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
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1 Short instruction manual HiFocus 161i with PGE 3-161
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hort instruction manual HiFocus 161i with PGE 3-161
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1.1 Safety
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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"!
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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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WARNING
Do not touch under electrical voltage related conductive parts!
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The safety circuits may not be suspended!
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The operator has to wear an adequate eye shield and insulating protective clothing!
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Suitable ear protection measures have to be taken in every case
(e.g. wearing of ear muffs or ear plugs)!
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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
Do not store flammable substances in the cutting area!
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Short instruction manual HiFocus 161i with PGE 3-161
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WARNING
Place the cylinders in an upright position and lock it against tilting over!
Don't use damaged cylinders, pressure reducers and armatures!
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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)!
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WARNING
Use only „Kjellfrost“ as coolant!
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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
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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
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Short instruction manual HiFocus 161i with PGE 3-161
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1.2 Consumable change at the plasma torch
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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!
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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.
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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.
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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.
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Use only exact the consumables which are destined for the technological operation!
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Short instruction manual HiFocus 161i with PGE 3-161
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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
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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.
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You have to mind on tightness of the plasma torch after consumable change, coolant does
not leave!
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The discharge chamber between cathode and nozzle has to be blown absolutely dry
(press tumbler switch “gas test” approx. 20 seconds - see “operation sequences”)
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Short instruction manual HiFocus 161i with PGE 3-161
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1.2.1 Plasma machine torch PerCut 200 / 210A / 210M
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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.
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1.2.2 Plasma machine torch PerCut 201 / 211A / 211M
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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.
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Short instruction manual HiFocus 161i with PGE 3-161
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Fig. 1.: Insert the nozzle into the torch head
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1.3 Operating and display elements of the power source
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Fig. 2.: Control- and display elements
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Short instruction manual HiFocus 161i with PGE 3-161
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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).

Short instruction manual HiFocus 161i with PGE 3-161
11
9. Potentiometer „Down
slope“ (11) activate tumbler switch “down slope-time“ (7) and adjust the “down slope” -
time with the potentiometer
look at the value shown at the current display (21) The display is in ms.
10. selector switch (12)
"up slope" Adjust the selector switch to position 1 (preferred value)
11. tumbler switch “gas
test” (6) Adjust the “Gas test”:
press the tumbler switch “gas test” (6) at the power source or
the switch/button “gas test” at the gas console
The gas test starts automatically:
when unit becomes switched ON
when changing gases
inspection:
blowing out of the plasma torch
for example blowing out of the coolant residue after consumable change
LED signal lamp yellow "cumulative error" (18):
lights
The voltage display (20) shows “GAS” 6A5
12. position the plasma
torch Bring the plasma torch in the start position.
Adjust the ignition height according to the cutting chart.
Hole piercing occurs over the work piece.
Flying cutting is only possible with the cutting technology HiFocus F.
13. plasma torch ON Plasma torch can be switched on through:
the ON-signal of the CNC-control from the guiding system or
pressing the ON-button at the remote control (FB)
Pilot arc ignition:
LED signal lamp white “current flows” (16) :
lights
after pilot arc contacts work piece, main arc ignites automatically
LED signal lamp white main arc (17) :
lights
14. plasma cutting Plasma cutting according to the cutting chart.
15. plasma torch OFF Plasma torch can be switched off through:
discontinuation of the ON-signal of the CNC-control from the guiding system
or
pressing the OFF-button at the remote control (FB)
Plasma arc extinguishes
16. plasma unit OFF Turn key switch S1 „Mains ON" (2) to
Position „0 “
or
Position „PGC“ (for consumable change)
The unit is switched off..
17. emergency stop Press the red mushroom button S3 “emergency stop” (1).
All integrated components of the emergency stop circle are switched OFF, after
pressing the button.
Fig. 3.: Operation sequences
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1.4 Operating and display elements of the gas console
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Fig. 4.: Operating and display elements of the PGE 3-161
1 tumbler switch S5 “gas test” to be activated for adjusting the gas test
2 tumbler switch S2 “WG1 ON-OFF”
3 tumbler switch S3 “WG1 ON-OFF”
4 Flow meter "WG1"
5 Flow meter "WG2"
will be used for adjusting and controlling the flow. rates
acc. to the cutting chart
6 Manometer "Inlet WG1"
7 Manometer "Inlet WG2"
8 Manometer "Inlet PG1"
9 Manometer "Inlet PG2"
displays the gas inlet pressure
10 Pressure controller "PG2" and Manometer
"outlet PG2" will be used for adjustment and control of the recommended cutting pressure acc. to the cutting chart
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1.5 Information for trouble shooting
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error reason / solution
1. After activating the key switch S1 “mains
ON“ (2) to position „I“ and switching on the
green illuminated push button S2
“readiness for operation“ (3) do the fan und
pump not start to run
emergency-stop S3 “emergency stop“ (1) is activated
(reset switch)
link X102 (C3-C4) (emergency stop CNC) and
link X106 (3-4) (emergency stop of CNC) are not plugged
cover plate on back wall or door of PBA open
control cable plasma torch not connected to X121
2. Fan and pump run, LED signal lamp yellow
"cumulative error" (18) is ON and LED
signal lamp green "Gas supply o.k." (14) is
OFF
low pressure of selected gases (see cutting chart)
3. LED signal lamp yellow "cumulative error"
(18) is ON and LED signal lamp green
"Cooling circuit o.k." (13) is OFF
coolant flow < 1.6 l/min
no or less coolant filled up
4. LED signal lamp yellow "cumulative error"
(18) is ON and LED signal lamp green
"Temperature power source o.k." (15) is
OFF
thermal overload on rectifier
cool down by running fan
eventually clean device including the filter mats of the
inverter module (behind the side flap)
corresponding to the maintenance order
5. LED signal lamp yellow "cumulative error"
(18) is ON,
plasma cutting machine switches OFF
after ca. 15 s
pilot arc time > 15 s;
no current flow to workpiece
-workpiece cable not connected
-ignition height not correct
-pilot arc without contact to workpiece
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The plasma sequence control of the plasma cutting system is displaying certain error codes, if during service
or operation errors are noticed. The current display indicates the corresponding error messages and
additionally the respective LED light.
The description of these errors and the rectification is given in the following chart:
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error chart / error codes - of the power source
current-
display relevance
LED-display cause end or fault clearance
“Cumulative
error“(18)
Gas, gas missing
coolant or coolant missing
ER 1 gas-coolant-
temperature
disturbance
temperature OFF high temperature
settle disturbances see
appropriate chapter at the
instruction manual
ER43 coolant error “Cumulative
error“(18) ON and
“Cooling circuit o.k."
(13) OFF
coolant missing
ER51 temperature
error „“Cumulative
error“(18) ON and
„Temperature power
source o.k.“ (15)
OFF
high temperature
ER70 gas error “Cumulative
error“(18) ON and
„Gas supply o.k.“
(14) OFF
gas missing
settle disturbances see
appropriate chapter at the
instruction manual
ER 2 source defect LED signal lamp
yellow “Cumulative
error“(18) is ON and
LED signal lamp
yellow “Process
error“ (19) flashes
current relay ”current
flows” K7 or current
relay “main arc” K1 is
pulled or
voltage at the torch
without ON signal
remote control:
press FB OFF CNC:
stop ON
inform
the
service!
ER21 Current Module current relay K7
module
ER24 Main arc current relay K1 main
arc
ER26 nozzle voltage
LED signal lamp
yellow “Cumulative
error“(18) is ON and
LED signal lamp
yellow “Process
error“ (19) flashes voltage at the torch
without ON signal
remote control:
press FB OFF CNC:
stop ON
inform
the
service!

Short instruction manual HiFocus 161i with PGE 3-161
15
current-
display relevance
LED-display cause end or fault clearance
ER 3
or
ER30
Torch defect LED signal lamp
yellow “Cumulative
error“(18)
current flow during
gas preflow
short circuit at the
torch
switch OFF unit, check torch
and consumables
ER31 Current module current relay K7
module
ER34 Main arc
LED signal lamp
yellow “Cumulative
error“(18) current relay K1 main
arc
switch OFF unit, check torch
and consumables
ER 4 Pilot arc time LED signal lamp
yellow “Process
error“ (19)
pilot arc time
exceeded remote control: press FB OFF
CNC: stop ON
ER 5 Ignition time LED signal lamp
yellow “Process
error“ (19)
HV ignition time
exceeded or no
ignition
remote control:
press FB OFF
CNC: stop ON
ER 6 Main arc inter-
ruption LED signal lamp
yellow “Process
error“ (19)
arc interruption during
cutting (main source) end after ca. 1 s
ER 7 Nozzle height LED signal lamp
yellow “Process
error“ (19)
arc voltage to low
height nozzle-
workpiece too small
remote control:
press FB OFF
CNC: stop ON
ER 8 Gas test period LED signal lamp
yellow “Process
error“ (19)
max. time exceeded,
stop gas test and start
again if required
tumbler switch "gas test" OFF
ER 9 Pilot arc
interruption LED signal lamp
yellow “Process
error“ (19)
plasma arc
interruption during
ignition (pilot source)
main arc is not formed
end after ca. 1 s
P
os: 1.51 /Kurzbetri ebsanleitung/Kjel lberg_Adresse @ 1\mod_ 1221824758746_19.doc @ 5326 @ @1

Short instruction manual HiFocus 161i with PGE 3-161
Kjellberg Finsterwalde Plasma und Maschinen GmbH
Germany • D - 03238 Finsterwalde • Oscar-Kjellberg-Str. 20
phone: [phone] • Fax: [phone]
e-mail: [email protected]
Internet: www.kjellberg.de
os: 2 /Überschrif ten/Sicherheitshin weise_Produktna me@ 1\ mod_1222148646980_19. doc @ 5440 @ @ 1P
- Saftety
Pos: 3 /Überschrif ten/Verschleißteil wechsel_Produktnam e @ 1\mod_1222148651251_1 9.doc @ 5445 @ @ 1
- Consumable change of the p lasma torch
os: 4 /Überschrif ten/Schneiddatenhandb uch_Produktname @ 1\ mod_1222088018302_19. doc @ 5421 @ @ 1P
- Cutting charts
=== Ende der Liste für Textmarke Inhalt ===
16

Instruction Manual
- Power source HiFocus 161i neo
- Plasma gas control unit PGE 3-161
- Plasma machine torch PerCut 200 / 210 …
- Plasma machine torch PerCut 201 / 211 …
- Plasma torch connection unit PBA-161
Art.-Nr.: .11.034.902.BA

General information
2
Pos: 1 /Allgemeines/Copy right und Inhalts verzeichnis @ 0\mod_1197 373477322_19.doc @1421 @ @ 1
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, 2013
Kjellberg Finsterwalde Plasma und Maschinen GmbH
Oscar-Kjellberg-Straße 20
DE - 03238 Finsterwalde
Tel.: [phone]
Fax.: [phone]
E-Mail: [email protected]
Web: www.kjellberg.de

General information
3
Contents
1General information ...............................................................................................................................7
1.1 Warranty claim ................................................................................................................................. 7
1.2 Standards and Directives ................................................................................................................. 7
1.3 Information to the instruction manual - target groups ...................................................................... 8
1.4 Plasma cutting as procedure............................................................................................................ 9
2Safety instructions...............................................................................................................................11
2.1 Explanation of the safety symbols.................................................................................................. 11
2.2 Endangerment by high contact voltage.......................................................................................... 17
2.3 Working in environments with increased electric endangerment................................................... 17
2.4 Endangerment by high voltage ignition.......................................................................................... 18
2.5 Endangerment by electromagnetic fields....................................................................................... 19
2.6 Endangerment by heat and light radiation ..................................................................................... 21
2.7 Endangerment by gases, smoke and types of dust ....................................................................... 22
2.8 Prevention of formation of oxyhydrogen ........................................................................................ 23
2.9 Endangerment by noise ................................................................................................................. 24
2.10 Endangerment by spatter............................................................................................................... 25
2.11 Handling of pressure reducer......................................................................................................... 25
2.12 Handling of the coolant "Kjellfrost" ................................................................................................. 26
3Maintenance..........................................................................................................................................28
3.1 Maintenance general...................................................................................................................... 28
3.1.1 Intervals of maintenance............................................................................................................ 28
3.1.2 Cleaning..................................................................................................................................... 29
3.1.2.1 Cleaning of the power source ........................................................................................... 29
3.1.2.2 Cleaning of the gas supply................................................................................................ 29
3.1.3 Electrical revision ....................................................................................................................... 30
3.1.4 Plasma torch .............................................................................................................................. 31
3.2 Maintenance special....................................................................................................................... 32
3.2.1 Gas pressure test....................................................................................................................... 32
3.2.2 Coolant system .......................................................................................................................... 35
3.2.3 Preventive periodic maintenance - component change plan..................................................... 36
4Customer information on repair processing.....................................................................................38
5Disposal.................................................................................................................................................39
5.1 Disposal of the packing material .................................................................................................... 39
5.2 Disposal of the units after decommissioning.................................................................................. 39
6Power source HiFocus 161i neo.........................................................................................................40
6.1 Technical data ................................................................................................................................ 41

General information
4
6.2 Technical description...................................................................................................................... 42
6.2.1 Setup.......................................................................................................................................... 42
6.2.2 HiFocus- technology .................................................................................................................. 43
6.2.3 Electronic control ....................................................................................................................... 43
6.2.4 Special parameters of the power source.................................................................................... 44
6.3 Cutting technology.......................................................................................................................... 45
6.4 Plasma marking.............................................................................................................................. 49
6.5 Putting into operation ..................................................................................................................... 50
6.5.1 Check, placement and transport................................................................................................ 50
6.5.2 Installation.................................................................................................................................. 52
6.5.2.1 Mains connection .............................................................................................................. 52
6.5.2.2 Workpiece connection / current return line ....................................................................... 52
6.5.2.3 Connections at the rear panel of the power source .......................................................... 55
6.6 Remote control FB ......................................................................................................................... 57
6.7 Filling up the coolant ...................................................................................................................... 57
6.8 Operating and display elements..................................................................................................... 58
6.9 Cutting operation............................................................................................................................ 63
6.10 Combination of the HiFocus with CNC-controls of the guiding systems and robots ..................... 69
6.11 Multiple machine operation ............................................................................................................ 72
6.12 Switching regime of the power source ........................................................................................... 73
6.12.1 Start by remote control FB (at commissioning).......................................................................... 73
6.12.2 Start by CNC.............................................................................................................................. 73
6.12.3 Start from CNC with special function "separate ignition signal" ................................................ 74
6.12.4 Start from CNC with special function "pre-impulse"................................................................... 74
6.13 Protective facilities.......................................................................................................................... 75
6.14 Information for trouble shooting ..................................................................................................... 76
7Plasma gas control unit PGE 3-161....................................................................................................79
7.1 Technical data ................................................................................................................................ 80
7.2 Technical description...................................................................................................................... 81
7.3 Connection of the Plasma Gas Control Unit PGE.......................................................................... 83
7.4 Operating and display elements..................................................................................................... 84
7.5 Connection of the gas hoses between plasma gas console and PBA........................................... 85
7.6 Connection of the gas supply......................................................................................................... 85
7.6.1 Plasma gases ............................................................................................................................ 86
7.6.2 Swirl gases................................................................................................................................. 88
8Plasma machine torch PerCut 200 / 210 …........................................................................................91
8.1 Technical data ................................................................................................................................ 92
8.2 Technical description...................................................................................................................... 93
8.3 Connection of the plasma torch to the plasma torch connection unit PBA .................................... 94