Kjellberg FineFocus 800 User manual

Instruction Manual
Plasma Cutting Unit
FineFocus 800
with swirl-gas torch for dry and under water cutting,
suitable for CNC controlled cutting systems
Article no.: .11.036.102 / .106 / .108

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Quality Guarantee
The plasma cutting unit possesses CE-conformity and meets the regulations and instructions of the
European Community.
Developed and manufactured on basis of the standard EN 60974-1 (VDE 0544, part 1) and BGV D1
(accident prevention rules).
All Kjellberg plasma cutting units have the S-sign and are therefore applicable in environments with
increased hazard of electric shock.
All products are manufactured under strict quality assurance control and proved by certificates and
product test records.
The production takes place according to DIN EN ISO 9001.
Please take absolute notice !
New Coolant “Kjellfrost”
From today Kjellberg Finsterwalde is offering a new antifreezer with improved properties at the same price.
The new antifreezer “Kjellfrost” contains anodic and cathodic acting inhibitors. These ingredients are
protecting more effective all components of the cooling circuit against corrosion, even if compound members
of steel, copper and copper alloys are in the circuit.
The new “Kjellfrost” (colourless) replaces the former “Kjellfrost” (blue) by and by. Please check carefully what
kind of coolant your cooling system contains before filling up with the new “Kjellfrost” and pay attention for the
following points :
 The new antifreezer is nearly colourless (whereas the former was blue coloured).
 The new “Kjellfrost” still is classified as a hazardous substance in sense of the standard for
hazardous substances, but not in the sense of the standard for the transportation of hazardous
substances.
 Never mix the new “Kjellfrost” (colourless) with the old “Kjellfrost” (blue)!
 Never add water to the new “Kjellfrost” for dilution or filling up: The corrosion inhibitors become
inactive and the coolant acidic, which is leading very fast to corrosive damages!
Therefore pure “Kjellfrost” has to be used for filling up!
 In case the old coolant has to be replaced by the new antifreezer “Kjellfrost” (colourless) the
complete cooling circuit has to be drained fully and rinsed repeatedly with water. Only after this
procedure the new coolant may be filled up!
 Safety regulations for handling, storing, etc. are given in a safety data sheet, which is available on
request (Tel. [phone]).
All details given on the label of the new antifreezer have to be followed consequently !
All former information in our Instruction Manuals contradictory to this advise are invalid!
Kjellberg Finsterwalde
January 2002
S
EN
ISO
9001

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Vorsicht
beim Umgang mit
Kjellfrost !
Caution
if handling coolant
Kjellfrost!
- Kjellfrost nicht trinken
- Von Nahrungsmitteln, Getränken
und Futtermitteln fernhalten
- Berührung mit den Augen und der
Haut vermeiden
- Vor den Pausen und bei Arbeits-
ende Hände waschen
- Beschmutzte, getränkte Kleidung
sofort ausziehen
- Don’t drink Kjellfrost.
- Keep it away from food, drinks and
fodder.
- Avoid the contact with eyes and
skin.
- Always clean your hands after end
of work.
- Don’t wear contaminated clothes.
Erst-Hilfe-Maßnahmen
First aid measure
- nach Verschlucken
Kein Erbrechen herbeiführen, Mund aus-
spülen, reichlich Wasser nachtrinken und für
Frischluftzufuhr sorgen; unverzüglich den
Arzt hinzuziehen
- nach Augenkontakt
Augen bei geöffnetem Lidspalt mehrere
Minuten unter fließendem Wasser ab-spülen
und Arzt konsultieren
- nach Hautkontakt
Sofort mit Wasser und Seife abwaschen und
gut nachspülen
- After swallowing
Don’t bring up, clean the mouth, drink much
water, open the window for fresh air and call the
doctor.
- 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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Contents pages
1 Safety instruction 6
2 The plasma cutting process 10
2.1 Dry plasma cutting 11
2.2
2.2.1
2.2.2
Swirl gas technology
Dry plasma cutting
Under water plasma cutting
11
11
11
2.3
2.4
2.4.1
2.4.2
Advantages and main features
Range of application
Dry plasma cutting
Under water plasma cutting
11
12
12
13
3 Technical data 14
3.1 Plasma rectifier FINEFOCUS 800 14
3.2 Plasma torches 14
3.2.1 Plasma machine torch PB-S77 W-x 14
3.2.2 Plasma hand torch PB-S75 WH-1 15
3.3 Components 15
3.3.1 Plasma gas controller PGE 1-800 15
3.3.2 Plasma gas controller PGE 2-800 15
3.3.3 Plasma ignition box PZ-800 16
3.3.4 Plasma gas supply unit PGA 3-800 16
3.3.5 Plasma torch connection unit PBA-800 16
3.3.6 Plasma counter PZE 1 16
17
4
4.1
4.2
4.2.1
4.2.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.3.10
Technical description
Plasma rectifier FINEFOCUS 800
Plasma torches
Plasma machine torch PB-S77 W
Plasma hand torch PB-S75 WH-1
Plasma components
Remote control FB 1
Plasma gas controllers PGE 1-800 and PGE 2-800
Cable set PZL-800
Plasma ignition box PZ-800
Plasma gas connection unit PGA 3-800
Plasma torch connectio unit PBA-800
Cable set PBL-800
Plasma counter PZE 1
Tractor unit FE1
Accessories for the plasma hand torch
17
17
17
17
18
18
18
19
19
19
19
20
20
20
20
5
5.1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.5.1
5.2.5.2
5.2.5.3
Commissioning
Check out, placement and installation
Installation
Mains connection
Workpiece connection / current return line
Grounding
Connection of the FineFocus 800
Connection of the plasma torches
Connection of the plasma torches to the FineFocus 800
Plasma torch connection to the plasma ignition box PZ-800 /
plasma gas connection unit PGA 3-800
Plasma torch connection to the PBA-800
21
21
21
21
22
22
22
22
22
23
23

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pages
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
5.2.11
5.2.12
5.2.12.1
5.2.12.2
5.2.13
5.2.14
Connection of the plasma gas controller PGE 1-800
Connection of the plasma gas controller PGE 2-800
Connection of the plasma ignition box PZ-800
Connection of the plasma torch connection unit PBA-800
Connection of the gas hoses between PGE 1-800/PGE 2-800 and
PGA 3-800
Connection of the gas hoses between PGA 3-800 and PBA-800
Connection of the plasma gas supply
Plasma gases
Swirl gases (oxygen, nitrogen)
Filling up the coolant
Connection to CNC-control
23
24
24
24
24
25
25
25
26
27
27
6
6.1
6.1.1
6.1.2
6.2
6.3
6.4
6.4.1
6.4.2
6.5
6.6
6.6.1
6.6.2
6.6.3
6.7
Operation
Control and display elements
Front wall controls and displays
Service elements inside of the plasma cutting unit
Cutting operation
Machine torch operation
Hand torch operation
Cutting
Plasma gouging
Switching OFF the plasma unit
Change of consumables
Change of spare parts on plasma torch PB-S77 W
Preparation of torch PB-S77 for dry cutting without swirl gas
Change of spare parts on plasma torch PB-S75 W/WH
Hints for trouble shooting and protective circuits
29
29
29
30
31
32
32
32
33
33
33
34
34
36
38
7
7.1
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.2
Maintenance
Plasma rectifier
Cleaning
Gas supply
Plasma gas pressure test
Cooling system
Electrical revision
Plasma torches
39
39
39
39
39
39
40
40
Enclosure 41
42
46
51
52
Scheme “piercing sequences during plasma cutting”
Connection diagrams
Cutting data FineFocus 800
Wiring diagram FineFocus 800
Spare parts lists PB-S77 W and PB-S75 WH-1

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1 Safety instructions
All endangerments through the plasma cutting process are related with the process itself.
Endangerments may occur due to:
• High contact voltage
• High-voltage (HV) ignition
• Heat and light radiation
• Gases and smoke
• Noise
• Hot metal and spatter
• Handling of pressure cylinders
The plasma cutting machine has been developed in compliance with following standards:
 EN 60974-1 (VDE 0544 , part 1)
Safety requirements for installations for arc welding and welding power sources
 EN 50078 (VDE 0544 , part 203)
Safety requirements for installations for arc welding in connection with
 prEN 50192
Arc welding and plasma cutting systems
 EN 50199 (VDE 0544 , part 206)
Electromagnetic compatibility (EMC)
 BGV D1 (accident prevention regulation)
Welding, cutting and relating applications
The rules of the BGV D1 “Welding, cutting und related processes” from the 01.04.1990 and the
directive from April 2001 have to be followed strictly through the user. Before starting the Plasma
Cutting Machine carefully read this Instruction Manual. Only advised personnel are allowed to operate
the plasma installation!
Hint!
National and local codes governing plumbing and electrical installation shall take precedent
over any instruction contained in this manual!
Endangerments through high contact voltage
Attention!
Before opening the plasma rectifier generally the input power has to be disconnected
visible from the mains (unplug mains cable)!
Only advised personnel is allowed to carry out any maintenance and repair work to
the machine (see VDE 0105 or national codes).
Before starting the machine connect the workpiece cable and earth the workpiece!
Power sources with integrated cooling systems normally are having a high Ohmic conducting path
through the coolant to the housing. If the workpiece is not earthed the open circuit or cutting voltage
is applied to the housing after switching on the power source. But the resistance in a complete dirty
coolant in any case is more than 10kOhm, reducing the touch potential to a not dangerous level. The
touch voltage nevertheless is sensible.
With the plasma cutting unit the cooling circuit is insulated from the power source. Therefore a
contact potential does not appear.
Further requirements:
• Connect the power source only to a correct earthed mains socket with properly fitted protective
conductor
• Wear insulated protective clothing (safety shoes, leather apron, gloves)
• Place the torch on an insulated place
• Keep environment and plasma equipment dry
• Don´t use damaged cables and torches
• Arrange regular electric inspections
• Never shorten safety circuits (door contact, protective caps)

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Working in environments with increased hazard of electric shock
The Plasma Cutting Machine is built in compliance with valid standards (EN 60974-1, BGV D1) and
therefore applicable in environments with increased hazard of electric shock:
• The plasma power source and the plasma torch are forming a safety-proofed installation, which
can be separated only by a special tool
• If the cover plate isn´t properly closed the power source can´t be switched ON
• The plasma hand torch can be operated only, if the insulating protective cap, which prevents
against touching the life nozzle cap, is properly fitted. (safety circuit)
Therefore the plasma cutting unit is S-marked and applicable in environments with increased hazard
of electric shock.
Attention!
Always follow valid instructions and local safety rules (BGV D1 and EN 60974-1)!
Endangerments through high-voltage ignition
For igniting the pilot arc a High Voltage Igniter is installed in the power source. When pressing the
ON-button (remote control or CNC-signal) the high voltage is applied to the cathode. After initiating
the pilot arc the HV-supply becomes switched off automatically. After the cutting process has started
the pilot extinguishes.
Attention! Never touch the nozzle if the power source is switched ON!
Therefore the nozzle cap of the plasma hand torch is shielded by the protective cap to prevent
touching.
The HV-ignition may establish electric or electro-magnetic fields, which can cause interference to
 heart pace-makers and
 other electronic devices
in proximity of plasma installations.
Endangerment through electromagnetic interferences
The plasma cutting installation complies with the instructions of the EN 50199 (VDE 0544, part 206)
“Electromagnetic Compatibiliy (EMC), product standard for Arc Welding Equipment”. This standard is
valid for Arc Welding Installations and related processes (e.g. plasma cutting), which are designed for
the use in industrial and private areas.
Warning!
It may be necessary to provide special measures if plasma cutting machines are used
in private areas (screened power cables, etc.)
The user is responsible for installing and using the installation according to the manufacturer´s
instruction. If electromagnetic disturbances are detected then the user is responsible to arrange the
technical solution with the assistance of the manufacturer.
Recommendations for assessment of the area (EN 50199)
Before installing the equipment the user shall make an assessment of potential electromagnetic
problems in the surrounding area, and shall take the following into account:
• Other supply cables, control cables, signalling and telephone cabels below and adjacent to the
installation
• Radio and television transmitters and receivers
• Computer and other control equipment
• Safety devices, e.g. protections for industrial equipment
• Health of the people around, wearing pacemakers or hearing aids
• Equipment for calibration and measuring
• Immunity of other equipment in the environment. The user shall ensure that other equipment
being used in the environment is compatible. This may require additional protection measures.
• Time of day that cutting has to be carried out

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Recommendations of methods to minimize disturbances
If disturbance are detected it may be necessary to carry out following precautions:
• Filtering of the mains supply – shielding of the mains cable of the permanently installed plasma
cutting unit (good contact necessary between shielding and housing)
• Regular maintenance of the plasma cutting installation
• Doors and covers should be closed and properly fastened
• Cutting and workpiece cables should be kept as short as possible
• Potential equalization of all metallic components inside and adjacent to the installation (the
operator should be insulated from all metallic components)
• Earthing of the workpiece
• Selective screening of all other cables and equipment
Endangerment through heat and light radiation
The plasma arc produces intense ultraviolet and infrared rays that can hurt eyes and skin. Therefore
following precautions have to be arranged:
• Wearing of flame-retardant welding clothes (helmet, apron, gauntlet gloves, safety shoes)
• Hand or head shield with protective glasses of medium shade for watching the cutting process
• The cutting area should be prepared so that reflections and transmission of ultraviolet light is
reduced:
o Arranging painting of walls with dark colour
o Use of protective walls
Endangerment through fumes and smoke
Due to the plasma process itself hazardous substances may be produced. To avoid risks for health
the following has to be arranged:
• Keep cutting place well ventilated
• Remove fumes and smoke by exhaustion devices
• Remove all chlorinated and other solvents from the cutting area because they could form
phosgene gas when exposed to ultraviolet radiation
• Wear breathing mask when cutting galvanized materials
• Ensure that toxic limits become not exceeded
• When cutting is performed under water all toxic gases which are not taken of from the water itself
(~ 10 %) have to be exhausted
Attention!
In any case the user of the plasma cutting installation has to carry out measurements
of the concentration of toxic substances to proof the effectiveness of the exhaust
equipment!
Furthermore he is responsible the environment safe deposition of the solid
substances of the water bath.
Endangerment through noise
Be aware that during the plasma cutting a high noise level is produced.
mode of cutting cutting current material thickness noise level in distance of
1.0 m 3.0 m
no load
pilot arc
dry cutting
under water cutting
-
24 A
250 A
250 A
250 A
-
-
10 mm
40 mm
40 mm
70 dB (A)
96 dB (A)
103 dB (A)
105 dB (A)
73 dB (A)
-
88 dB (A)
93 dB (A)
99 dB (A)
71 dB (A)
Table 1 : noise level during plasma cutting
Therefore wear approved ear protection when using the plasma system.

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Endangerment through spatter
During plasma cutting sparks, slag and hot metal are produced. The risk of burns and fire exists!
To avoid endangerments the following has to be arranged:
• Removal of all potential flammable materials from the cutting area, at least in a distance of 10 m
• Cool down freshly cut material before handling or storing
• Make fire extinguishers available in the cutting area
Handling of pressure cylinders
For the plasma cutting process compressed gases are used. To avoid endangerments following
instructions have to be taken:
• Place cylinders upright in secured position
• Don´t use damaged cylinders, pressure reducers and armatures
• Use pressure reducers only for the gas it is determined
• Never lubricate pressure reducers with grease or oil
• Keep parts coming in contact with oxygen absolutely free of oil and grease
• When using oxygen the pressure reducer must be furnished with an explosion protection
• Perform gas pressure test acc. to chapter 7.3.1
Under water plasma cutting of aluminium
The molten aluminium forms in the water a granular slag which is having a relatively large surface. In
connection with the oxygen of the water hydrogen is exposed, which comes up to the surfaces and
get burned.
This chemical reaction between Al-granulates and the water can continue sometimes for longer
times. In connection with the compressed air, which mainly is used for the water level adjustment and
hydrogen-air-mixture will be formed, which is highly explosive (when containing 4 – 76 vol. % H2). If
this mixture will collect in the expansion chamber or underneath the cutting plate and becomes
ignited by the plasma arc the explosion may have fatal consequences.
Measurements to avoid oxyhydrogen gas
o Use nitrogen (poor quality is sufficient) for the water level adjustment instead of air.
o Water tables without level adjustment should ensure, that
• The hydrogen can escape unobstructed from the water and than get burned off
• The inside of the water table is even, to avoid the collection of granulates
• Slag and granulates become removed from the water table immediately after cutting
• No hydrogen can collect underneath the plates placed on the cutting table
• The cutting machine after the cutting is placed outside the water table to avoid, that
hydrogen or oxyhydrogen can penetrate hollow spaces (switch boards, etc).
o Storing of plates on the cutting table for longer times is not allowed!

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AB
C
E
F
A
B
C
D
E
F
without swirl gas with swirl gas
2 The plasma cutting process
2.1 Dry plasma cutting
The plasma is defined as a gas having atoms and molecules which are partly split into ions and
electrons and having therefore a high electrically conductivity.
In the plasma torch this gas becomes heated up extremely and leaves it through the nozzle with a
high speed. Due to the high heat concentration all electrically conductive materials will melt and due
to the high speed and pressure of the plasma arc the molten material will be blown away forming a
very small kerf in the material.
The plasma arc hereby is transferred from the cathode, installed in the plasma torch and conducted
to the negative pole of the plasma power source to the workpiece (transferred arc).
The plasma cutting is a technology for cutting of electrically conductive metals, like constructional
steels, stainless, aluminium, copper, etc.
1 pilot resistor
2 HV-igniter
3 gas supply
4 cathode
5 nozzle
6 plasma arc (main arc)
7 workpiece
Fig. 1: principle of dry plasma cutting
The safe ignition of the main arc (cutting arc) will be achieved through (see fig. 1):
• disconnection of HV-igniter just after ignition of pilot arc
• pilot arc current is limited by the pilot arc resistor
• as far as the pilot arc contacts the workpiece the main arc will be initiated between cathode and
workpiece (transferred arc)
2.2 Swirl gas technology
Plasma torches for the swirl gas technology
are using a swirl gas for shielding the
plasma arc from the atmosphere.
This shielding action favourable can be used
for “dry”-cutting torches and “under water”-
cutting as well.
Fig. 2: shows the principle of the swirl
gas technology in comparisation
to the conventional dry cutting
A– coolant inlet
B– coolant outlet
C– plasma gas
D– swirl gas
E– cutting direction
F– cutting edge