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Plasma Cutting Products

for each Task the optimum System

Made in Germany

Pioneers in Plasma Cutting since 1959

www.kjellberg.de
Plasma Cutting Technology made in Germany

Kjellberg Finsterwalde – a company with long


tradition – offers a wide range of products for
CNC-guided and manual plasma cutting that fit
different demands and requirements.

With products made in Germany users obtain


not only state-of-the-art equipment but also the
2D plasma cutting 3D plasma cutting
latest plasma cutting technology:

• HiFocus neo series with Contour Cut technology


• FineFocus series
• 3D plasma cutting with robots
• CutFire series
• PA-S series
• CUTi series
Contour Cut Underwater plasma
• Additional Equipment

Marking Manual plasma cutting

neo: new – efficient – original Contour Cut – Precision in Detail

neo: high speed, best quality, long lifetime, low costs

High cutting speed and best quality are no


contradiction with plasma cutting units from
Kjellberg Finsterwalde. Contour Cut stands for the precise cutting
of mild steel. When cutting small contours,
Further: neo offers long-living consumables, narrow bars and small holes with a diameter to
optimised technology and low gas consumption thickness ratio of 1:1 an outstanding cut quality
as well as reduced cutting costs and increased is achieved.
productivity.
Smooth cut surfaces and shar p cut edges
reduce time-consuming aftertreatment.
Thus, productivity increases while costs are
reduced.

With Contour Cut Speed contours can be


new – efficient – original cut at similar quality up to 50 % faster. Due
to the shorter processing time the costs per
cutting metre are reduced.
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HiFocus neo – Precise and efficient Plasma Cutting

HiFocus neo systems offer a higher level of


performance. Users benefit from an excel-
lent cutting and marking quality. Moreover, high
cutting speeds improve productivity and lower
process costs.

With cutting currents of maximum 600 A the


HiFocus neo series covers a cutting range from
0.5 mm to 160 mm.

All HiFocus neo systems can be used in combi-


nation with all CNC-guiding and robot systems
in the market.
HiFocus 280i neo, HiFocus 360i neo, HiFocus 440i neo
In addition to straight, contour and bevel cuts
up to 50°, the plasma cutting systems For frequently changing cutting tasks, like
HiFocus 130 neo, HiFocus 161i neo, HiFocus cutting different materials or a wide range of
280i neo, HiFocus 360i neo, HiFocus 440i neo material thicknesses, HiFocus neo is the perfect
and HiFocus 600i neo can also be used for solution.
marking, notching and punching.

Cutting Ranges HiFocus


Cutting Material thickness in mm
Current
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

80 A HiFocus 80i

130 A HiFocus 130 neo

160 A HiFocus 161i neo

280 A HiFocus 280i neo

360 A HiFocus 360i neo

440 A Mild steel HiFocus 440i neo


Stainless Steel
600 A HiFocus 600i neo

Recommended cutting range (1) Max. cutting range (2) Piercing (1), (2)
(1)
These data are depending on the materials to be cut and their compositions. (2)
Observe piercing capability.

Technical Data HiFocus


Power source HiFocus 80i HiFocus 130 neo HiFocus 161i neo HiFocus 280i neo HiFocus 360i neo HiFocus 440i neo HiFocus 600i neo (5)

Mains voltage (3) 3x 400 V, 50 Hz 2x 3x 400 V, 50 Hz

Fuse, slow 25 A 50 A 50 A 100 A 125 A 200 A 125 A + 134 A

Connected load, 17 kVA 32 kVA 28 kVA 67 kVA 87 kVA 127 kVA 87 kVA + 93 kVA
max.

Cutting current 80 A 130 A 160 A 280 A 360 A 440 A 600 A


100 % duty cycle

Marking current - 16 A 5-25 A 5-50 A 5-50 A 5-50 A 5-50 A

Dimensions 970 x 510 x 960 x 540 x 985 x 570 x 1030 x 680 x 1030 x 680 x 1030 x 680 x 2 x 1030 x 680 x
(L x W x H) 970 mm 1050 mm 1140 mm 1450 mm 1450 mm 1450 mm 1450 mm

Mass 161 kg 251 kg 206 kg 505 kg 517 kg 589 kg 517 kg + 510 kg

Plasma gases O 2, N 2 O2, Ar, H2, N2 O2, Ar, H2, N2 O2, Ar, H2, F5 (4)
O2, Ar, H2, F5 (4)
O2, Ar, H2, F5 (4)
O2, Ar, H2, F5 (4)

Marking gases - Ar Ar Ar Ar Ar Ar

Swirl gases O2, N2, Air, F5 (4)


O2, N2, Air, F5 (4)
O2, N2, Air, F5 (4)
O2, N2, Air O 2, N2, Air O 2, N2, Air O 2, N2, Air
(3)
Other voltages and frequencies on request (4)
Forming gas F5 (95% N2/5% H2) (5)
Consisting of HiFocus 360i neo and PowerModul HiFocus 600i neo

-3-
Flow Control – Automatic Adjustment of Plasma and Swirl Gases

The settings for different materials and material


thicknesses can be accessed and used from
the factory-adjusted cutting database. Speci-
fic or modified data can be saved in a special
customer database. The FlowControl can also
be installed in existing guiding systems
without database capabilities.

The settings for different materials and material


Automatic Plasma Gas Unit FlowControl for HiFocus thicknesses can be accessed and used from
The optimum gas mixture and the volume flow the provided cutting database. Specific or mo-
play an essential role in order to achieve a dified data can be saved in a special customer
high cut quality. Kjellberg Finsterwalde offers database. The FlowControl can also be instal-
a flow-controlled plasma gas control unit for led in existing guiding systems without databa-
the automatic adjustment of plasma and swirl se capabilities.
gases.
The FlowControl can be controlled by a serial
interface and can be used for HiFocus neo
systems from HiFocus 130 neo to HiFocus 600i
neo – also for marking.

ATChanger – Automatic Torch Changing Unit

ATChanger changing a plasmatorch

The automatic torch changing unit ATChanger


allows the automated change of plasma torch
heads. Based on the quick-change system
used for Kjellberg plasma torches. ATChanger
offers the following advantages:
• Almost fully automated controll of the cutting
system
• Increase of productivity due to reduced down-
times
• Equipping of system with up to eight torch-
heads with consumables for constant or ATChanger offers space for up to eight plasmatorches
different cutting tasks
• Quick change between highest cutting output The ATChanger can be installed in 2D and
and finest marking possible 3D guiding systems. It can be used for
HiFocus 280i neo, HiFocus 360i neo and
HiFocus 440i neo – also as retrofit.

-4-
FineFocus – For the upper Cutting Range

The robust systems of the FineFocus series offer


high performance even under extreme condi-
tions. Good cut qualities can be achieved even
under heavy load. Besides of technical gases,
it is also possible to cut with air and achive high
quality.

The FineFocus 800 is the most powerful system


of the series. Two of them connected in parallel
make the FineFocus 1600 which achieves
highest cutting performance. Furthermore, both
the FineFocus 800 and the FineFocus 1600 can
be used for underwater plasma cutting. FineFocus 800, FineFocus 600, FineFocus 450

Due to their attractive price-performance ratio,


the FineFocus systems are ideally suited for all
metal-working industries, e.g. steel and metal
construction, shipbuilding or metal service
centres.

HotWire
The FineFocus 800 can be modified quickly
and easily for applying the HotWire technology
for cutting electrically conductive, non-conducti-
ve, combined and interrupted materials.

HotWire: patented and Quality cutting of


unique gratings

Cutting Ranges FineFocus


Cutting Material thickness in mm
Current

20 40 60 80 100 120 160

130 A FineFocus 450

200 A FineFocus 600

300 A FineFocus 800

Recommended cutting range (1) Max. cutting range (2) Piercing (1), (2)
(1)
These data are depending on the materials to be cut and their compositions. (2)
Observe piercing capability.

Technical Data FineFocus


Power source FineFocus 450 FineFocus 600 FineFocus 800

Mains voltage (3) 3x 400 V, 50 Hz

Fuse, slow 50 A 100 A 125 A

Connected load, max. 34 kVA 60 kVA 83 kVA

Cutting current 100 % duty cycle 100 A (130 A at 75 % ED) 200 A 300 A

Mass 1025 x 711 x 970 mm 980 x 644 x 1320 mm 1370 x 870 x 1505 mm

Dimensions (L x W x H) 251 kg 370 kg 556 kg

Plasma gases O 2, Air, Ar, H2, N2 O2, Air, Ar, H2 O2, Air, Ar, H2

Swirl gases Air, N 2 Air, N 2 Air, N 2


(3)
Other voltages and frequencies on request

-5-
Robot-Guided Plasma Cutting

All systems of the HiFocus neo series and the


FineFocus 800 can be used in combination with
all robotsystems in the market. Diverse types of
work-pieces can be cut with robot systems:
• Structural components for vehicles
• Pipes and containers
• Hollow profiles, open and closed profiles as
well as bulb flat profiles
• Dished bottoms
Plasma cutting of a pipe

Robot-guided plasma cutting offers the follo-


wing advantages:
• Cost-efficient cutting
• Simple programming
• High cutting speeds
• High cut quality, almost no rework required
• High flexibility in application

Plasma cutting of open profile

Torches for Every Task


For all plasma cutting systems, we offer plasma
torches that can be used in combination with
robots, partly different designs:
• Straight version with 60° angled torch head
• Straight version with 90° angled torch head
• With quick-change head

Plasma cutting of a closed profile

Kjellberg plasma torches can be used


for bevel cutting up to 50°, with special
torches up to 60°.

-6-
PA-S – Plasma Cutting with Machine and Hand Torches

The PA-S series is based on conventional


step-switched power sources which are ideally
suited for automated cutting tasks with machine
torches in combination with 2D guiding systems
and 3D robots, but also for manual use with
hand torches.

We offer straight standard torches and special


torches with short shafts as well as torches with
a 60° or 90° angled torch head.

Further advantages are:


PA-S70 W, PA-S45 W
• Good quality of both cut surfaces
• High lifetime of consumables due to direct
liquid cooling Plasma gouging
Both the machine and hand torches can be
It is possible to perform contour and straight
quickly converted for plasma gouging. Plasma
cuts as well as bevel cuts up to 60° and inter-
gouging is ideal for eliminating welding defects,
rupted cuts in all 2D and 3D positions.
cracks, cavities and inclusions for preparing for
backwelding.
A wide range of accessories is available for the
hand torches which make it easy to perform
many diverse cutting tasks.

Plasma gouging does not require after-treatment and produces


less smoke compared to gouging with carbon electrodes.

Cutting Ranges PA-S


Cutting Material thickness in mm
Current

10 20 30 40 50 60 70

130 A PA-S45 W

240 A PA-S70 W

Recommended cutting range (1) Max. cutting range (2) Piercing (1), (2)
(1)
These data are depending on the materials to be cut and their compositions. (2)
Observe piercing capability.

Technical Data PA-S


Power source PA-S45 W PA-S70 W

Mains voltage (3)


3 x 400 V, 50 Hz

Fuse, slow 63 A 125 A

Connected load, max. 38 kVA 76 kVA

Cutting current 45 A at 100 % d.c. 80 A at 100 % d.c.


85 A at 100 % d.c. 160 A at 100 % d.c.
130 A at 60 % d.c. 240 A at 80 % d.c.

Dimensions (L x W x H) 1025 x 711 x 970 mm 1380 x 870 x 1080 mm

Mass 240 kg 460 kg


(3)
Other voltages and frequencies on request

-7-
CutFire – Starting Technique for Metal Construction

For simple automated cutting tasks Kjellberg


Finsterwalde offers the easy-to-use plasma cut-
ting inverters CutFire 100i and CutFire 65i with
low investment costs. They are preferable used
for mild steel up to 20 mm.

The inverters can be used in combination with


CNC guiding systems and other automatic guiding
systems to perform straight and contour cuts.

Typical fields of application are the metalwor-


king industry and many other workshops,
production plants and industrial enterprises.
CutFire 100i, CutFire 65i

The CutFire inverters work cost-saving and


safe due to:
• Using air as plasma gas
• Low costs for consumables
• Safe high-voltage ignition
• Stepless adjustment of cutting current

The CutFire 65i can be used for mechanised


as well as manual plasma cutting by simply
Cutting on guided system with CutFire
changing the torch.

Cutting Ranges CutFire


Cutting Material thickness in mm
Current

10 20 30

65 A CutFire 65i

100 A CutFire 100i

Recommended cutting range (1) Max. cutting range (2)

Piercing (1), (2)

(1)
These data are depending on the materials to be cut and their compositions.
(2)
Observe piercing capability.

Technical Data CutFire


Power source CutFire 65i CutFire 100i

Mains voltage (3) 3 x 400 V, 50 Hz

Fuse, slow 16 A 25 A

Connected load, max. 9.8 kVA 16.6 kVA

Cutting current 65 A at 35 % d.c. 100 A at 100 % d.c.


150A at 100 % d.c.

Mass 470 x 180 x 270 mm 710 x 280 x 590 mm

Dimensions (L x W x H) 17 kg 50 kg

Plasma gases Air


(3)
Other voltages and frequencies on request

-8-
FineMarker – Separate Plasma Marking Unit

The FineMarker is a separate unit for marking,


notching and punching tasks on unalloyed
steels, stainless steels and semi-finished pro-
ducts, e.g. sheets, pipes, profiles, circuit boards
and others.

The FineMarker makes it possible to mark com-


ponents with simple annealing colours or deep
notches and punches.

Penetration depth and line width are determined


by marking current, speed and the chosen
marking gas.
FineMarker

Technical Data FineMarker


Power source FineMarker

Mains voltage (3) 3 x 400 V, 50 Hz

Fuse, slow 10 A

Connected load, max. 5.2 kVA

Cutting current 25 A

Mass 710 x 400 x 440 mm

Dimensions (L x W x H) 30 kg

Marking gas Ar
Plasma marking (3)
Other voltages and frequencies on request

The FineMarker is well suited to supple-


ment existing oxy-fuel or plasma cutting
systems and can be controlled from the
guiding system via interface.

Height Control Units Make the Cutting Process Safe

It is crucial for a safe cutting process and the


quality of the cutting results to keep a constant
distance between torch and work-piece and
to lift the torch during piercing.

In addition to the simple, cost-efficient height


control unit for simple cutting applications,
Kjellberg Finsterwalde offers other data-
base-supported and bus-compatible, fully
automated control units for highest demands
regarding automated cutting processes.

It is possible to update existing cutting


machines by retrofitting a height control unit.

Height control KHC 4 Height control B 1000

-9-
CUTi – Manual Plasma Cutting Inverters

The CUTi series offers powerful lightweights


with high reliability for the flexible and mobile
use at construction sites and in workshops.
They are suitable for environments with increa-
sed hazard of electric shock.

The CUTi-inverters can be used for straight,


profile an contour cutting in all positions.

CUTi 35, CUTi 35C, CUTi 70, CUTi 90, CUTi 120

The CUTi 35C takes a special position: It has


an internal compressor and can therefore be
operated without external compressed air supply
for cutting a maximal material thickness of six
mm. With compressed air supply with material
thicknesses up to ten mm can be cut.

CUTi series stands for mobility in practice

Accessories

A large variety of accessories is available


for the flexible use of the CUTi units.

Cutting Ranges CUTi Bevelling cap Long consumables


Cutting Material thickness in mm
current
10 20 30 40 50

35 A CUTi 35C
35 A CUTi 35
70 A CUTi 70
90 A CUTi 90
120 A CUTi 120
Circle cutting device Template cuts
Recommended cutting range (1) Max. cutting range (1)
(1)
These data are depending on the materials to be cut and their compositions.

Technical Data CUTi


Power source CUTi 35C CUTi 35 CUTi 70 CUTi 90 CUTi 120

Mains voltage 1 x 230 V 1 x 230 V 3 x 400 V 3 x 400 V 3 x 400 V

Fuse, slow 16 A 16 A 16 A 25 A 32 A

Connected load, max. 3.3 [4,8 ] kVA


(2)
3.7 kVA 11.1 kVA 15 kVA 16.7 kVA

Cutting current 100 % d.c. 12–25 [35 (2)] A 5–35 A 26–70 A 26–90 A 25–120 A

Duty cycle 25 % I 35 A 40 % I 35 A 35 % I 70 A 40 % I 90 A 35 % I 120 A


35 % I 25 A 60 % I 28 A 60 % I 60 A 60 % I 74 A 60 % I 95 A
100 % I 20 A 100 % I 22 A 100 % I 50 A 100 % I 55 A 100 % I 80 A

Dimensions (L x W x H) 550 x 150 x 245 mm 480 x 150 x 225 mm 470 x 180 x 250 mm 470 x 180 x 270 mm 610 x 230 x 410 mm

Mass 12.5 kg 10 kg 16.4 kg 17 kg 28.5 kg

Plasma gas Air


(2)
With external compressed air supply

- 10 -
Tradition determines Identity, Character and Profil of an Enterprise

1922 Foundation of Kjellberg Elektro-Maschinen GmbH


1934 First welding technique from Finsterwalde
1936 Kjellberg is Europe's biggest manufacturer of arc
welding technique
1941 Kjellberg is the world's biggest manufacturer of arc
welding technique with 5,000 employees
1959 Year of birth of Kjellberg Finsterwalde plasma technology
1962 First use of an industrial plasma cutting system
with 50 kW ready for series production
Patent for fine focus plasma cutting in cooperation
with the institute “Manfred von Ardenne” in Dresden
1970 First use of air as carrying gas for plasma cutting
1975 Kjellberg systems conquer the Japanese
shipbuilding industry
1986 Beginning of the underwater plasma cutting
technology
1988 First primary-switched inverter – the plasma cutting
system PA-12 I
1991 Innovative new developments in the product range
and a new distribution system are the basis for the
company's reorganisation
1995 Consumables of the XL-Life system increase the
lifetime for plasma cutting with oxygen
1998 Introduction of the swirl gas technology for fine
focus plasma cutting
2000 HiFocus® – a new technology with laser-like cut
quality – conquers the market
2004 Very first flow-controlled automatic plasma gas sup-
ply unit worldwide – a big step towards a new dimen-
sion of quality and reproducibility of plasma cuts
2006 HiFocus 80i/160i/280i/360i make up the first com-
plete series with primary-switched inverter technology
2007 Introduction of new YellowXLife® generation of
consumables
2008 High flexibility with the new HiFocus 440i – at the
present time the most powerful highprecision
plasma cutting system worldwide
2010 Development of the new generation of plasma
torches PerCut 440/450 and PerCut 200/210 with
new consumables
2011 Introduction of the new plasma cutting technology-
Contour Cut®
2013 Generation HiFocus neo and copper cathodes
make plasma cutting more efficient

- 11 -
Plasma Cutting Technology made in Germany

FR

Munich

Kjellberg-plasma cutting units are CE-conform and correspond with the valid
guidelines and instructions of the European Union. They are developed and
fabricated on basis of the standard EN 60974 (VDE 0544). The plasma cutting
Kjellberg Finsterwalde Group units are labelled with the S-sign and therefore applicable to environments with
increased hazard of electric shock. The fabrication takes place according to DIN
Welding Electrodes EN ISO 9001. The factory-owned quality assurance comprises piece and cutting
performance tests, documented by test certificate.
Welding Equipment
Cutting Equipment Our products represent a high level of quality and reliability. We reserve the
rights to change design and/or technical specification during the series fabricati-
Mechanical Engineering on. Claims of any kind cannot be derived from this brochure.

, , , YellowXLife, XL, HiFocus, PGC, PerCut


Kjellberg Finsterwalde Plasma und Maschinen GmbH CUTi und Contour Cut are trademarks of the Kjellberg Foundation/Kjellberg
Finsterwalde and may be registered in Germany and/or other countries.
Oscar-Kjellberg-Str. 20 | 03238 Finsterwalde | Germany
13-11-01

Phone: +49 3531 500-0 | Fax: +49 3531 500-8510 Copyright © 2013 Kjellberg Finsterwalde Plasma und Maschinen GmbH.
plasma@kjellberg.de | www.kjellberg.de All rights reserved.