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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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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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.
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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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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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.
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 “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!
4.
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).

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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 “
or
•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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