Kjellberg PerCut 200 User manual

Short Instruction Manual
Short instruction manual HiFocus 161i with PGE 3-161
- Saftety
- Consumable change of the plasma torch
- Cutting charts
Art.-Nr.: .11.034.902.KBA

Short instruction manual HiFocus 161i with PGE 3-161
P
os: 1.1 /Überschrif ten/1/KBA/KBA HiFo 161i + PGE 3-161 @ 12\ mod_1385361813652_19. doc @ 192112 @ 1 @ 1
1 Short instruction manual HiFocus 161i with PGE 3-161
S
P
hort instruction manual HiFocus 161i with PGE 3-161
os: 1.2 /Überschri ften/1.1/Sicher heit_KBA @ 1\mod_12220903334 31_19.doc @ 5425 @ 2 @ 1
1.1 Safety
P
os: 1.3 /Kurzbetriebsan leitung/KBA ordnung sgemäß installiert @ 1\ mod_1222067978521_19. doc @ 5350 @ @ 1
The short instruction manual is valid for the properly installed and with decrease protocol handed over
plasma cutting machine! The detailed safety references are to be inferred from the manual the point „safety"!
P
os: 1.4 /Warnung, Vorsicht, Verbot, Gebot, Hin weis/Warnung (orange) / Rettungszeichen (grün)/W arnung Öffnen des Gerätes @ 0\ mod_1199714392778_19. doc @ 2391 @ @ 1
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!
P
os: 1.5 /Warnung, Vorsicht, Verbot, Gebot, Hin weis/Warnung (orange) / Rettungszeichen (grün)/ elektrisch leitende Teile@ 1\mod_1222078213884_19. doc @ 5365 @ @ 1
WARNING
Do not touch under electrical voltage related conductive parts!
P
os: 1.6 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Verbotszeic hen( rot)/Sicherheitsscha ltungen @ 1\mod_1222076180234_1 9.doc @ 5354@ @ 1
The safety circuits may not be suspended!
P
os: 1.7 /Warnung, Vorsicht, Verbot, Gebot, Hin weis/Gebotszeichen ( blau)/Augenblendsc hutz + Schutzkleidung @ 1\ mod_122208230293 2_19.doc @ 5400 @ @ 1
The operator has to wear an adequate eye shield and insulating protective clothing!
Pos: 1.8 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Gebotszeic hen( blau)/Gehörschutz @ 1\mod_122207 9237524_19.doc @ 5395 @ @ 1
Suitable ear protection measures have to be taken in every case
(e.g. wearing of ear muffs or ear plugs)!
P
os: 1.9 /Warnung, Vorsicht, Verbot, Gebot, Hin weis/Gebotszeichen (blau) /gesundheitssc hädliche Stoffe @ 0\ mod_1199803444549_19.d oc @ 2517 @ @ 1
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!
P
os: 1.10 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettung szeichen (grün)/brennbar eStoff ei mSc hneidbereich @ 1\mod_1222078 297625_19.doc @ 5370 @ @ 1
WARNING
Do not store flammable substances in the cutting area!
Pos: 1.11 /----- ---------- Seitenumbruc h ----------- ---- @ 0\mod_1197390577023_19. doc @ 1454 @ @ 1
2

Short instruction manual HiFocus 161i with PGE 3-161
os: 1.12 /Warnung, Vorsicht, Verbot, Gebot, Hin weis/Warnung (orange) / Rettungszeichen (grün)/ Umgang mit Gasflaschen 1 @ 1\ mod_1222078509612_19. doc @ 5375 @ @ 1P
WARNING
Place the cylinders in an upright position and lock it against tilting over!
Don't use damaged cylinders, pressure reducers and armatures!
P
os: 1.13 /Warnung, Vorsicht, Verbot, Gebot, Hin weis/Warnung (orange) / Rettungszeichen (grün)/ Verschleißteile in Ber ührung mit Sauerstoff öl- und fettfrei (Explosi onsschutzsicher ung) @ 0\mod_12010054457 51_19.doc @ 3177 @ @ 1
WARNING
All parts that come into contact with oxygen must be kept oil and grease free! When using
oxygen, the explosion protection for oxygen must be connected to the pressure-reducer
(protects against backfiring)!
P
os: 1.14 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettung szeichen (grün)/Kühlmit tel@ 1\mod _1222078951578_19. doc @ 5390 @ @1
WARNING
Use only „Kjellfrost“ as coolant!
P
os: 1.15 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Vorsicht (gelb) /Vorsicht beim Umgang mit Kjellfrost @ 0\mod_1199803 848670_19.doc @2533 @ @ 1
CAUTION
All details given on the label of the new anti-freezer have to be followed consequently!
„Kjellfrost“ is injurious to health
Don’t drink Kjellfrost
Keep it away from food, drinks and fodder
Always clean your hands before a break and after end of work
Avoid the contact with eyes and skin
Safety goggles recommended during filling
Wear protection suit
Wear gloves from Nitril or Viton (see safety data sheet)
Immediately taking off soiled, watered clothes
Special danger of skidding by run out or spilled "Kjellfrost"
Keep away from children
P
os: 1.16 /Warnung, Vorsicht, Verbot, Gebot, Hin weis/Warnung (orange) / Rettungszeichen (grün)/ Erste Hilfe Maßnahmen @ 0\mod _1199802224840_19. doc @ 2497 @ @ 1
First aid
after swallowing
Don’t bring up, clean the mouth, drink much water, open the window for fresh air and call the
doctor , present packing or label.
after eye contact
Clean the eyes with much flowing water some minutes and call the doctor
after skin contact
Quickly clean it with much water and soap
Pos: 1.17 /----- ---------- Seitenumbruc h ----------- ---- @ 0\mod_1197390577023_19. doc @ 1454 @ @ 1
3

Short instruction manual HiFocus 161i with PGE 3-161
os: 1.18 /Überschri ften/1.1/Verschleißt eilwechsel beim Brennerk opf @ 1\mod_122206561477 8_19.doc @ 5330 @ 2 @ 1P
1.2 Consumable change at the plasma torch
P
os: 1.19 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettung szeichen (grün)/Versc hleißteilwechsel am Plasmabrenn er -Plasmaanlage von Ne tztr ennen @ 0\mod_1200055457 147_19.doc @ 2774 @ @ 1
WARNING
In order to change consumables, the plasma cutting system shall be switched OFF and
secured against any accidental start. An unauthorised start-up is prevented by e.g. pulling
out the key of the key-operated switch after switching off the plasma cutting system!
P
os: 1.20 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Verbotszeic hen( rot)/Verbot - ungeeignete Werkzeuge für B rennerwechsel @ 0\mod_119971036391 5_19.doc @ 2366 @ @ 1
Under no circumstances pliers or other unsuitable tools have to be used for consumable
change, they entail inevitably the damage of the consumables, for example burr formation
and thereby malfunctions of the plasma torch.
P
os: 1.21 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Gebotszeic hen( blau)/Original-Kje llberg-Verschleißtei le@ 0\mod_1 202913276255_19.doc @ 3649 @ @1
You are only allowed to use ORIGINAL Kjellberg spare parts and consumables!
The use of other manufacturer consumables leads to the loss of the warranty claim.
P
os: 1.22 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettung szeichen (grün)/Öl-und fettf reier Brenner @ 0\mod_1199373195000_19. doc @ 2300 @ @ 1
WARNING
All components and parts coming in touch with oxygen have to be kept free of oil and
grease!
This refers specially to the torch head and the consumables.
P
os: 1.23 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Vorsicht (gelb) /technologischer Einsa tz@ 1\mod_122 2083106421_19.doc @ 5405 @ @ 1
Use only exact the consumables which are destined for the technological operation!
Pos: 1.24 /----- ---------- Seitenumbruc h ----------- ---- @ 0\mod_1197390577023_19. doc @ 1454 @ @ 1
4

Short instruction manual HiFocus 161i with PGE 3-161
os: 1.25 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Gebotszeic hen( blau)/Schutzkappe überpr üfen, PerCut210 @ 5\mod_12888731919 68_19.doc @ 41226 @ @ 1P
After screwing off the protective cap to replace the swirl gas cap without any further
replacement of consumables, the tightness of the nozzle cap must absolutely be checked
and, if required, tightened again before mounting the protective cap!
apply to plasma torch:
PerCut 200 / 210A / 210M
PerCut 201 / 211A / 211M
P
os: 1.26 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Gebotszeic hen( blau)/Auf Vollständigkei tder Ver schleißteile achten @ 0\mod_1200 055848051_19.doc @ 2782 @ @ 1
Make sure that all wearing parts are complete and correct installed!
Especially the cooling tube has to be inserted. Other wise the cooling is ineffective and the
torch gets damaged.
No other parts as mentioned before have to be changed unauthorised on the plasma
machine torch.
A further opening of the torch from the front side is not possible.
P
os: 1.27 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettung szeichen (grün)/Dic htheitdes P lasmabrenners @ 1\mod_12220832588 75_19.doc @ 5409 @ @ 1
You have to mind on tightness of the plasma torch after consumable change, coolant does
not leave!
P
os: 1.28 /Warnung, Vorsic ht, Verbot, Gebot, Hinweis/Warnung (orange) / Rettung szeichen (grün)/Entladu ngsraum zwischen Katode und Düse @ 1\mod_122 2083434736_19.doc @5413 @ @ 1
The discharge chamber between cathode and nozzle has to be blown absolutely dry
(press tumbler switch “gas test” approx. 20 seconds - see “operation sequences”)
Pos: 1.29 /----- ---------- Seitenumbruc h ----------- ---- @ 0\mod_1197390577023_19. doc @ 1454 @ @ 1
5

Short instruction manual HiFocus 161i with PGE 3-161
os: 1.30 /Überschri ften/1.1.1/Plasmam aschinenbrenner Per Cut 210 @ 5\mod_128888294958 2_19.doc @ 41346 @ 3 @ 1P
1.2.1 Plasma machine torch PerCut 200 / 210A / 210M
P
os: 1.31 /Brenner/ PerCut 200/210/Verschl eißteilübersic ht PerCut 210 @ 5\mod_12888734 32771_19.doc @ 41237 @ @ 1
Dismounting of used consumables
1. Manually unscrew the protective cap (xx.07) together with the swirl gas cap (xx.06).
(Press out swirl gas cap from protective cap.)
2. Unscrew nozzle cap (xx.05) by aid of a torch tool - PerCut 440-450* (60.02).
3. Take out the nozzle (xx.04) together with the gas guide (xx.03) by aid of a
torch tool - PerCut 440-450* (60.02).
4. Pull out the gas guide (xx.03) from the nozzle (xx.04) by aid of the specific wrench (60.03).
5. Unscrew the cathode (xx.02) by aid of a torch tool - PerCut 440-450* (60.02).
6. Remove the cooling tube (xx.01) using the socket wrench (60.01) when changing technology or
changing data set in accordance with the cutting data.
Mounting of new consumables
1. Screw in the cooling tube (xx.01) by aid of a socket wrench (60.01).
2. Tightly screw in the cathode (xx.02) by aid of a torch tool - PerCut 440-450* (60.02).
3. Insert the gas guide (xx.03)
4. Insert the nozzle (xx.04) into the torch head (see picture on next page). Turn the nozzle such that the
nozzle’s wide groove is positioned exactly above the oval opening in the torch head. Then insert the
nozzle until stop. Now the nozzle is locked and cannot be turned anymore.
5. Position the nozzle cap (xx.05) by aid of a torch tool - PerCut 440-450* (60.02) and fasten hand tight
6. Position the swirl gas nozzle (xx.06) and manually fasten with the protective cap (xx.07).
O-rings only need replacement in case of deformation or damage.
* The torch tool - PerCut 440-450 (60.02) is a multifunctional tool to:
screw and unscrew the cathode by means of hexagon 11 mm,
pull out the nozzle by means of the engraved notches 6 mm, 7 mm and 8 mm and
screw and unscrew the nozzle cap by means of opening Ø 37 mm.
Pos: 1.32 /----- ---------- Seitenumbruc h ----------- ---- @ 0\mod_1197390577023_19. doc @ 1454 @ @ 1
6

Short instruction manual HiFocus 161i with PGE 3-161
os: 1.33 /Überschri ften/1.1.1/Plasma- Maschinenbrenner PerCut 201 / 211A / 211M @ 8\mod_13354345 66622_19.doc @ 153764 @ 3 @ 1P
1.2.2 Plasma machine torch PerCut 201 / 211A / 211M
P
os: 1.34 /Brenner/ PerCut201/211/VT-Üb ersicht +Aus-u.Ei nbau @ 8\mod_1335432657792_ 19.doc @ 153656 @ @ 1
Dismounting of used consumables
Before dismounting the consumables of the PerCut 211A please insert the change head in the “Station for
the change heads” (see chapter “Dismantling of the change head”) and remove with the aid of compressed
air the coolant from the change head.
1. Manually unscrew the protective cap (xx.07) together with the swirl gas cap (xx.06).
(Press out swirl gas cap from protective cap.)
2. Unscrew nozzle cap (xx.05) by aid of a torch tool - PerCut 440-450* (60.02).
3. Take out the nozzle (xx.04) together with the gas guide (xx.03) by aid of a torch tool - PerCut 440-450*
(60.02).
4. Pull out the gas guide (xx.03) from the nozzle (xx.04) by aid of the specific wrench (60.03).
5. Unscrew the cathode (xx.02) by aid of a torch tool - PerCut 440-450* (60.02).
6. Remove the cooling tube (xx.01) using the socket wrench (60.01) when changing technology or
changing data set in accordance with the cutting data.
Mounting of new consumables
1. Screw in the cooling tube (xx.01) by aid of a socket wrench (60.01).
2. Tightly screw in the cathode (xx.02) by aid of a torch tool - PerCut 440-450* (60.02).
3. Insert the gas guide (xx.03)
4. Insert the nozzle (xx.04) into the torch head (see picture on next page). Turn the nozzle such that the
nozzle’s wide groove is positioned exactly above the oval opening in the torch head. Then insert the
nozzle until stop. Now the nozzle is locked and cannot be turned anymore.
5. Position the nozzle cap (xx.05) by aid of a torch tool - PerCut 440-450* (60.02) and fasten hand tight
6. Position the swirl gas nozzle (xx.06) and manually fasten with the protective cap (xx.07).
O-rings only need replacement in case of deformation or damage.
* The torch tool - PerCut 440-450 (60.02) is a multifunctional tool to:
screw and unscrew the cathode by means of hexagon 11 mm,
pull out the nozzle by means of the engraved notches 6 mm, 7 mm and 8 mm and
screw and unscrew the nozzle cap by means of opening Ø 37 mm.
Pos: 1.35 /----- ---------- Seitenumbruc h ----------- ---- @ 0\mod_1197390577023_19. doc @ 1454 @ @ 1
7

Short instruction manual HiFocus 161i with PGE 3-161
os: 1.36 /Brenner/ PerCut 440/450/Montagehi nweis Düse @ 6\mod_1299572 476000_19.doc @ 55454 @ @ 1P
Fig. 1.: Insert the nozzle into the torch head
Pos: 1.37 /----- ---------- Seitenumbruc h ----------- ---- @ 0\mod_1197390577023_19. doc @ 1454 @ @ 1
8

Short instruction manual HiFocus 161i with PGE 3-161
os: 1.38 /Überschri ften/1.1/Bedien- und Anz eigeelemente der Stromquelle @ 2\mod_12363398184 23_19.doc @ 9395 @ 2 @ 1P
1.3 Operating and display elements of the power source
P
os: 1.39 /Stromque llen/HiFocus/HiFo161i /Bedien- und Anzeigee lemente @ 6\mod_1305094 057624_19.doc @ 61750 @ @ 1
Fig. 2.: Control- and display elements
Pos: 1.40 /----- ---------- Seitenumbruc h ----------- ---- @ 0\mod_1197390577023_19. doc @ 1454 @ @ 1
9

Short instruction manual HiFocus 161i with PGE 3-161
10
os: 1.41 /Stromque llen/HiFocus/HiFo161i /Reihenfolge der Bedienung@ 6\mod_1305116445455_19. doc @ 61848 @ @ 1P
Operation sequences
1. red mushroom button
S3 “emergency stop"
(1) Unlock the button by turning it in one direction.
2. Key switch S1
“Mains ON" (2) Turn the key switch to the position „I“. switch to “PGC” when change consumables.
Mains voltage is applied to the control transformer.
Display of consumables at operation screen “Record parameter” of the PGC
(only for FlowControl).
3. green illuminated
push button S2
“readiness for
operation" (3)
Activate the plasma unit with the illuminated push button.
Main transformer, pump and control are switched on.
Inspection:
The display screens appear for a short moment after starting the unit following
messages:
at the voltage display (20):
U-1 = device-no. example: device 1
0 =voltage actual value example: 0 V
at the current display (21):
705 =software-version example: V 7.05
160 =current nominal value example: 160 A
green illuminated push button S2 “readiness of operation" (3):
lights
LED signal lamp green “Temperature power source o.k." (15):
lights
LED signal lamp green “Cooling circuit o.k." (13):
lights
“gas test“ starts automatically
LED signal lamp green “Gas supply o.k." (14):
lights
LED signal lamp „Cumulative error" (18):
is off
Unit ready for operation!
4. Selector switch S5
“technology range” (4) Dial the technology range according cutting chart.
5. Operation gas
console See instruction manual of corresponding gas console.
Select the necessary plasma regime.
Adjust plasma - and swirl gases according to the cutting charts.
6. potentiometer "cutting
current" (9) Adjust the cutting current with the potentiometer.
Look at the value shown at the current display (21).
7. potentiometer
“marking current” (8) applies only to power sources and gas consoles which support the marking:
Adjust the marking current with the potentiometer.
Look at the value shown at the current display (21).
8. potentiometer
“current reduction”
(10)
current reduction at signal „corner“ from CNC:
Activate the tumbler switch „gas test“ (6) to the upper position
and adjust current reduction with the potentiometer:
maximum value: 30 % of nominal current.
Look at the value shown at the current display (21).