Plasma Cutting Products

Plasma Cutting Products for each task the optimum system Pioneers in Plasma Cutting since 1959 made in Germany

Plasma Cutting Technology for each Cutting Task Kjellberg insterwalde a company with long tradition offers a wide range of products for CNC-guided and manual plasma cutting that fit different demands and requirements. With products made in Germany users obtain not only state-of-the-art equipment but also the latest plasma cutting technology. 2D-Plasma 3D-Plasma Contour Cut Underwater Plasma Marking Hand plasma Precise and Efficient Plasma Cutting with Hiocus The modern high-precision plasma cutting systems of the Hiocus series stands for plasma cutting at the highest level. With a current range from 10 Ato 440A the Hiocus series cover a cutting range between 0.5 mm and 120 mm. In addition to straight, contour and bevel cuts up to 50, the plasma cutting systems Hiocus 130, Hiocus 161i, Hiocus 280i, Hiocus 360i and Hiocus 440i can be also used for marking, notching and punching. or frequently changing cutting tasks, like cutting different materials or a wide range of material thicknesses, the plasma cutting systems Hiocus 280i, Hiocus 360i and Hiocus 440i are the perfect solution for dry plasma cutting as well as for underwater plasma cutting. Hiocus systems can be used in combination with all CNC-guiding and robot systems in the market.

Precision in Detail Today Contour Cut the further developed Hiocus technology for cutting precise contours in mild steel defines the state of the art. Contour Cut is standard in new Hiocus 130 to Hiocus 440i systems. Customers who already use one of the Hiocus systems can also upgrade their systems to Contour Cut after retrofitting. This patented plasma cutting technology provides a perfect cut quality: Holes of cut qualities ranging between 2 and 4 according to the standard DIN EN ISO 9013 Highest cut quality and contour accuracy Reduced angular deviations and improved quality of cut surfaces Very high repeatability and dimension accuracy High productivity at low cost Range of Application Max. Cutting current 80 A 130 A 160 A 280 A Material thickness in mm 10 20 30 40 50 60 70 80 90 100 110 120 Hiocus 80i Hiocus 130 Hiocus 161i Hiocus 280i 360 A 440 A Hiocus 360i Hiocus 440i Mild steel Stainless steel Recommended cutting range 1) Maximum Cutting range 1) Piercing 1)2) These data depending on the materials to be cut and their compositions. Attend piercing technology!! 1) 2) Technical Data Power Source 3) Mains voltage use, slow Connected load Cutting current range at 100 % d. c. Marking current Dimensions (L x W x H) Weight Plasma gases Marking gas Swirl gases Hiocus 80i Hiocus 130 Hiocus 161i Hiocus 280i Hiocus 360i Hiocus 440i 25 A 17 kva 10-80 A - 970 x 510 x 970 mm 161 kg O, N - O, N, Air, 5* 50 A 32 kva 20-130 A 16 A 960 x 540 x 1050 mm 251 kg O, Ar, H, N 2 Ar O, N, Air, 5* 50 A 28 kva 10-160 A 5-25 A 985 x 570 x 1140 mm 206 kg O, Ar, H, N 2 Ar O, N, Air, 5* 3~, 400 V, 50 Hz 100 A 67 kva 10-280 A 5-50 A 505 kg O, Ar, H, 5* Ar O, N, Air 125 A 87 kva 10-360 A 5-50 A 1030 x 680 x 1450 mm 517 kg O, Ar, H, 5* Ar O, N, Air 200 A 127 kva 10-440 A 5-50 A 589 kg O, Ar, H, 5* Ar O, N, Air 3) Other voltages and frequencies on request. *) orming gas 5 (95 % N 2/5 % H 2)

Automatic Plasma Gas Unit The optimum gas mixture and the volume flow play an essential role in order to achieve a high cut quality. Kjellberg insterwalde offers a flow-controlled plasma gas control unit for the automatic adjustment of plasma and swirl gases the lowcontrol. It controls the volume flow and the timing of the different process gases and guarantees optimum and reproducible gas mixtures by: Reliable adjustment of the gas parameters due to microprocessor control and monitoring Balance of pressure fluctuations Safe dosage even of smallest amounts of gas Avoiding operating errors The settings for different materials and material thicknesses can be accessed and used from the factory-adjusted cutting database. Specific or modified data can be saved in a special customer database. The lowcontrol can also be installed in existing guiding systems without database capabilities. lowcontrol can be used for Hiocus systems from Hiocus 130 to Hiocus 440i also for marking tasks. It can be controlled by a serial interface. Automatic Torch Changing Unit The automatic torch changing unit ATChanger allows the automated change of plasma torch heads. It is based on the quick-change system used for Kjellberg plasma torches. The advantages of the ATChanger are: Almost automatically controlled cutting system Increasing of productivity due to reduced downtimes The system can be equipped with up to 8 torch heads with consumables for constant cutting tasks or with consumables for different cutting tasks Quick change between highest cutting output and finest marking possible The ATChanger can be installed in 2D and 3D guiding systems also as retrofit.

Cutting 160 mm with ineocus The robust systems of the ineocus series offer a high performance even under extreme conditions. Good cut qualities can be achieved even under heavy load. In addition to the use of technical gases for high quality, it is also possible to cut with air. The ineocus 800 is the most powerful system of this series. Two of them connected in parallel make the ineocus 1600 which achieves highest cutting performance. urthermore, both the ineocus 800 and the ineocus 1600 can be used for underwater plasma cutting. Due to their attractive price-performance ratio, the ineocus systems are ideally suited for all metal-working industries, e.g. steel and metal construction, shipbuilding or metal service centres. ields of Application Max. Cutting current 130 A 200 A 300 A 300 A 600 A 600 A 3) Material thickness in mm 10 50 100 160 ineocus 450 Dry Plasma ineocus 600 Dry Plasma ineocus 800 Dry Plasma ineocus 800 Underwater Plasma 2) ineocus 1600 Dry Plasma 2) ineocus 1600 Underwater Plasma Technical Data Recommended cutting range 1) Maximum Cutting range 1) Piercing1)3) 1) These data depending on the materials to be cut and their compositions. 2) Two Plasma systems ineocus 800 parallel connected. 3) Attend piercing technology! Power Source 4) Mains voltage use, slow Connected load Cutting current range at 100 % d. c. Dimensions (L x W x H) Weight Plasma gases Swirl gases ineocus 450 ineocus 600 ineocus 800 ineocus 800 UWP 5) ineocus 1600 50 A 34 kva 40-100 A (130 A at 75% d.c.) 1025 x 711 x 970 mm 251 kg O, Air, Ar, H, N 2 Air, N 2 100 A 60 kva 40-200 A 980 x 644 x 1320 mm 370 kg O, Air, Ar, H Air, N 2 3~, 400 V, 50 Hz 125 A 83 kva 80-300 A 1370 x 870 x 1505 mm 556 kg O, Air, Ar, H Air, N 2 160 A 100 kva 80-300 A 1370 x 870 x 1505 mm 564 kg O, Air, Ar, H, N 2 Air, N 2 2 x 160 A 2 x 100 kva 160-600 A 2 x 1370 x 870 x 1505 mm 2 x 564 kg Ar, H Other voltages and frequencies on request. UWP - Underwater plasma cutting 4) 5) - 2

Plasma Cutting with Robots Today robot-guided plasma cutting technique is mainly used for processing three-dimensional workpieces, in particular in the automotive industry and its suppliers as well as in the shipyard, container and pipe construction industry. All systems of the Hiocus series and the ineocus 800 can be used in combination with all robot systems in the market. Robot-guided plasma cutting meets the main demands of industry and craft and, therefore, has the following advantages: Cost-efficient cutting Simple programming High cutting speeds High cut quality without any rework required High flexibility of use Compared to other cutting methods, plasma cutting with robots offers the following possibilities: Cutting of diverse types of work-pieces Structural components for vehicles Pipes and containers Hollow profiles, open and closed profiles as well as bulb flat profiles Dished bottoms A Torch for Every Task or all plasma cutting systems, we offer plasma torches that can be used in combination with robots, some even in several versions: straight version, with 60 or 90 angled torch head or with quick-change head. Kjellberg plasma torches can be used for bevel cutting up to 50, with special torches up to 60.

Well-Proven Technology is the Basis of the PA-S Series The PA-S series is based on conventional step-switched power sources which are ideally suited for automated cutting tasks with machine torches in combination with 2D guiding systems and 3D robots, but also for manual use with hand torches. Hand torches as well as machine torches can quickly be retooled for plasma gouging. Plasma gouging is ideally suited to remove seam defects as well as to prepare back-welding processes. We offer straight standard torches and special torches with short shafts as well as torches with a 60 or 90 angled torch head. urther advantages are: Good quality of both cut surfaces High lifetime of consumables due to direct liquid cooling It is possible to perform contour and straight cuts as well as bevel cuts up to 60 and interrupted cuts in all 2D and 3D positions. A wide range of accessories is available for the hand torches which make it easy to perform many diverse cutting tasks. ields of Application Max. Cutting current 70 A 130 A Materialthickness in mm 10 20 30 40 50 60 70 PA-S25 W PA-S45 W 240 A PA-S70 W Recommended cutting range 1) Maximum Cutting range 1) Piercing1)2) 1) These data depending on the materials to be cut and their compositions. 2) Attend piercing technology!! Technical Data Power Source 3) Mains voltage use, slow Connected load Cutting current Dimensions (L x W x H) Weight Plasma gases PA-S25 W PA-S45 W PA-S70 W 32 A 21 kva 25 A at 100% d. c. 45 A at 100% d. c. 70 A at 75% d. c. 920 x 630 x 960 mm 168 kg Air (O 2, Ar, H 2) 3~, 400 V, 50 Hz 63 A 38 kva 45 A at 100% d. c. 85 A at 100% d. c. 130 A at 60% d. c. 1040 x 710 x 990 mm 240 kg Air (O 2, Ar, H 2) 125 A 75 kva 80 A at 100% d. c. 160 A at 100% d. c. 240 A at 80% d. c. 1380 x 870 x 1080 mm 460 kg Air, Ar/H2-mixture 3) Other voltages and frequencies on request.

Cutire 100i Inverter Technology for the Professionals in Metal Construction or simple automated cutting tasks at low investment costs Kjellberg insterwalde offers the easy-to-use plasma cutting inverter Cutire 100i. It can be used in combination with CNC guiding systems and other automatic guiding systems to perform straight and contour cuts. The machine torch lash 100 can be used for so-called flying cutting start and for hole cutting; a reference edge is not necessary. Typical fields of application are in the metalworking industry and many other workshops, production plants and industrial enterprises. This flexible and powerful power source is especially suited for the cost-efficient cutting of thin sheets, preferably on mild steel. It works cost-saving and safe due to: Using air as plasma gas Low costs for consumables Safe high-voltage ignition ields of Application Max. Cutting current Material thickness in mm 1 10 20 100 A Cutire 100i Recommended Maximum Piercing 1)2) cutting range 1) cutting range 1) 1) 2) These data depending on the materials to be cut and their compositions. Attend piercing technology! Technical Data Power Source Mains voltage use, slow Connected load Cutting current range Dimensions (L x W x H) Weight Plasma gases Cutire 100i 3~ 400 V, 50 Hz 25 A 16.6 kva 20-100 A at 100% d. c. 710 x 280 x 590 mm 50 kg Air

inemarker A Separate Plasma Marking Unit The inemarker is a separate unit for marking, notching and punching tasks on unalloyed steels, stainless steels and semi-finished products, e.g. sheets, pipes, profiles, circuit boards etc. It is well suited to supplement existing oxy-fuel or plasma cutting systems and can be controlled from the guiding system via interface. The inemarker makes it possible to mark components with simple annealing colours or deep notches and punches. Penetration depth and line width are determined by marking current, speed and the chosen marking gas. Plasma marking saves work steps and reduces related costs: Components can be marked permanently or temporarily Marking and labelling for further processing can be created Technical Data Power Source 1) Mains voltage use, slow Connected load Marking current Dimensions (L x W x H) Weight Marking gas inemarker 3~ 400 V, 50 Hz 10 A 5.2 kva 4-25 A 710 x 400 x 440 mm 30 kg Ar 1) Other voltages and frequencies on request. Height Control Units Make the Cutting Process Safe It is crucial for a safe cutting process and the quality of the cutting results to keep a constant distance between torch and work-piece and to lift the torch during piercing. In addition to the simple, cost-efficient height control unit for simple cutting applications, Kjellberg insterwalde offers other height control units which also include a database-supported and bus-compatible, fully automated control unit for highest demands regarding automated cutting processes. It is possible to update existing cutting machines by retrofitting a height control unit.

CUTi Manual Plasma Cutting Inverters The CUTi series are powerful lightweights of high reliability for the flexible and mobile use at construction sites and in workshops. They are suitable for environments with increased hazard of electric shock. They can be used for straight, bevel, and contour cuts in all positions. A wide range of accessories guarantees simple and diverse handling possibilities. The CUTi 35C takes a special position. It has an internal compressor and can, therefore, be operated without external compressed air supply for cutting a max. material thickness of 6 mm. With compressed air supply cutting of material thicknesses of up to 10 mm is possible. Having a weight of only 12.5 kg, the CUTi 35C can easily be transported by means of a shoulder strap. ields of Application Max. Cutting current 35 A 40 A 70 A 90 A 120 A Material thickness in mm 10 20 30 40 50 CUTi 35C CUTi 40 CUTi 70 CUTi 90 CUTi 120 Recommended cutting range 1) Maximum Cutting range 1) 1) These data depending on the materials to be cut and their compositions. Technical Data Power Source CUTi 35C CUTi 40 CUTi 70 CUTi 90 CUTi 120 Mains voltage use, slow Connected load Cutting current range Duty cycle Dimensions (L x W x H) Weight Plasma and cooling gas 230 V 16 A 3.3 kva / 4.8 kva 2) 12-25 A (35 A ) 20 A at 100% 25 A at 35% 35 A at 25% 550 x 150 x 245 mm 12.5 kg Air 2) 230 V 16 A (32 A CEE) 6.5 kva 15-40 A 25 A at 100% 32 A at 60% 40 A at 40% 460 x 180 x 220 mm 11.5 kg Air 400 V 16 A 11.1 kva 26-70 A 50 A at 100% 60 A at 60% 70 A at 35% 470 x 180 x 250 mm 16.4 Air 400 V 25 A 15 kva 26-90 A 55 A at 100% 74 A at 60% 90 A at 40% 470 x 180 x 270 mm 17 kg Air 400 V 32 A 16,7 kva 25-120 A 80 A at 100% 95 A at 60% 120 A at 35% 610 x 230 x 410 mm 28.7 kg Air 2) With external air supply.

Tradition gives an Enterprise Identity, Character and Profile 1922 oundation of Kjellberg Elektro-Maschinen GmbH 1934 irst welding technique from insterwalde 1936 Kjellberg is Europe's biggest manufacturer of arc welding technique 1941 Kjellberg is the world's biggest manufacturer of arc welding technique with 5,000 employees 1959 Year of birth of Kjellberg insterwalde plasma technology 1962 irst use of an industrial plasma cutting system with 50 kw ready for series production Patent for fine focus plasma cutting in cooperation with the institute Manfred von Ardenne in Dresden 1970 or the first time ever air is used as carrying gas for plasma cutting 1975 Kjellberg systems conquer the Japanese shipbuilding industry 1980 Beginning of the underwater plasma cutting technology 1988 irst primary-switched inverter the plasma cutting system PA-12 I 1991 Innovative new developments in our product range and a new distribution system are the basis for the company's reorganisation 1995 Consumables of the XL-Life system increase the lifetime for plasma cutting with oxygen 1998 Introduction of the swirl gas technology for fine focus plasma cutting 2000 Hiocus a new technology with laser-like cut quality conquers the market 2002 The very first flow-controlled automatic plasma gas supply unit worldwide is a big step towards a new dimension of quality and reproducibility of plasma cuts 2006 Hiocus 80i/160i/280i/360i make up the first complete series with primary-switched inverter technology 2007 Introduction of new YellowXLife generation of consumables 2008 Incomparable flexibility with the new Hiocus 440i at present the most powerful highprecision plasma cutting system worldwide 2010 Development of the new generation of plasma torches PerCut 440/450 and PerCut 200/210 with new consumables 2011 Introduction of the new plasma cutting technology Contour Cut Customer and Application centre - Europe's latest and biggest Plasma Centre

Plasma Products Made in Germany Kjellberg plasma cutting systems are CE-conform and correspond with the valid guidelines and legislation of the European Union. They are developed and fabricated on the basis of following standards and regulations: EN 60974 (VDE 0544). All plasma cutting systems are labelled with the S sign and are therefore applicable to environments with increased hazard of electric shock. The fabrication takes place according to DIN EN ISO 9001. The in-house quality assurance comprises piece and cutting performance tests documented by test certificates. Our products represent a high level of quality and reliability. We reserve the right to change the design and/or technical specifications during the series fabrication. Claims of any kind cannot be derived from this brochure. 12-01-07 Kjellberg insterwalde Plasma und Maschinen GmbH Germany D - 03238 insterwalde Leipziger Str. 82 Tel.: +49 3531 500-0 ax: +49 3531 500-227 E-Mail: plasma@kjellberg.de Internet: www.kjellberg.de,,, YellowXLife, XL Hiocus, PGC, PerCut and Contour Cut are trademarks of the Kjellberg oundation / Kjellberg insterwalde and may be registered in Germany and/or other countries. Copyright 2012 Kjellberg insterwalde Plasma und Maschinen GmbH All rights reserved.

Precision in Detail Small holes, fine inner and outer contours: the precision of Contour Cut revolutionises the plasma cutting of mild steel. www.kjellberg.de

Contour Cut for Highest Quality Standards Until now the quality of cutting edges has been insufficient when cutting small holes with a diamter equal to the material thickness. Being the technology leader in plasma cutting, Kjellberg insterwalde offers an optimum solution for this problem. The Hiocus systems with Contour Cut redefine the state of the art. The result - excellent quality without time-consuming aftertreatment at low costs. Precision in Detail Contour Cut is the further development of our successful Hiocus technology for cutting contours in mild steel, in particular small holes as well as fine inner and outer contours. This newest development ensures the further improvement of the quality with respect to contour accuracy, perpendicularity and surface quality. Contour Cut is integrated as standard into all plasma cutting systems of the Hiocus series with the plasma torches PerCut 200/210 and PerCut 440/450. Results When cutting small contours, i.e. holes, slotted holes, squares and hexagons, convincing cut qualities can be achieved: Ÿ Ÿ Ÿ Holes with angular deviations ranging between 2 and 4 according to DIN EN ISO 9013 urther reduction of perpendicularity tolerances at inner and outer contours Reduced difference of angular deviations on all sides of outer contour Competitior Kjellberg insterwalde Plasma und Maschinen GmbH Leipziger Straße 82 03238 insterwalde Phone.: 03531 500-0 ax: 03531 8510 Mail: plasma@kjellberg.de

Plasma Cutting with Contour Cut Contour Cut is the latest patented plasma cutting technology for mild steel. The following points should be considered to achieve good results when cutting holes with a diameter to thickness ratio of 1:1: Ÿ Ÿ Ÿ Ÿ Ÿ Align the work-piece horizontally to the plasma torch that is in absolutely vertical position Adjust correct torch height reeze the height control for hole diameters of up to 25 mm Select speed in correspondence with the cutting parameters for Contour Cut Program contours according to the following drawings 0...1 time the cutting kerf 1 time the cutting kerf 1...3 times the cutting kerf Sequence for 1-6 mm material thickness minimum hole diameter 4 mm Sequence for 6-25 mm material thickness Sequence for material thickness from 25 mm Advantages at a Glance High cut quality and contour accuracy on inner and outer contours Reduced angular deviations and improved quality of cut surfaces Very high repeatability and dimension accuracy High productivity at low costs No further equipment or software required No new consumables required Standard for all Hiocus systems with the new plasma torches 10 mm mild steel with 264 holes à 10 mm in diameter Our products represent a high level of quality and reliability. We reserve the right to change design and/or technical specification during the series fabrication. Claims of any kind can not be derived from this brochure. Copyright 2011 Kjellberg insterwalde Plasma und Maschinen GmbH All rights reserved. 11-05-01