Kjellberg FineFocus Flash 101 User manual

Instruction Manual
- Power source CutFire 100i
- Plasma machine torch Flash 101 G/L
Art.-No.: .11.034.812BA
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General information
2
Copyright
The reproduction, distribution and utilization of this document as well as
the communication of its contents to others without express
authorization is prohibited. Offenders will be held liable for the payment
of damages. All rights reserved in the event of the grant of a patent,
utility model or design.
Subject to alterations.
Kjellberg Finsterwalde Plasma und Maschinen GmbH, 2017
Kjellberg Finsterwalde Plasma und Maschinen GmbH
Oscar-Kjellberg-Straße 20
DE - 03238 Finsterwalde
Tel.: [phone]
Fax.: [phone]
E-Mail: plasm[email protected]
Web: www.kjellberg.de

General information
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Contents
1General information ...............................................................................................................................5
1.1 Warranty claim................................................................................................................................... 5
1.2 Standards and Directives................................................................................................................... 5
1.3 Information to the instruction manual - target groups........................................................................ 6
1.4 Plasma cutting as procedure............................................................................................................. 7
2Safety instructions.................................................................................................................................9
2.1 Explanation of the safety symbols..................................................................................................... 9
2.2 Endangerment by high contact voltage ........................................................................................... 15
2.3 Working in environments with increased electric endangerment.................................................... 15
2.4 Endangerment by high voltage ignition ........................................................................................... 16
2.5 Endangerment by electromagnetic fields ........................................................................................ 17
2.6 Endangerment by heat and light radiation....................................................................................... 18
2.7 Endangerment by gases, smoke and types of dust ........................................................................ 19
2.8 Endangerment by oxyhydrogen....................................................................................................... 19
2.9 Endangerment by noise................................................................................................................... 21
2.10 Endangerment by spatter ................................................................................................................ 22
2.11 Handling of pressure reducer .......................................................................................................... 22
3Maintenance..........................................................................................................................................23
3.1 Maintenance general ....................................................................................................................... 23
3.1.1 Intervals of maintenance.............................................................................................................. 23
3.1.2 Cleaning....................................................................................................................................... 24
3.1.2.1 Cleaning of the power source.............................................................................................. 24
3.1.2.2 Cleaning of the gas supply .................................................................................................. 24
3.1.3 Electrical revision......................................................................................................................... 25
3.1.4 Plasma torch................................................................................................................................ 26
4Customer information on repair processing.....................................................................................27
5Disposal.................................................................................................................................................28
5.1 Disposal of the packing material...................................................................................................... 28
5.2 Disposal of the units after decommissioning................................................................................... 28
6Power source CutFire 100i ..................................................................................................................29
6.1 Technical Data................................................................................................................................. 30
6.2 Technical description....................................................................................................................... 31
6.3 Advantages and features of the plasma cutting machine................................................................ 32
6.4 Ranges of application ...................................................................................................................... 33
6.5 Plasma marking, Plasma notching, Plasma punching .................................................................... 34
6.6 Putting into operation....................................................................................................................... 35
6.6.1 Check and placement.................................................................................................................. 35
6.6.2 Installation.................................................................................................................................... 36
6.6.2.1 Mains connection................................................................................................................. 36
6.6.2.2 Connection of the plasma torch........................................................................................... 36
6.6.2.3 Workpiece connection / current return line / potential equalisation..................................... 36
6.6.2.4 Potential equalisation, Earthing........................................................................................... 36
6.7 Connection of the gas supply .......................................................................................................... 37
6.7.1.1 Connections at the rear panel of the power source............................................................. 38

General information
4
6.8 Remote control FB (optional)........................................................................................................... 39
6.9 Operating and display elements...................................................................................................... 39
6.10 Cutting operation ............................................................................................................................. 42
6.11 Combination of the power source with CNC-controls of the guiding systems and robots .............. 46
6.12 Start regime CutFire ........................................................................................................................ 48
6.12.1 Start by remote control FB (at commissioning) ....................................................................... 48
6.12.2 Start by CNC............................................................................................................................ 48
6.12.3 Start from CNC with special function "pre-impulse" ................................................................ 48
6.13 Protective facilities........................................................................................................................... 49
6.14 Information for trouble shooting....................................................................................................... 50
7Plasma machine torch Flash 101 G/L.................................................................................................53
7.1 Technical Data................................................................................................................................. 54
7.2 Technical description....................................................................................................................... 55
7.3 Advantages and features of the plasma cutting machine................................................................ 56
7.4 Putting into operation....................................................................................................................... 57
7.5 Connection of the plasma torch to the plasma unit ......................................................................... 58
7.6 Consumables and their exchange................................................................................................... 59
7.7 Accessories...................................................................................................................................... 61
8Wiring diagrams ...................................................................................................................................63
9Spare parts lists....................................................................................................................................66
9.1 Spare parts list CutFire 100i............................................................................................................ 67
9.2 Spare parts lists Flash 101 G/L ....................................................................................................... 75
10 Index ......................................................................................................................................................78
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General information
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1 General information
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1.1 Warranty claim
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We point out explicitly that only spare parts and consumables of Kjellberg original have to be used!
Otherwise a warranty claim does not exist. Kjellberg Finsterwalde as manufacturer of the equipment can not
make any guarantees for the safety of the equipment according to the valid regulations.
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1.2 Standards and Directives
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The CE mark indicated on our plasma cutting and welding machines shows the
conformity of our products with the latest effective European CE Directives.
IEC
Development and production take place according to the following standard:
IEC 60974 (EN 60974).
All plasma systems and welding systems are in possession of the S-mark and therefore
applicable to work places with increased electrical endangerment.
The production takes place according to DIN EN ISO 9001.
All products are manufactured under strict quality assurance control and proved by
certificates and product-related test records.
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General information
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1.3 Information to the instruction manual - target groups
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Our products are of first-rate quality and high reliability and are in operational condition at any time. You fully
will enjoy all these benefits, as long as you carefully observe these instructions for operation, maintenance
and handling.
For any request you are kindly asked to quote model name and serial number.
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Please keep this instruction manual always carefully!
The instruction manual always must accompany the machine.
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For damages due to misuse or wrong service we will not take any responsibility!
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To avoid dangers for itself and others, operations at the unit may be carried out only by
persons who have read and understood this instruction manual as well as were introduced
to the correct handling.
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Target groups for this instruction manual are:
Operator:
Persons recognising risks and avoiding endangerments by electricity with suitable training and suitable
education by which they are enabled to operate the product and to execute basic maintenances and which
are informed sufficiently and enabled with that by an authorised electrician.
Authorised electrician:
Persons with a suitable training, suitable education and experience, by which they are enabled to recognize
risks and to avoid endangerments, which can go out of the electricity.
Work which may be executed only by authorised electrician is indicated clearly by warning signs and
mandatory signs.
Kind of work
Target group
Operator
Authorised electrician
Connection and putting into operation
x
Operation of the machine
x
x
Maintenance:
basic maintenance
x
special marked maintenance
x
shut down at the end of the lifetime
x
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General information
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1.4 Plasma cutting as procedure
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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 steels, aluminium, copper, etc. It is suitable for straight, profile, template and bevel cutting. Thus
semi-finished products such as sheet metal, sheet metal packages, tubes, profiles, blanks, forged forming
parts, cast products and scrap metal can be thermally cut or worked.
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Plasma cutting process
Dry plasma cutting
Under water
plasma cutting
Without
swirl gas technology
With
swirl gas technology
with enhanced
constriction of the
plasma arc
With
swirl gas technology
without enhanced
constriction of the
plasma arc
With
swirl gas technology
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General information
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Plasma cutting process
Dry-plasma cutting
Under water-plasma cutting
without swirl gas
with swirl gas
with swirl gas
In plasma cutting without
swirl gas the plasma arc hits
the workpiece immediately
after crossing the nozzle.
The nozzle can be damaged
by Spatter and resulting
double arcs.
A damage of the nozzle
causes a poor cutting quality.
Plasma torches with swirl gas
technology are using the swirl
gas for shielding the plasma arc
from the environment.
The nozzle of the plasma torch is
protected against spatter by the
swirl gas cap and the
intermediately streaming swirl
gas (vitally important while hole
piercing).
By the possibility to vary also the
swirl gas in composition and flow
rate, the cutting quality can be
improved further.
The under water plasma cutting process
reduces the pollution of the environment
by dust, aerosol, and noise level
considerably in comparison to the dry
plasma cutting process, in addition,
ultraviolet radiation is filtered in the water.
The distortion of the cutting material is
very low.
The energy consumption compared with
the dry plasma cutting is however higher.
By using swirl gas technology the cutting
process expires with high process
stability. This guarantees also high cutting
quality for under water cutting.
Dry plasma cutting process with swirl gas
without enhanced constriction of the plasma
arc
Dry plasma cutting process with swirl gas
with enhanced constriction of the plasma arc
(HiFocus-technology)
Angle deviations of the cutting surface are
possible, especially at thin materials.
The new HiFocus-technology reduces the angle deviation of
the cutting surface by an enhanced constriction and
stabilization of the plasma arc.
At sheets up to 5 mm the angle deviation can
amount 5 to 10 degrees.
The cutting surfaces in the thin sheet metal range are
nearly rectangular, that results in much higher accuracy,
comparable with laser cuts.
Reworking of the metallic blank and dross free cutting
surface is normally not necessary.
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A Coolant circuit
B Plasma gas
C Swirl gas

Safety instructions
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2 Safety instructions
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2.1 Explanation of the safety symbols
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DANGER, WARNING and CAUTION are signal words, which describes a degree of exposure.
DANGER
DANGER describes an endangerment with a high degree of risk, when it is not avoided, it
results in death or a severe injury.
WARNING
WARNING describes an endangerment with a middle degree of risk, when it is not avoided, it
could result in death or a severe injury.
CAUTION
CAUTION describes an endangerment with a low degree of risk, when it is not avoided, it could
result in a slight or a moderate injury.
The Safety information are developed after the SAFE-structure:
S… Symbol with signal word
CAUTION
A… Art und Quelle der Restgefahr - Kind and source of the residual danger
F… Folge bei Missachtung - Consequence at ignoring
E… Entkommen - Escape
Example:
CAUTION
Endangerment through free standing wheels by manual moving of the unit.
Foot injuries are possible.
Caution by the manual moving of the unit - wear food guards!
WARNING
Warning of dangerous electric voltage
Electric shock can be deadly. Further personal and material damages can result from
impact.
Before opening (for example error search) or starting any maintenance and repair work
principally the power supply source has to be switched off and visibly disconnected from
the mains.
Opening the plasma unit may be carried out only under responsibility of a qualified
electrician!

Safety instructions
10
Warning symbols (choice):
A black graphic symbol within a yellow triangle with a black edge defines a safety sign,
which describes an endangerment.
Warning of general hazard area
Warning of dangerous electrical voltage!
Warning of flammable substances
Warning of explosive substances
Warning of poisonous substances
Warning of optical radiation
Warning of electromagnetic radiation
Warning of noxious or irritant substances
Warning of gas cylinder
Warning of hot surface
Warning of slip danger

Safety instructions
11
Mandatory sign (choice):
A white graphic symbol within a blue circle defines a safety sign, which indicates that an
action shall be carried out, in order to prevent an endangerment.
General mandatory sign
Use eye shield
Use ear protection
Use inhalation protection
Use foot guard
Use hand guard
Use protective clothing
Before opening disconnect the mains plug
Consider instruction manual
Pressure gas cylinder locked by linkage

Safety instructions
12
Prohibition sign (choice):
A black graphic symbol within a red circle with a red diagonal bar defines a safety sign,
which indicates that an action shall be stopped or not be carried out.
Smoking is forbidden
Fire, open light and smoking are forbidden
Contact is forbidden
Meal and drinking are forbidden
Do not use in housing areas
Emergency sign (choice):
First aid
Fire protection sign (choice):
Fire extinguisher
Information is not a signal word that describes a degree of exposure.
Information
The symbol signalised hints or special useful information.
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Safety instructions
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Warning label
The warning label is visibly attached on the power source.
The operator and the maintenance personnel must familiarize themselves with the meaning of the symbols
before working at the unit.
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1.
The operator and the maintenance personnel
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 regulations 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 inflammable
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.
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!
Wearing of protective clothing (helmet, welder’s overall, leather apron, gauntlets, safety shoes).
The protective clothing has to be isolating, dry and heavily inflammable.
6.
Working with plasma cutting systems 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.
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Safety instructions
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Further information and warning:
to ensure stableness of the plasma unit, 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 switching 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 avoid or suspend the safety interlock (for example door-, gas nozzle- and protection cap safety
switch)
do not cut closed containers
The plasma cutting system 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.
it can come to injuries caused by contacting sharp edges of the workpiece
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Safety instructions
15
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2.2 Endangerment by high contact voltage
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WARNING
Warning of dangerous electric voltage
Electric shock can be deadly. Further personal and material damages can result from impact.
Before opening (for example error search) or starting any maintenance and repair work
principally the power supply source has to be switched off and visibly disconnected from the
mains.
Opening the plasma unit may be carried out only under responsibility of a qualified
electrician!
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Before starting the machine connect the workpiece cable and earth the workpiece!
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2.3 Working in environments with increased electric endangerment
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The plasma cutting system 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 system:
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 present).
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The machine cannot be switched on as long no torch is attached or the attached torch isn't assembled
completely.
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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 available the torch can not
switched on (security circuit).
Therefore the plasma cutting system is S-marked and applicable in environments with increased hazard to
electric shock.
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The operator has to follow national and local regulations! (for example in germany
Employer’s Liability Insurance Association and in canada CAN/CSA-W117.2)
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Safety instructions
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2.4 Endangerment by high voltage ignition
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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 extinguishes.
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WARNING
Electric shock through touching of the torch head, if the plasma unit is switched on.
Electric shock can be deadly. Further personal and material damages can result from
impact.
Never touch the torch head, if the power source is switched on!
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WARNING
Warning of electromagnetic interferences
Through the operation of the plasma cutting system in particular by the temporary high
voltage ignition procedure results electromagnetic fields, which can lead to the influencing
of an 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
cutting system!
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Safety instructions
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2.5 Endangerment by electromagnetic fields
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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).
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WARNING
Warning of electromagnetic interferences
Through the operation of the plasma cutting system in particular by the temporary high
voltage ignition procedure results electromagnetic fields, which can lead to the influencing
of an 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
cutting system!
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WARNING
The plasma cutting system 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 quarters, 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
electromagnetic compatibility.
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General
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.
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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.
The size of the observed surrounding area depends on the design of the building and other activities taking
place there. The range can extend over the property boundary.
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Safety instructions
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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 necessary 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
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Cutting cables should be kept as short as possible and closely together or take course close to the bottom
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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
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The operator has to follow national and local regulations! (for example in germany
Employer’s Liability Insurance Association and in canada CAN/CSA-W117.2)
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2.6 Endangerment by heat and light radiation
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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, safety
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
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The operator has to follow national and local regulations! (for example in germany
Employer’s Liability Insurance Association and in canada CAN/CSA-W117.2)
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Safety instructions
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2.7 Endangerment by gases, smoke and types of dust
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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, smoke and dust by exhaustion devices
Removed all chlorinated and other solvents from the cutting area because they could form phosgene gas
when exposed to ultraviolet radiation
Ensure that toxic limits become not exceeded
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In any case the user of the unit installation has to carry out measurements of the
concentration of toxic substances to proof the effectiveness of the exhaust equipment!
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WARNING
Danger by gases and fumes when cutting galvanized material
Health damage by inhalation of these gases and fumes
Carry special breathing mask when cutting galvanized material!
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The operator has to follow national and local regulations! (for example in germany
Employer’s Liability Insurance Association and in canada CAN/CSA-W117.2)
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2.8 Endangerment by oxyhydrogen
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Oxyhydrogen is an hydrogen-air mixture, that explosively reacts in a hydrogen proportion between
4 and 76 Vol.-%.
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WARNING
Danger of formation of highly explosive oxyhydrogen
at hollow spaces,
at the displacing chamber of the water cutting table and
below the sheet panel lying on the cutting table.
There is danger of injury by exploding oxyhydrogen and flying parts.
The following information has to be observed to avoid the danger!
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Safety instructions
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If you use process gases, which contains hydrogen,for plasma cutting in connection with water, there may
lead to formation of highly explosive oxyhydrogen.
For water tables with level control it has to be ensured, that:
nitrogen is used instead of compressed air for regulating the level.
For water tables without level control it has to be ensured, that:
hydrogen can escape freely everywhere and is burnt out
the guiding machine has to be positioned after the cutting outside the water table to avoid, that hydrogen or
oxyhydrogen (hydrogen-air mixture) can gather in hollow spaces (like switch boxes)
that no hydrogen can gather below the plate which is placed on the table grating
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It is not allowed to store the plates on the cutting grating for a longer time!
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