
 Spare parts lists
.11.846.921.E0 08.07.2008
pos article no. designation code pcs.
36.11 .11.841.721.081 Protective cap T502 1
36.12 .11.833.101.1550 Swirl Gas Cap 3,0 dry V4330 1
36.12 .11.833.101.157 Swirl Gas Cap 4,5 dry V4345 1
36.12 .11.833.101.159 Swirl Gas Cap 6 dry V4360 1
36.12 .11.833.101.158 Swirl Gas Cap 5 dry V4350 1
36.12 .11.833.101.156 Swirl Gas Cap 4,0 dry V4340 1
36.12 .11.833.101.155 Swirl Gas Cap 3,5 dry V4335 1

37.01 .11.828.911.230 Cooling tube PB-S75 ArH2 1

37.02 .11.836.911.500 Cathode T051 ArH2 1
37.02 .11.836.911.520 Cathode T053 ArH2 1
37.04 .10.505.908 O-ring 18.2 X 1.9 VMQ ISO 1629 70SHSW 1
37.05 .11.846.911.627 Nozzle T2427 ArH2 360A 2,7mm 1
37.05 .11.846.911.629 Nozzle T2429 ArH2 440A 2,9mm 1
37.07 .11.846.901.1608 Nozzle cap T3208 1
37.07 .11.846.901.1619 Nozzle cap T3219 1
37.07 .11.846.901.1628 Nozzle cap T3228 1
37.07 .11.846.901.1609 Nozzle cap T3209 1
37.09 .11.846.901.1540 Swirl gas cap T4040 1
37.09 .11.846.901.1545 Swirl gas cap T4045 1
37.09 .11.846.901.1550 Swirl gas cap T4050 1
37.10 .11.846.901.081 Protective cap T503 1

50.08 .12.29270 Filter M5x22 1

50.09 .12.49050 FILTER M 8X25, 9T2228 1
50.10 .12.49050 FILTER M 8X25, 9T2228 1

60.00 .16.500.006 Torch tools

60.10 .10.615.909 Torque screwdriver 1
60.11 .10.615.909.1 Connecting shaft E 6,3 / 1/4" 1
60.12 .10.615.909.2 Hexagon application, long, 1/4" SW 5,5 1
60.13 .10.615.909.3 Hexagon application, long, 1/4" SW 9 1
60.14 .10.615.909.4 Hexagon application, long, 1/4" SW 6 1
Spare parts lists
.11.846.921.E0 08.07.2008
pos article no. designation code pcs.
62.01 .12.38180 Socket Spanner for Cooling Tube 1
62.02 .12.38170 Socket Spanner for Cathode 1
62.03 .12.40320 Cap puller 1
62.04 .12.38190 Socket Spanner for Nozzle Cap 1
62.05 .10.712.536 Hexagonal Wrench 4.0 mm 1
62.06 .12.38540 Test Gauge 1
62.07 .10.710.560 Pin Spanner With Hinge For DIA. 4 1
62.08 .11.840.301.824 Nozzle Puller PB-S70/75/76/77 1

70.00 .16.500.129 Accessories:

70.01 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1
70.10 .11.846.921.830 Station for quick change head PerCut 370M 1
70.20 .11.846.921.840 Tool for Quick-Change Head PerCut 370M 1
Spare parts lists
Spare parts lists

Spare parts list PBA-360

.11.820.250 17.04.2008
pos article no. designation code pcs.

01.01 .10.500.057 support sleeve brass 2

01.02 .10.500.058 clamping ring set 6mm brass 2
01.03 .10.500.065 metric tube Dm6 MS 2
01.04 .10.508.021 Polyamide plastic hose 6/4mm black 1
01.05 .10.109.519 push button Z-15 GQ 250V/10A 1 changer 1
01.06 .10.148.902 pressure switch 804-10-213 1/4" MS blade terminal 1
01.07 .10.164.052 screwed-in socket M12x0,75 4mm red 1
01.08 .11.035.002.070 HF-Transformer PA-SXX W/CNC 1
01.09 .101.30.029 WID KERA 4K7 4,00 W 5% TK 200 1
01.10 .12.LP078303 PCB_078303_a ignition box 1
01.11 .10.189.361 fuse 5x20 1A/380 V FF 1

02.01 .10.164.173 plug base. 3

02.02 .10.164.174 socket insert 7-poles 1
02.03 .10.164.175 plug insert 7-poles 1
02.04 .10.164.198 plug insert 8-poles 1
02.05 .10.164.177 plug insert 10-poles screw terminal 1
02.06 .10.164.179 plug base 1
02.07 .11.820.250.800 solenoid valve set 4 MV PBA-360 1
02.08 .10.504.867 rubber buffer 4,5x20x12 NR/SBR-1000 70SHO 4
02.09 .10.184.827 standoff M6 X 10 , I/A galvanised 4
 Spare parts lists

Fig. 8: Plasma Torch Connection Unit PBA-360

Spare parts lists

Spare parts list Cooling Unit KWE 360

.11.141.102 17.04.2008
pos article no. designation code pcs.

01.01 .11.573.005.005 mains cable 4x1,5 qmm, 5m, with plug X1 1

01.02 .16.004.600 PRESSURE SWITCH G1/4" MS S2 1
01.03 .10.640.167 PUMP 0,55kW 400V M1 1
01.04 .10.140.714 FAN COMPLETE DIA. 300 M2 1
01.05 .10.615.121 HEAT EXCHANGER FOR FF800 WITHOUT FAN 1
01.06 .10.184.760 recessed grip TT 1,2-1,6mm POLYAMID SW 2
01.07 .10.105.629 LED TYPE S311, GREEN H1 1
01.08 .10.146.018 TYP CA 10 A MAIN SWITCH S1 1
01.09 .10.164.065 Socket insert 4 poles + PE X133A 1
01.09 .10.164.200 Body Part 1
01.10 .10.190.021 Mains transformer 400V/42V 0,8A, 50/60 Hz T1 1
01.11 .10.161.711.48 contactor BG0610A048 50/60Hz Q1 1
01.12 .10.148.301 Motor protection switch F4 1
01.13 .10.148.305 Motor protection switch PKZMO-0,63 F5 1
01.14 .10.189.300 Fuseholder 6,3X32 mm F1,2,3 3
01.14 .10.189.302 Fuse cap 6,3 x 32 mm 3
01.14 .10.189.313 FUSE T 10A 6.3x32mm 440V 3
01.15 .10.163.777 ball valve Mini G1/2 I with flank MS 2
01.16 .11.141.102.310 coolant reservoir mont., KWE360 1
01.17 .10.580.574 fixed castor for heavy loads 100X30 70kg 2
01.18 .10.580.573 guide roll 100X30 70kg 2
01.19 .10.500.704 Filter for pump 1/2" 1
01.20 .10.190.287 Transformer 440-480-500/400V T2(optional) 1
 Spare parts lists

Fig. 9: side view of Cooling Unit KWE 360

 Protocol

for the

monthly gas pressure test

- 24.10.2006 - page A5-1 - Kjellberg Finsterwalde

Protocol for the monthly gas pressure test

Attention!
Due to the existing risk of fire and explosion by using of oxygen, hydrogen and in-
flammable gas mixtures, the monthly spot check of the gas supply system has to be
carried out carefully and proofed by protocol. The spot check occurs according to the
section "gas pressure test" at the instruction manual separatly for oxygen, hydrogen
and all inflammable gas mixtures.

Year Month carried out gas pressure test for : Date Name Signature

Oxygen Hydrogen

Jan.
Feb
Mar
Apr
Mai
Jun
Jul
Aug
Sep
Oct
Nov
Dec

Jan.
Feb
Mar
Apr
Mai
Jun
Jul
Aug
Sep
Oct
Nov
Dec

- 24.10.2006 - page A5-2 - Kjellberg Finsterwalde

 Year Month carried out gas pressure test for : Date Name Signature

forming gas

Jan.
Feb
Mar
Apr
Mai
Jun
Jul
Aug
Sep
Oct
Nov
Dec

Jan.
Feb
Mar
Apr
Mai
Jun
Jul
Aug
Sep
Oct
Nov
Dec

- 24.10.2006 - page A5-3 - Kjellberg Finsterwalde