Kjellberg Smartfocus 300 User manual

Short Instruction Manual

Short instruction manual Smart Focus 300 with FC-300

- Safety

- Consumable change of the plasma torch

- Cutting charts

Art.-No.: .11.037.3002KBA

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Short instruction manual Smart Focus 300 with FC-300

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1 Short instruction manual Smart Focus 300 with FC-300

Short i nstr uction m anual S mart Fo cus3 200 with F C-300

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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 Smart Focus 300 with FC-300

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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 Smart Focus 300 with FC-300

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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 Smart Focus 300 with FC-300

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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 2000

PerCut 4000

PerCut 4000 XS

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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 Smart Focus 300 with FC-300

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1.2.1 Plasma machine torch PerCut 2000/2000A / PerCut 4000/4000A

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Dismounting of used consumables

Before dismounting the consumables of the PerCut 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.

Manually unscrew the protective cap (xx.07) together with the swirl gas cap (xx.06).

(Press out swirl gas cap from protective cap.)

Unscrew nozzle cap (xx.05) by aid of a torch tool - PerCut 440-450* (60.02).

Take out the nozzle (xx.04) together with the gas guide (xx.03) by aid of a torch tool - PerCut 440-450*

(60.02).

Pull out the gas guide (xx.03) from the nozzle (xx.04) by aid of the specific wrench (60.03).

Unscrew the cathode (xx.02) by aid of a torch tool - PerCut 440-450* (60.02).

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

Screw in the cooling tube (xx.01) by aid of a socket wrench (60.01).

Tightly screw in the cathode (xx.02) by aid of a torch tool - PerCut 440-450* (60.02).

Insert the gas guide (xx.03)

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.

Position the nozzle cap (xx.05) by aid of a torch tool - PerCut 440-450* (60.02) and fasten hand tight

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 Smart Focus 300 with FC-300

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Fig. 1: Insert the nozzle into the torch head

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Short instruction manual Smart Focus 300 with FC-300

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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 Smart Focus 300 with FC-300

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Operation sequences

Check before starting the gas supply,corresponding to the point "connection of the gas supply" of gas

console.

1. Red emergency stop

device S3

“emergency stop” (1) Unlock the button by turning it in one direction.

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 “data set parameter” of the PGC

(only for FlowControl).

3. Illuminated button

green S2 „PA ON" (3)

Activate the plasma unit with the illuminated push button.

Main transformer, fan, 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 (17):

U-1 = device-no. example: device 1

SF = device typ example: Smart Focus

0 = voltage actual value example: 0 V

at the current display (16):

100 = software-version example: V 1.00

=max. current power source example: A

300 = current nominal value example: 300A

•

•green illuminated push button S2 “PA ON" (3):

lights

•LED signal lamp green H30 “Temperature OK" (9):

lights

•LED signal lamp green H29 “Coolant OK" (7):

lights

•An automated gas purging is started.

•LED signal lamp green H28 “Gas OK" (8):

lights

•LED signal lamp yellow H31 “Cumulative error" (13):

does not light

Unit is ready for operation!

Selector switch S7

“technology” (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 P5

"cutting current" (12) •Adjust the cutting current with the potentiometer.

•Look at the value shown at the current display (16).

Short instruction manual Smart Focus 300 with FC-300

7. potentiometer P7

“marking current” (15)

•Adjust the marking current with the potentiometer.

•Look at the value shown at the current display (16).

8. tumbler switch S2

“gas test” (5) Adjust the tumbler switch “Gas test”:

•press the tumbler switch “gas test” (5) 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 of PGV

inspection:

•blowing out of the plasma torch

for example blowing out of the coolant residue after consumable change

•LED signal lamp yellow H31 "cumulative error" (13):

lights

•

The voltage display (17) shows “GAS” (6A5)

9. 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 switch position 3 of the tumbler switch S7

“technology” (4).

10. plasma torch ON Plasma torch can be switched on through:

•the “torch 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 H11“current flows” (10) :

lights

•after pilot arc contacts work piece, main arc ignites automatically

•LED signal lamp white H10 “main arc” (11) :

lights

11. plasma cutting Plasma cutting according to the cutting chart.

12. plasma torch OFF Plasma torch can be switched off through:

•discontinuation of the “torch ON”-signal of the CNC-control from the guiding

system or

•pressing the OFF-button at the remote control (FB)

Plasma arc extinguishes

13. plasma unit OFF Turn key switch S1 „Mains ON" (2) to

•Position „0 “

•Position „PGC“ (for consumable change)

The unit is switched off..

14. Red emergency stop

device S3

“emergency stop” (1)

Press the red emergency stop device S3 “emergency stop” (1).

All integrated components of the emergency stop circle are switched OFF, after

pressing the button.

Fig. 1: Operation sequences

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Short instruction manual Smart Focus 300 with FC-300

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1.4 Operating and display elements of the gas console

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Fig. 3: Control and display elements FlowControl-300

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Short instruction manual Smart Focus 300 with FC-300

1 button „GASTEST"

2 display for gas control signal

3 display error

4 LCD Display

5 F1 button ”technology data

6 F2 button “to set selection”

7 F3 button “set change”

8 DEL button “delete button”

9 COPY button “new data set“

10 ENTER button “input confirmation“

11 PAGE button “changes display pages“

12 FIELD button “position change field“

13 CHAR-buttons “position change sign modification“

14 LED-Power - power supply ON

15 contrast adjustment display

16 hand wheel for parameter selection

17 option: binary data transmission to guiding system (X6)

18 serial interface RS-232 (X5)

19 switch of interfaces RS-485 – RS-232

20 connection to power source RS-485 (X4)

21 CAN1 signal connection to PGV (X2)

22 socket current supply PGC (X1)

23 store key of data set 0

24 store key of data set I

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Short instruction manual Smart Focus 300 with FC-300

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1.5 Filling up the coolant

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The coolant circuit is to be filled with "Kjellfrost -15 °C" (frost-resistant up to -15 °C) or "Kjellfrost -25 °C"

(frost-resistant up to -25 °C). In addition to frost protection, these coolants with specially developed corrosion

protection are also used for increasing the lifetime of the pump and seals as well as for increasing the

service life of the coolant channels of the plasma torch. Therefore, please use exclusively the coolant

„Kjellfrost“! The use of simple, standard antifreeze may cause the failure of the plasma system within a very

short time.

The volume of the coolant tank amounts to approx. 17 l. The filler neck (2) is at the rear panel of the power

source.

Please connect the plasma torch and fill in the coolant until it reaches the upper mark (max) of the filling level

indicator (1) before switching on the plasma system.

Warning: If the maximum filling quantity is exceeded, the coolant will exit the tank through the overflow and

run on the floor.

Switch on the plasma system and watch the filling level indicator.

After the pump has vented the coolant hoses and the plasma torch and the coolant level does not go down

any further, please refill „Kjellfrost“ up to the upper mark.

Changing the consumables and the plasma torch causes losses of the coolant. Therefore it is necessary to

control the coolant level regularly and to refill the coolant before it reaches the lower mark (min) of the filling

level indicator.

Regardless of the service life of the plasma system, the coolant has to be changed completely at least every

12 months.

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Short instruction manual Smart Focus 300 with FC-300

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1.6 Information for trouble shooting

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error reason / solution

After activating the key switch S1 “mains

ON“ (2) to position „I“ and switching on the

green illuminated push button S2 “PA ON“

(3), Pa does not switch ON

•emergency-stop device S3 “emergency stop“ (1) is

activated (reset switch)

•„emergency stop“ of CNC is activated

•link X102 (C3-C4) and X106 (1-2) for operation without

CNC

•cover plate on back wallof PA or door of PBA open

•control cable plasma torch not connected to X121/X122

•filling level in the coolant tank to low

LED signal lamp yellow H31 "cumulative

error" (13) is ON and LED signal lamp

green H28 "Gas OK" (8) is OFF

•low pressure of selected gases (see cutting chart)

LED signal lamp yellow H31 "cumulative

error" (13) is ON and LED signal lamp

green H29 "Coolant OK" (7) is OFF

•coolant flow < 3.0 l/min

•no or less coolant filled up

LED signal lamp yellow H31 "cumulative

error" (13) is ON and LED signal lamp

green H30 "Temperature OK" (9) is OFF

•thermal overload on rectifier

cool down by running fan

LED signal lamp white H11 “Pilot arc” (10)

OFF:

•no ignition

•check the pilot current

LED signal lamp white H10 “Main arc” (11)

OFF: plasma cutting machine switches

OFF after ca. 10 s

•no cutting power, main power source OFF

•pilot arc time > 10 s;

•pilot arc without contact to workpiece

•no current flow to workpiece

-workpiece cable not connected

-ignition height not correct

Should coolant leak out, the cutting machine has to be switched off immediately, resolve the error and dry

the cutting machine!

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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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Short instruction manual Smart Focus 300 with FC-300

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current-

display relevance

LED-display cause end or fault clearance

ER 2

Error power

source

LED-signal lamp

yellow H31

“Cumulative error“

(13) lights and LED-

signal lamp yellow

H32 “Process error“

(14) flashes

current relay

K1.x “main source” or

K2 ”current flows” or

K3 ”current pilot

source flows“ is pulled

or voltage at the torch

without “torch ON”-

signal

remote control:

press “FB OFF”

stop “torch ON”

inform

the

service!

ER21

Transfer arc current relay K3

ER22

Main arc current relay K1

ER24

Pilot arc current relay K2

ER25

Actual current

detected Current flow without

ON signal

ER27

Fuse PBA defect check measuring

cable cathode voltage

and fuse F1 in PBA

ER28

Torch solenoid

valve Voltage of torch

solenoid valves not

ER 3

Error torch LED-signal lamp

yellow H31

“cumulative error“ (13)

current flow during

gas preflow

short circuit at the

torch

switch OFF unit, check

torch and consumables

ER31

Transfer arc Current relay K3

ER32

Main arc K1 Current relay K1

ER34

Pilot arc Currnt relay K2

ER35

Actual current

detected Current flow with ON

signal

ER 4

Pilot arc time LED-signal lamp

yellow H32 “Process

error“ (14)

pilot arc time

exceeded remote control:

press FB OFF

CNC: stop ON

ER 5

Ignition time LED-signal lamp

yellow H32 “Process

error“ (14)

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 H32 “Process

error“ (14)

arc interruption during

cutting (main source) end after ca. 1 s

Short instruction manual Smart Focus 300 with FC-300

current-

display relevance

LED-display cause end or fault clearance

ER 8

Gas test period LED-signal lamp

yellow H32

“Process error“ (14)

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 H32

“Process error“ (14)

plasma arc

interruption during

ignition (pilot source)

main arc is not formed

end after ca. 1 s

ER10

Communication

error LED-signal lamp

yellow H32

“Process error“ (14)

CAN communication

between

PGCPGV

interrupted

Control connection

PGC - PGV

ER43

Coolant error LED-signal lamp

yellow H31

“Cumulative error“

(13) ON and green

H29 “coolant OK”

(7) OFF

coolant quantity not

enough settle disturbances

ER51

Temperature

error LED-signal lamp

yellow H31

“Cumulative error“

(13) ON and green

H30 “temperature

OK” (9) OFF

high temperature settle disturbances

ER60

Sequence error LED-signal lamp

yellow H32

“Process error“ (14)

Error in the cutting

sequence

external release missed

ER70

Gas error

LED-signal lamp

yellow H31

“Cumulative error“

(13) ON and green

H28 “gas OK” (8)

OFF

gas missing check gas bottle if necessary

replace

ER71

gas missing at start of

power source open gas bottle

ER72

gas pressure too low check gas, start the power

source again

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Kjellberg Finsterwalde Plasma und Maschinen GmbH

Germany • D - 03238 Finsterwalde • Oscar-Kjellberg-Str. 20

phone: +49 3531 500-0 • Fax: +49 3531 500-227

e-mail: plasma@kjellberg.de

Internet: www.kjellberg.de

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- Safety

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- Cons umabl e c hang e o f t he pl asm a tor c h

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- Cutti ng chart s

=== En de der Lis te für T extmar ke Inhal t= ==

Instruction Manual

- Power source Smart Focus 300

- Plasma gas control unit FlowControl-300

- Plasma machine torch PerCut 2000/2000A

PerCut 4000/4000A

- Plasma torch connection unit PBA-300

Art.-No.: .11.037.3002BA

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General information

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

utility model or design.

Subject to alterations.

Kjellberg Finsterwalde Plasma und Maschinen GmbH, 2015

Kjellberg Finsterwalde Plasma und Maschinen GmbH

Oscar-Kjellberg-Straße 20

DE - 03238 Finsterwalde

Tel.: +49 3531 500-0

Fax.: +49 3531 8510

E-Mail: plasma@kjellberg.de

Web: www.kjellberg.de

General information

Contents

1General information ...............................................................................................................................6

1.1 Warranty claim................................................................................................................................... 6

1.2 Standards and Directives................................................................................................................... 6

1.3 Information to the instruction manual - target groups........................................................................ 7

1.4 Plasma cutting as procedure............................................................................................................. 8

2Safety instructions...............................................................................................................................10

2.1 Explanation of the safety symbols................................................................................................... 10

2.2 Endangerment by high contact voltage ........................................................................................... 16

2.3 Working in environments with increased electric endangerment.................................................... 16

2.4 Endangerment by high voltage ignition ........................................................................................... 17

2.5 Endangerment by electromagnetic fields ........................................................................................ 18

2.6 Endangerment by heat and light radiation....................................................................................... 20

2.7 Endangerment by gases, smoke and types of dust ........................................................................ 21

2.8 Prevention of formation of oxyhydrogen.......................................................................................... 22

2.9 Endangerment by noise................................................................................................................... 23

2.10 Endangerment by spatter ................................................................................................................ 24

2.11 Handling of pressure reducer .......................................................................................................... 24

2.12 Handling of the coolant "Kjellfrost"................................................................................................... 25

3Maintenance..........................................................................................................................................27

3.1 Maintenance general ....................................................................................................................... 27

3.1.1 Intervals of maintenance.............................................................................................................. 27

3.1.2 Cleaning....................................................................................................................................... 28

3.1.2.1 Cleaning of the power source.............................................................................................. 28

3.1.2.2 Cleaning of the gas supply .................................................................................................. 28

3.1.3 Electrical revision......................................................................................................................... 29

3.1.4 Plasma torch................................................................................................................................ 30

3.2 Maintenance special........................................................................................................................ 31

3.2.1 Gas pressure test ........................................................................................................................ 31

3.2.2 Coolant system............................................................................................................................ 34

3.2.3 Preventive periodic maintenance - component change plan....................................................... 35

4Customer information on repair processing.....................................................................................36

5Disposal.................................................................................................................................................37

5.1 Disposal of the packing material...................................................................................................... 37

5.2 Disposal of the units after decommissioning................................................................................... 37

6Power source Smart Focus 300..........................................................................................................38

6.1 Technical data ................................................................................................................................. 39

6.2 Technical description....................................................................................................................... 40

6.2.1 Setup............................................................................................................................................ 40

6.2.2 Electronic control ......................................................................................................................... 41

6.2.3 Special parameters of the power source ..................................................................................... 41

6.3 Cutting technology........................................................................................................................... 42

6.4 Plasma marking............................................................................................................................... 43

6.5 Putting into operation....................................................................................................................... 44

6.5.1 Check, placement and transport.................................................................................................. 44

General information

6.5.2 Installation.................................................................................................................................... 46

6.5.2.1 Mains connection................................................................................................................. 46

6.5.2.2 Workpiece connection / current return line.......................................................................... 47

6.5.2.3 Connections at the rear panel of the power source............................................................. 50

6.6 Remote control FB (optional)........................................................................................................... 52

6.7 Filling up the coolant........................................................................................................................ 53

6.8 Operating and display elements...................................................................................................... 54

6.9 Cutting operation ............................................................................................................................. 60

6.10 Combination of the HiFocus with CNC-controls of the guiding systems and robots....................... 66

6.11 Multiple machine operation.............................................................................................................. 69

6.12 Switching regime of the power source............................................................................................. 70

6.12.1 Start by remote control FB (at commissioning) ....................................................................... 70

6.12.2 Start by CNC............................................................................................................................ 70

6.12.3 Start of Underwater Plasma Cutting (UWP Cutting)................................................................ 70

6.12.4 Start from CNC with special function "separate ignition signal" .............................................. 71

6.12.5 Start from CNC with special function "pre-impulse" ................................................................ 71

6.13 Protective facilities........................................................................................................................... 72

6.14 Information for trouble shooting....................................................................................................... 73

7Plasma gas control unit FlowControl-300 .........................................................................................76

7.1 Technical data ................................................................................................................................. 77

7.2 Technical description....................................................................................................................... 78

7.2.1 Operation ..................................................................................................................................... 79

7.2.2 Operation screen "start screen“................................................................................................... 80

7.2.3 Operation screen "Cutting".......................................................................................................... 81

7.2.4 Operation screen "record parameters"........................................................................................ 85

7.2.5 Operation screen "data survey"................................................................................................... 87

7.2.6 Operation screen "Configuration data"........................................................................................ 88

7.2.7 Operation screen "Support"......................................................................................................... 91

7.2.8 Selection of data sets for the cutting and marking process......................................................... 91

7.2.8.1 Manual selection of cutting data at the PGC 3.................................................................... 91

7.2.8.2 Selection of a data set of the PGC ...................................................................................... 92

7.2.8.3 Fast data set selection by using the keys "0" and "I"........................................................... 93

7.2.8.4 Safe of user data set............................................................................................................ 95

7.2.8.5 Delete of data sets............................................................................................................... 95

7.2.8.6 Preselection of gas parameters from the external control................................................... 96

7.3 Operating and display elements...................................................................................................... 98

7.4 Connection of the plasma gas valve unit PGV.............................................................................. 100

7.5 Connection of the gas hoses between plasma gas console and PBA.......................................... 102

7.6 Connection of the gas supply........................................................................................................ 102

7.6.1 Plasma gases ............................................................................................................................ 103

7.7 Assembly of clamping ring connections ........................................................................................ 105

7.7.1 Initial assembly .......................................................................................................................... 105

7.7.2 Dismantling................................................................................................................................ 105

7.7.3 Reassembly............................................................................................................................... 106

8Plasma machine torch PerCut 2000/2000A / PerCut 4000/4000A..................................................107

8.1 Technical data ............................................................................................................................... 108

8.2 Technical description..................................................................................................................... 110