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

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2.2.1 Dry plasma cutting
With the conventional dry plasma cutting the plasma arc is directly transferred from the nozzle to the
workpiece. Spatter and upcoming material can lead to double arcing and to reduced nozzle life and
poor cutting quality.
Plasma torches using the swirl gas technology are avoiding those disadvantages. The nozzle of the
plasma torch effectively is protected by the swirl gas cap and the surrounding swirl gas against
upcoming material, especially when cutting starts by piercing.
Flow rate and composition of the swirl gas can be optimised to obtain best cutting results on different
materials.
2.2.2 Under water plasma cutting
The unter water cutting process reduces the pollution of the environment, the noise level of the
process and the light radiation considerably in comparison to the dry cutting. The distortion of the
cutting material is very low.
But the consumption of electrical energy is higher.
One of the advantages of the swirl gas technology is the fact that the plasma torch is suitable for the
dry cutting and the underwater cutting as well without any adaptation to the torch.
Furthermore the cutting process grants highest stability, ensuring optimum cutting quality for both:
“dry” and “under water”.
2.3 Advantages and main features
By the application of the Plasma Fine-Focus-Principle acc. to Professor Manfred von Ardenne with its
extreme constriction of the plasma arc an extraordinary energy density will be achieved, resulting in
various technological advantages, as there are:
• double-straight-effect (high cutting quality of both sides on the cut)
• small cutting kerfs
• reduced loss of material
• low heat input
• low distortion
• excellent cutting quality
Further technological advantages will be achieved by the application of the swirl gas technology for
the dry cutting and the under water cutting in connection with the XL-Life-Time-System and the
plasma gas oxygen.
Further advantages und features:
• Cutting range (material depending) for the FineFocus 800: quality cut – 1.0 to 40 mm (dry cutting);
severance – max. 80 mm; with 50 (60) kW cutting power
• Steepless current adjustment from 80 to 300 A ensures optimum current adaptation to all cutting
jobs
• Excellent cutting quality because of twelve-pulse rectification
• Micro electronic process control ensures high constancy of the cutting parameters
• CNC-interface allows automatic operation in connection with NC and CNC controlled profile
cutting systems, robots and other guiding machines
• Set value control from CNC systems possible
• Adjustable soft start minimizes consumption of nozzles and cathodes
• Integrated cooling circuit ensures longevity of consumables
• Easy operation by automatic ignition:
o pilot arc ignition by high-voltage igniter
o main arc excitation by pilot arc

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• control devices for safe operation:
o plasma gas monitored by gas pressure controller
o coolant controlled by flow switches
o time limitation for pilot arc
o automatic current cut-off by nozzle-workpiece contact
• Comfortable torch change because of easy to reach connectors with safety circuit
• Clearly arranged service and display elements (symbol marking) for easy and comfortable
operation
• High efficiency and low operational costs through:
o internation cooling unit, reduces gas consumption
o possibility to use air as plasma gas
• transportable by crane or fork lift
• various plasma gases ensure optimum cutting quality at all electrically conductive materials: air,
oxygen, Ar/H2-, Ar/N2- and Ar/N2/H2-mixtures
• machine or hand torch operation by choice
• hand torch suitable for:
o plasma cutting with guiding bow, wheel guide, circle attachment or tractor unit
o plasma arc gouging
2.4 Range of application
2.4.1 Dry plasma cutting
The transferred arc principle allows cutting with swirl gas on all electrically conductive materials up to
60 mm (material depending) with a cutting power of max. 50 (60) kW. Cutting of mild steels, high
alloyed steels, non-ferrous metals (aluminium, etc.) and special alloys is practicable in a wide range.
 mild steel - plasma gas air / swirl gas air:
High productivity, no or less dross formation; surface nitration or oxidation may
appear
- plasma gas oxygen / swirl gas air:
high productivity, no nitration or oxidation on the cutting surfaces
 CrNi-steel - plasma gas air / swirl gas air:
High productivity, no or less dross formation; surface nitration or oxidation may
appear; cutting quality not like cutting with Ar/H2- resp. Ar/H2/N2-mixtures
- plasma gas Ar/H2- resp. Ar/H2/N2– mixuteres / swirl gas N2:
Metallic clean surfaces; on thins sheet metal dross formation possible if using
Ar/N2-mixtures; can be avoided or reduced by adding of N2to the plasma gas
(Ar/H2/N2- mixture)
 aluminium - plasma gas air / swirl gas air:
High productivity, no or less dross formation, cutting quality not so good as with
Ar/H2-mixture
- plasma gas Ar/H2 / swirl gas air :
Much better cutting quality as with plasma gas air
All plasma torches ar capable to start the cutting by running start or by piercing.
The torches are suitable for straight-, bevel-, profile- and position cutting. Cutting and gouging is
applicable to plates, sheet metal, tube and pipes, forced and forged parts, piled plates, casted parts
and scarp metal.
The stepless cutting adjustment offers the possibility to adapt the cutting current to the material
conditions.
After changing some few torch components (see chapter 6.6) the plasma machine torches of the
PB-S77 W-series are suitable for dry cutting processes without swirl gas.
The plasma hand torch PB-S75 WH-1 also is suitable without swirl gas for dry cutting and gouging.
For the plasma hand torch various accessories, like circle attachment KSE 6, wheel guide RW2 and
the tractor unit FE 1 are optional available.

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2.4.2 Under water plasma cutting
The under water plasma cutting technology enables the cutting of electrically conductive materials
with swirl gas up to 40 mm (material depending).
It is possible to cut mild steels, high-alloyed steels, non-ferrous metals and special alloys. The cutting
surfaces are showing a slightly roughness.
Following plasma gases are recommended:
 mild steel - plasma gas air / swirl gas air:
high productivity, no or less dross formation, surface nitration or oxidation can
appear
- plasma gas oxygen / swirl gas air:
high productivity, no surface nitration and nearly no dross formation
 CrNi-steel - plasma gas air / swirl gas air:
High productivity, no or less dross formation, surface nitration or oxidation may
appear, cutting quality not so good as with Ar/H2- or Ar/H2/N2-mixtures
- plasma gas Ar/H2- resp. Ar/H2/N2– mixtures / swirl gas N2:
metallic clean cutting surface, dross formation specially with Ar/H2-mixture
possible, can be avoided by adding N2to the plasma gas (Ar/H2/N2-mixture)
- plasma gas Ar/N2/ swirl gas N2:
very sharp cutting edges and metallic clean surfaces

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3 Technical data
3.1 Plasma rectifier FINEFOCUS 800
Primary side
Input voltage U1: .11.036.102
.11.036.106
.11.036.108
Fuse, slow
Cross section Cu
Power factor cos ϕ
Efficiency
3~ 400V +5/-10%, 50Hz
3~ 500V +5/-10%, 50Hz
3~ 440V +5/-10%, 60Hz
125A
4 x 35mm2
0.8 (250A)
0.9
Dry cutting Under water cutting
80 - 300A
400V
80 - 300A
24A
200V
60kW (100% duty cycle)
Secondary side
Cutting range
Open circuit voltage UO
Cutting current IS
Pilot arc current IPB
Cutting arc voltage US
Cutting power PS
Material thickness ds: quality cutting / severance 40 mm / 80 mm 25 mm / 40 mm
Characteristic
Ignition
Workpiece cable
droping
Pilot arc ignition by HV-ignitor
Main arc exitation by pilot arc
70 mm2
Weight m
Dimensions (l x w x h)
Safety class
Thermal class
Cooling
556 kg
1375 x 870 x 1505 mm
IP22
F
By fan
Torch cooling
coolant
pressure
tank capacity
Internal cooling circuit
Coolant “Kjellfrost” (freeze-proofed up to –10oC) or “Kjellfrost-SUPER”
(freeze-proofed up to –25oC) with integrated corrosion protection
0,55 MPa (5,5 bar) at 6 l/min
approx. 50 l
Table 2
3.2 Plasma torches
3.2.1 Plasma machine torch PB-S77W-x
PB-S77 W-1, PB-S77 W-2
Technology
- dry, without WG* cutting thickness/~current / piercing:
- dry, with WG* cutting thickness /~current / piercing:
- UWP** with WG* cutting thickness /~current / piercing:
75 mm (250A) / 40mm (250A)
60 mm (250A) / 40 mm (250A)
40 mm (250A) / 25 mm (250A)
Open circuit voltage UO
Pilot arc current IPb
Duty cycle
Ignition
Torch diameter
Weight m
max. 400 V
max. 24 A
100%
High voltage ignition (max. 10 kV) with pilot arc
58 mm
15.7kg (10 m hose parcel)
Torch cooling
Flow rate
Coolant “Kjellfrost” (freeze-proofed up to –10oC) or “Kjellfrost-SUPER”
(freeze-proofed up to –25oC) with integrated corrosion protection
approx. 6 l/min
Plasma gases
Swirl gas
air, O2, Ar, N2, H2and mixtures (quality, pressure and flow rate see
PGE 1-800 and PGE 2-800)
O2, N2and mixtures
(quality, pressure, and flow rate see PGE 1-800)
Hose parcel length 6m / 10m / 15m (PB-S77 W-1) or 1m / 1.5m (PB-S77 W-2)
Connectors
Coolant outlet / cathode cable
Coolant inlet
Pilot cable
Control cable solenoids
Swirl gas
Plasma gases
G1/2”
M18x1.5
Single pin plug
8-pin plug
G1/4”
G3/8” - air, O2, Ar(N2) and G3/8” left – air, H2
Table 3 (** UWP = under water plasma / * WG = swirl gas)

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3.2.2 Plasma hand torches PB-S75 WH-1
PB-S75 WH-1/L
.11.828.701
PB-S75 WH-1/A
.11.828.711
Cutting thickness (~current) / Piercing: 75 mm (250A) / 40 mm (250A)
Open circuit voltage UO
Pilot arc current IPb
Duty cycle
Ignition
Weight m
max. 400V
max. 24A
100%
High voltage ignition (max. 10 kV) with pilot arc
10.7 kg (10 m hose parcel)
Torch cooling
Flow rate
Coolant “Kjellfrost” (freeze-proofed up to –10oC) or “Kjellfrost-SUPER” (freeze-
proofed up to –25oC) with integrated corrosion protection
approx. 6 l/min
Plasma gases
pressure
Flow rate
Used as:
air
(free of dirt, oil and water, use
micro filters)
0.8 MPa (8bar)
1680 l/h (28l/min)
ignition and cutting gases
Ar/H2/N2- mixtures
(with PV-800)
0.8 MPa (8bar)
2800 l/h (46l/min)
ignition and cutting gases
Hose parcel (length 6 or 10 m)
Coolant outlet/cathode cable
Coolant inlet
Pilot cable
Control cable solenoids
Control cable torch switch
Connectors
G1/2”
M18x1.5
Single pin plug
7 pin plug
3 pin plug
Plasma gases G3/8” (air)
G3/8” left (air)
G3/8” (Ar)
G3/8” left (H2)
Table 4
3.3 Components
3.3.1 Plasma gas controller PGE 1-800
Art.-No.: .11.824.222
Input voltage (solenoids)
Dimensions (l x w x h):
Weight:
24 V AC, 50 / 60 Hz
360 x 240 x 425 mm
14 kg
Plasma gases:
Max. pressure:
Max. flow rate (torch connected):
Connector size:
air
(free of dirt, oil and water, use micro
filter)
0.8 MPa (8 bar)
2800 l/h
G1/4“
oxygen
(99.5 %, dry, free of dirt, use micro
filter)
0.8 MPa (8 bar)
2800 l/h
G1/4“
Swirl gases:
Max. pressure:
Max. flow rate (torch connected):
Connector size:
air
(free of dirt, oil and water,
use micro filter)
0.8MPa (8bar)
2800 l/h
G1/4“
oxygen
(99,5 %, dry, free of dirt, use
micro filter)
0.8MPa (8bar)
3200 l/h
G1/4“
nitrogen
(min. 99.9 %)
0.6MPa (6bar)
1200 l/h
G1/4“
Table 5
3.3.2 Plasma gas controller PGE 2-800
Art.-No.: .11.824.227
Input voltage (solenoids):
Dimensions (l x w x h):
Weight:
24 V AC, 50 / 60 Hz
360 x 240 x 425 mm
10 kg
Plasma gases:
Max. pressure:
Max. flow rate (torch connected):
Connector size:
argon
(99.996 %)
0.6 MPa (6bar)
2100 l/h
G1/4“
hydrogen
(99.95 %)
0.8 MPa (8bar)
400 l/h
G3/8” links
nitrogen
(99.999 %)
0.6 MPa (6bar)
500 l/h
G1/4“
Table 6

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3.3.3 Plasma ignition box PZ-800
Art.-no.: .11.821.980
Input voltage (solenoids):
Dimensions (l x w x h):
Weight:
Connection to:
24 V AC, 50 / 60 Hz
450 x 185 x 240 mm
8.5 kg
FineFocus 800 with hose parcel extension PZL-800
Table 7
3.3.4 Plasma gas supply unit PGA 3-800
Art.-no.: .11.825.245
Dimensions (l x w x h):
Weight:
Plasma gases, swirl gas:
Connection to:
180 x 185 x 240 mm
4.0 kg
(see chapter 3.3.1 and 3.3.2)
PGE 1-800/PGE 2-800 by gas hoses
Table 8
3.3.5 Plasma torch connection unit PBA-800
Art.-no.: .11.820.231 (3x solenoids)
Input voltage (solenoids):
Dimensions (l x w x h):
Weight:
Plasma gases, swirl gas :
Connection to:
24 V AC, 50 / 60 Hz
170 x 220 x 335 mm
3 kg
(see chapter 3.3.1 and 3.3.2)
PZ-800 and PGA 3-800 resp. power source and PGA 1-800/PGA 2-800 with hose
parcel extension PBL-800
Table 9
3.3.6 Plasma counter PZE 1
Art.-No.: .11.824.254
Dimensions (l x w x h):
Weight:
Connection to:
180 x 185 x 140
2.0 kg
FineFocus 800 with 8pole control cable
Table 10

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4 Technical description
4.1 Plasma rectifier FINEFOCUS 800
All components of the plasma power source are mounted into a movable housing and cooled by a
fan.
The control and signalling elements and the workpiece cable connector are placed in the front panel.
The back wall contains the fuses, the connectors for the CNC-cable and the control cables for the
components, like PGE 1-800 / PGE 2-800 and PZE 1 as well as the mains cable entry.
The connectors for the cathode supply cables, the remote control and the connection cables to the
PZ-800 are placed inside of the plasma rectifier and accessible after opening the front door. All
connectors are marked.
The internal cooling system consists of the pump, the coolant tank, the heat exchanger and the flow
controller for switching off the power source in case of insufficient flow rate.
The power module of the FineFocus 800 consists of the main transformer, the 12-pulse rectifier, the
choke coil, the pilot rectifier with pilot resistors and the power contactors.
A high voltage igniter initiates the pilot arc.
4.2 Plasma torches
Attention!
The plasma cutting unit should be operated only with the plasma torches of the series
PB-S77 W-1 or PB-S77 W-2.
Before starting any installation or maintenance work the power source has to be
disconnected visible from the mains (unplug mains cable)!
The plasma torches of the PB-S77 W-series are suitable with the plasma gases air, oxygen, argon,
nitrogen and hydrogen. Secondary gases (swirl gas) are oxygen and nitrogen, mixtures of these
gases and air as well.
The cutting current is transferred to the cathode by a flexible copper cable, which in inserted is the
insulating water inlet hose.
The nozzle is fixed in the nozzle holder by a detachable nozzle cap. The cooling water circulates
between nozzle and nozzle cap. A special cooling tube arranges an effective cooling of the cathode.
Therewith a perfect cooling of all torch parts is granted.
Attention!
Before using a plasma torch it is necessary to ensure, that the torch is equipped with the parts
suitable for the plasma gases and the cutting technology! After each change of torch parts a
gas purge of about 20 sec. Is required, to blow out remaining water, which can damage the
torch during ignition (tumbler switch “Gas test”).
The operator is allowed to change only spare parts!
Only spare parts and consumables of Kjellberg origin have to be used!
Keep all parts (consumables included) coming in contact with oxygen free of oil and grease!
4.2.1 Plasma machine torch PB-S77 W
The plasma machine torch PB-S77 W is designed for a maximum cutting current of 300 A and
therefore suitable for thicknesses up to 80 mm. The main parts of the torch are torch head, torch
shaft, hase parcel and consumables. The torch is furnished with two plasma gas supply hoses and
one swirl gas hose.
4.2.2 Plasma hand torch PB-S75 WH-1
The plasma hand torch of the PB-S75 WH-1 series are suitable for a cutting current of max. 250 A,
which is sufficient for a max. thickness of 80 mm. The hand torch consists of torch head, handle with
torch switch, hose parcel and consumables.

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Following hand torches are available: PB-S75 WH-1/L
- plasma hand torch for plasma gas air
PB-S75 WH-1/A
- plasma hand torch for plasma gas Ar/H2/N2-mixture
The plasma torches are easily to convert to the demanded plasma gas by changing the consumables
only: - ../L = delivered with air consumables
- ../A = delivered with consumables for Ar/H2/N2-mixture
The following tables ar showing cathode and nozzle specifications for the different plasma gases and
the current ranges.
technology
plasma cutting with guide bow (from 50 mm wheel guide RW 2) plasma gouging
cutting current
cathode
nozzle
nozzle orifice
up to 120A
K2
L3
1.4mm
up to 160A
K2
L1
2.0mm
up to 250A
K2
L2
2.5mm
up to 160A
K2
L9
4.0mm
Table 11: Consumables of the PB-S75 WH-1 for plasma gas air
technology
plasma cutting with guide bow (from 50 mm wheel guide RW 2) plasma gouging
cutting current
cathode
nozzle
nozzle orifice
up to 120A
K5
A1
1.4mm
up to 160A
K5
A3
2.0mm
up to 250A
K5
A2
2.5mm
up to 160A
K5
A9
4.0mm
Table 12: Consumables of the PB-S75 WH-1 for plasma gas Ar/H2/N2-mixture
Consumables are: the cathode, the nozzle, the nozzle cap, the cooling tube, the guide bow and the
O-rings 18x2 and 28x2 as well.
Torch tools are: the gas guide puller, the gas cap puller, the hexagonal wrench and the socket
spanner for the cathode and the nozzle cap.
The placement of parts and the change of consumables is explained in chapter 6.6.
4.3 Plasma components
4.3.1 Remote control FB 1
With the remote control FB 1 the cutting process with a machine torch (ignition of pilot arc) can be
started and stopped.
It is provided with an ON-(green) and OFF-(red) button. The 10 m control cable becomes connected
to the connector X 132, placed on the connection board of the FineFocus 800.
4.3.2 Plasma gas controllers PGE 1-800 and PGE 2-800
The plasma gas controllers PGE 1-800 or PGE 1-800 with PGE 2-800 are required for the dosage
and control of the plasma and swirl gases.
The PGE 1-800 is provided with the gas connectors, the pressure switches, the solenoid valves and
the flow controllers for the plasma gases air and oxygen and the swirl gases as well.
A tumbler switch on the PGE 1-800 starts the “gas purge” of the plasma gas, preselected with the
selector switch on the FineFocus 800 and the activated swirl gas. The 25-pole control cable connects
the PGE 1-800 with the socket X126, placed on the back panel of the FineFocus 800.
The PGE 2-800 is provided with the gas connectors and contains the pressure switches, the solenoid
valves and the flow controller for argon, hydrogen and nitrogen.
By means of the installed tumbler switch from the PGE 2-800 the gas supply of the plasma gases
hydrogen and nitrogen can be stopped on demand. A 4-pole control cable connects the PGE 2-800
with the socket X122, placed on the back panel of the FineFocus 800.

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4.3.3 Cable Set PZL-800
For many applications the standard hose parcels of the plasma torches with 6 or 10 m length are to
short. The operational radius can be extended upt to 55 m when using a cable set PZL-800 in
connection with the plasma ignition box PZ-800.
The cable set PZL-800 consists of:
• coolant outlet hose
• coolant inlet hose
• 8-pole control cable
• 10-pole control cable PZ-800
• cathode cable 70 mm2
4.3.4 Plasma ignition box PZ-800
The plasma ignition box PZ-800 connects the plasma torch hose parcel respectively the cable set to
the PBA-800 with the
power source by the
cable set PZL-800. The
PZ-800 contains the
connectors for the
coolant inlet and outlet
hoses for the torch
hose parcel and the
cable set PZL-800 and
the torch solenoid
supply cables as well.
Optionally the PZ-800
can be provided with
coolant return flow
blocker. All terminals
are accessible after
opening the side walls
which are protected by
safety contacts.
Fig. 3: plasma ignition box with plasma gas connection unit
4.3.5 Plasma gas connection unit PGA 3-800
For extending the operational radius with the plasma ignition box PZ-800 the plasma gas connection
unit PGA 3-800 is required. All connectors and terminals for the gas supply are placed on the
backside, connecting the PGA 3-800 with the PGE 1-800 / PGE 2-800 and the plasma torches resp.
the plasma torch connection unit.
The PGA 3-800 is fixed on the top of the plasma ignition box PZ-800.
4.3.6 Plasma torch connection unit PBA-800
The plasma torch connection unit is the connection point between the plasma torches PB-S77 W-2
and the plasma ignition box PZ-800.
The PBA-800 contains the connectors for the water inlet, water return / cathode and the pilot current
and furthermore the solenoids with the connectors for the plasma gases and the swirl gas. All
components are accessible after opening the safety switch protected cover plate.
PGA3-800
PZ-800

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4.3.7 Cable set PBL-800
The cable set connects the plasma torch connection unit PBA-800 with the plasma ignition box
PZ-800 resp. the FineFocus 800. The cable set PBL-800 consists of:
• coolant inlet hose
• coolant outlet hose with inserted cathode cable 35 mm2
• pilot arc cable
• control cable (solenoids, safety circuit)
Furthermore the connection hoses for the PG 1 and PG 2 and the swirl gas from the PGA 3-800 have
to be connected.
4.3.8 Plasma counter PZE 1
The plasma counter PZE 1 records the number of ignitions, the arc stops and the effective cutting
time. A 3-pole control cable connects the PZE 1 with FineFocus 800 (back side wall).
4.3.9 Tractor unit FE 1
The transportable tractor unit FE 1 mechanises the cutting process when using the hand torch
PB-S75 WH-1.
Following procedures are possible:
• Straight line cutting on rails
• Manual guiding along markings on the workpiece
• Circle cutting of diameters 150 to 1500 mm with the circle attachment
Further details of the tractor unit FE 1 are shown in the Instruction Manual .11.824.540.
4.3.10 Accessories for the plasma hand torch
Optional for the plasma hand torch are available the wheel guide RW 2 and the circle attachment
KSE 6 for cutting of circles 62 to 600 mm diameter.