Instruction Manual

Plasma cutting machine

HiFocus 160i + FlowControl

Article-No.: .11.033.702

for the CNC-controlled cutting with Plasma torch

PerCut 160/170 (HiFocusplus-Technology)
for cutting and marking operations
Contents DI 0001 page

1 General 1.1 Warranty claim 1-1

information 1.2 Norms and rules 1-1
A 0001 / A 0002 / A 0002.04 1.3 Notes on the Instruction Manual 1-1
1.4 Safety instructions 1-2
1.4.1 Endangerments through high contact voltage 1-3
1.4.2 Working in environments with increased hazard of electric shock 1-4
1.4.3 Endangerments through high voltage ignition 1-4
1.4.4 Endangerments through electromagnetic interferences 1-4
1.4.5 Endangerments through heat and light radiation 1-5
1.4.6 Endangerments through fumes and smoke 1-6
1.4.7 Measures for prevention of "Oxyhydrogen gas formation" 1-6
1.4.8 Endangerments through noise 1-7
1.4.9 Endangerments through spatter 1-7
1.4.10 Handling of pressure cylinders 1-7
1.4.11 Handling of coolant 1-8
1.5 The Plasma Cutting Process 1-8
1.5.1 Dry cutting 1-9
1.5.1.1 Plasma cutting without secondary gas 1-9
1.5.1.2 Plasma cutting with secondary gas 1-10
1.5.2 Under water cutting process 1-11
1.6 Maintenance 1-11
1.6.1 General 1-11
1.6.1.1 Intervals of maintenance 1-11
1.6.1.2 Cleaning 1-12
1.6.1.3 Electrical revision 1-12
1.6.1.4 Plasma torch 1-12
1.6.2 Special 1-14
1.6.2.1 Gas pressure test 1-14
1.6.2.2 Cooling system 1-14
1.6.2.3 Preventive periodic maintenance - component change plan 1-15

2 HiFocus 160i 2.1 Technical data 2-1

G 0001
2.2 Technical description 2-1
2.3 Characteristic features and advantages 2-2
2.4 Ranges of application 2-2
2.5 Plasma marking 2-4
2.6 Putting into operation 2-4
2.6.1 Check out, placement and installation 2-4
2.6.2 Installation 2-5
2.6.2.1 Mains connection 2-5
2.6.2.2 Workpiece connection / current return line 2-5
2.6.2.3 Earthing 2-5
2.6.2.4 Connection of the HiFocus 160i 2-5
2.7 Control and display elements 2-6
2.8 Cutting operation 2-7
2.9 Remote control FB1 2-10
2.10 Filling up the coolant 2-10
2.11 Combination of the HiFocus 160i with CNC-controls of guiding 2-10
systems and robots
2.12 Start regime HiFocus 160i 2-11
2.12.1 Start by remote control 2-11
2.12.2 Start by CNC 2-11
2.12.3 Start from CNC with special function "separate ignition signal“ 2-12
2.12.4 Start from CNC with special function "pre-impulse“ 2-12
2.13 Protective facilities 2-12
2.14 Trouble shooting 2-13

DI 0001 - 01.01.2007 - page 0-2 - Kjellberg Finsterwalde

 page

3 Plasma machine 3.1 Technical data 3-2

torch 3.2 Technical description 3-2
PerCut160/170 3.3 Connection of the plasma torch to the PBA-H 160 3-3
Z 0001
3.4 Consumables of the PerCut 160 (overview) 3-4
3.5 Operating notes for the PerCut 170 3-8

4 FlowControl 4.1 Technical data 4-2

Z 0002 4.2 Technical description 4-2
4.2.1 Operation of PGC1 4-2
4.2.2 Start screen 4-3
4.2.3 Operation screen „Cutting“ 4-4
4.2.4 Operation screen „Record parameters“ 4-6
4.2.5 Operation screen „Data Survey“ 4-7
4.2.6 Operation screen „Input pressure“ 4-8
4.2.7 Operation screen „Configuration data“ 4-8
4.2.8 Operation screen „Support“ 4-10
4.2.9 Selection of data sets fort he cutting process 4-10
4.2.9.1 Manual selection of cutting data at the PGC 1 4-11
4.2.9.2 Selection of a data set of the PGC1 4-11
4.2.9.3 Fast data set selection by using the keys „0“ and „I“ 4-12
4.2.9.4 Safe of user data sets 4-13
4.2.9.5 Delete of data sets 4-14
4.2.9.6 Preselection of gas parameters from the external control 4-14
4.3 Control and display elements PGC 1 4-15
4.4 Connection of the plasma gas valve unit PGV1 4-16
4.5 Connection of the gas hoses between PGV1, PGA-HM and 4-16
PBA-H 160
4.6 Connection of the gas supply 4-16
4.6.1 Plasma gases 4-16
4.6.2 Swirl gases (Oxygen, Nitrogen, backing gas) 4-18

5 Plasma gas ignition 5.1 Technical data 5-2

box PZ-H 5.2 Technical description 5-2
Z 0005 5.2.1 line set PZL-H101 5-2
5.2.2 Plasma gas ignition box PZ-H 5-2
5.3 Connection of the plasma gas ignition box PZ-H 5-3

6 Plasma gas 6.1 Technical data 6-2

connection unit 6.2 Technical description 6-2
PGA-HM 6.2.1 Plasma gas connection unit PGA -HM 6-2
Z 0006 6.2.2 line set PBL-H160 6-2

7 Plasma torch 7.1 Technical data 7-2

connection unit 7.2 Technical description 7-2
PBA-H 160 7.3 Connection 7-3
Z 0007

DI 0001 - 01.01.2007 - page 0-3 - Kjellberg Finsterwalde

Enclosure

Enclosure1

SD 0001 Cutting tables of the HiFocus 160i with FlowControl

SD 0001.01 Cutting tables 3D- cutting tables HiFocus 160i

Enclosure 2

SP 0001 Wiring diagrams of the HiFocus 160i

SP 0002 Wiring diagrams of the HiFocus 160i and FlowControl
SP 0005 Wiring diagrams of the FlowControl

Enclosure 3

BHA 0001 Order information and of HiFocus 160i with the plasma machine torch PerCut 160/170
connecting diagrams

Enclosure 4

ETL 0001 Spare parts list of the HiFocus 160i

ETL 0002 Spare parts list of the PerCut 160-2
ETL 0003 Spare parts list of the PerCut 160-2-Robo
ETL 0004 Spare parts list of the PerCut 170-2

Enclosure 5 Protocol Protocol for the gas pressure test once a month

DI 0001 - 01.01.2007 - page 0-4 - Kjellberg Finsterwalde

1 General information

1.1 Warranty claim

We point out explicitly that only spare parts and consumables of Kjellberg origin
have to be used! Otherwise a warranty claim does not exist. Kjellberg as
manufacturer of the equipment can not make any guarantees for the safety of the
equipment according to the valid regulations.

1.2 Norms and rules

The CE mark indicated on our plasma cutting and welding machines shows the
conformity of our products with the latest effective European CE Guideline.

Development and production take place according to the following standards:

EN EN 60974 (VDE 0544).

All plasma systems and welding systems are in possession of the S-mark and

S
therefore applicable to work places with increased electrical endangerment.

All products are manufactured under strict quality assurance control and proved
by certificates and product-related test records.
ISO
9001 The production takes place according to DIN EN ISO 9001.

1.3 Hints on the instruction manual

Our products are of first-rate quality and high reliability and are in operational condition at any
time. You fully will enjoy all these benefits, as long as you carefully observe these instructions
for operation, maintenance and handling.
We ourselves reserve the right of alteration to the product in order to follow the latest technical
development.

Therefore, claims whatever kind can’t be derived from this instruction manual.
For any request you are kindly asked to quote model name and model number.

Please keep this instruction manual always ready for use. Read carefully all chapters
before starting the unit!

The instruction manual always must accompany the machine.

For damages due to misuse or wrong service we will not take any
responsibility

Kjellberg Finsterwalde Plasma und Maschinen GmbH

Germany D - 03238 Finsterwalde Leipziger Str. 82
phone: +49 3531 500-0 Fax: +49 3531 500-227
e-mail: [email protected]
Internet: www.kjellberg.de

A 0001 - 04.09.2007 - page 1-1 Kjellberg Finsterwalde

 1.4 Safety Instructions
All endangerments through the plasma cutting process are related with the process itself.
Endangerments may occur due to:

• high contact voltage

• high voltage (HV) ignition
• electromagnetic disturbances
• heat and light radiation
• gases, smokes and dust
• noise
• hot metal and spatter
• handling of pressure cylinders
• handling of coolant

The plasma cutting machine has been developed in compliance with following standards:

EN 60974 (VDE 0544) installation for arc welding

The user has to follow national and local regulations (e.g. Employer’s Liability Insurance
Association)! Before starting the plasma cutting machine this instruction manual has to be read
carefully! Only advised personnel are allowed to operate the plasma installation!

Warning label

The warning label is visibly attached on the plasma cutting machine.

The operator and the maintenance personnel must familiarize themselves with the meaning of the
symbols before working at the unit.

1. The operator and the maintenance per-

sonnel must read and understand the
instruction manual as well as learning the
operation of the unit before work with it to
avoid endangerments. The safety regula-
tions of the respective company have to be
taken into account.

2. Smoke, dust and gases developed during

the cutting process are harmful for health
and may not be breathed in. Principally a
suitable fume extraction device has to be
used.

3. Wearing of protective clothing (helmet,

welder’s overall, leather apron, gauntlets,
safety shoes). The protective clothing has
to be isolating, dry and heavily inflamma-
ble.

Attention!
To reduce the risk to yourself and others, read and understand this marking and manufac-
turer's instructions

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 4. Noise can damage the hearing! During the plasma cutting operation suitable ear protection has
to be used. The radiation of the plasma arc can lead to eye injuries and skin burns. Eyes and
skin have to be protected from the radiation of the plasma arc therefore. Protection devices are
safety goggles and hand shields, which must have a sufficient lens shade.

Attention!
The operator has to follow national and local regulations (e.g. Employer’s Liability
Insurance Association).

5. Electric shock can kill! Live electrical parts may not be touched.
Opening the plasma unit may be carried out only by an advised electrician. Before carrying out
any maintenance or repair work the unit has to be disconnected visibly from the mains!

6. Wearing of protective clothing (helmet, welder’s overall, leather apron, gauntlets, safety shoes).
The protective clothing has to be isolating, dry and heavily inflammable. Working with plasma
cutting machines possibly can lead to fire and explosions. Flammable and explosive materials
must therefore be kept away from the cutting area. It has to be ensured that suitable and easily
accessible extinguishing facilities are located nearby. The appropriate fire protection regulations
have to be taken into account.

7. Appropriate warning labels may not be removed, painted over or covered.

Further requirements and warnings:

• To ensure stableness of the plasma plant an inclination of 10°.may not be exceeded

• Connect the power source only with properly fitted protective conductor
• Place the torch on an insulated place, to protect the operator against workpiece and
ground potential
• Keep dry the working area and all parts of the unit
• Don’t start the unit if components or parts are defective
• The plasma cutting machine has to be earthed and connected to the workpiece before switch-
ing on
• Switch off the unit before touching the plasma torch and prevent accidental restart
• Arrange regular electric inspections (by an authorized electronics engineer)
• Keep doors and flaps closed as long as the unit is connected to the power supply
• Never shorten safety circuits (door contact, protective caps)
• Do not cut closed containers
• The plasma cutting machine may be used only for the appointed use. It may not be used e.g. to
defrost frozen pipes
• Do not touch the torch head, the workpiece or the water (if water table is used) when the
plasma unit is working
• Inflammable objects (e.g. lighters, matchsticks) may not be carried by the operator at the body
• During the operation of the plasma unit electromagnetic fields become originated which can in-
fluence the wearer of hearing aids, heart peacemakers or other body implants. Persons con-
cerned have to consult a specialized doctor before starting the job

1.4.1 Endangerment through high contact voltage

Attention!
Opening the plasma unit may be carried out only under responsibility of a qualified electri-
cian. Before starting any maintenance and repair work principally the power supply source
has to be switched off and visibly disconnected from the mains.
Before starting the machine connect the workpiece cable and earth the workpiece!

A 0002 - 01.09.2007 - page 1-3 - Kjellberg Finsterwalde

 Attention!

The following relates to cutting units with liquid cooling and hand torch connection:

Power sources normally are having a high ohmic conducting path through the coolant to the hous-
ing. If the torch trigger is activated and the workpiece is not earthed the open circuit voltage or the
arc voltage is applied to the housing as contact voltage. Because the resistance of the coolant,
even it is dirty, is in the range of > 10 kOhm the contact voltage breaks down to a value which is
absolute harmless. The touch voltage nevertheless is sensitive.

The cooling circuit is insulated from the housing of the plasma unit at devices with possibility con-
nected hand torch. The contact voltage does not occur. The housing of the pump is protected by a
residual- current circuit- breaker.

1.4.2 Working in environments with increased hazard of electric shock

The plasma cutting machine is built in compliance with valid standards EN 60974-1 and therefore
applicable in environments with increased hazard of electric shock.

The conditions for fulfilling these requirements are given by design measures in the plasma cutting
machine:

• The plasma power source and the plasma torch are forming a safety-proofed installation, which
can be separated only by a tool (as far as a central connector with mechanical locking is pre-
sent).The unit cannot be switched on as long no torch is attached or the attached torch isn't as-
sembled completely.
• Opening the control circuit effects switching off the open circuit voltage, which drops down
within the prescribed time below the limit
• Cutting with hand torch is only possible with mounted, electrically insulating protection cap,
which protects against accidental touching the live nozzle cap. If the protection cap is not avail-
able the torch can not switched on (security circuit).

Therefore the plasma cutting unit is S-marked and applicable in environments with increased haz-
ard to electric shock.

Attention!
The user has to follow national and local regulations (e.g. Employer’s Liability Insurance
Association) by all means!

1.4.3 Endangerments through high voltage ignition

For igniting the pilot arc a high voltage igniter is installed in the power source. When pressing the
ON-button the high voltage is applied to the cathode and nozzle. After initiating the pilot arc the
HV-supply becomes switched off automatically. After the cutting process has started the pilot ex-
tinguishes.
Attention!
Never touch the torch head if the power source is switched ON!

The HV-ignition may establish electric or electro-magnetic fields, which can cause

malfunctions and interferences around the plasma unit at

• heart pacemakers
• other body implants
• hearing aids
• other electronic devices

1.4.4 Endangerment through electromagnetic interferences

The plasma cutting installation complies with the instructions of the EN 60974-10 (VDE 0544, part 10)
"Arc Welding Equipment – part 10: requirements at the Electromagnetic Compatibility (EMC)". This
standard is valid for Arc Welding Installations and related processes (e.g. plasma cutting).

A 0002 - 01.09.2007 - page 1-4 - Kjellberg Finsterwalde

 General

The user is responsible for installing and using the installation according to the manufacturer’s in-
struction. If electromagnetic disturbances are detected then the user is responsible to arrange the
technical solution with the assistance of the manufacturer.

Recommendations for assessment of the area (EN 60974-10)

Before installing the equipment the user shall make an assessment of potential electromagnetic
problems in the surrounding area, and shall take the following into account:
• Other supply cables, control cables, signalling and telephone cables; below and adjacent to the
installation
• Radio and television transmitters and receivers
• Computer and other control equipment
• Safety devices, e.g. protections for industrial equipment
• Health of the people around, wearing pacemakers or hearing aids and other body implants

• Equipment for calibration and measuring

• Immunity of other equipment in the environment. The user shall ensure that other additional
protection measures in the environment are compatible
• Time of day that cutting has to be carried out.

Recommendations of methods to minimize disturbances

If disturbances are detected it may be necessary to carry out further precautions, such as those:
• Filtering of the mains supply
• Shielding the mains cable of the permanently installed plasma cutting (safe contact is neces-
sary
between shielding and housing)
• Regular maintenance of the plasma cutting installation
• All cover plates, service openings and flaps have to be closed before starting the unit.
• No alternations on adjustments and settings should be done at the plasma unit whitout the
acceptance of the producer
• Cutting cables should be kept as short as possible and closely together or take course close to
the bottom
• Potential equalization of all metallic components should be considered inside and adjacent to
the installation. The operator should be insulated from all metallic components.
• Earthing of the workpiece
• Selective screening of all other cables and equipment

Attention!
The user has to follow national and local regulations (e.g. Employer’s Liability Insurance
Association).

1.4.5 Endangerment through heat and light radiation

The radiation of the plasma arc can lead to eye injuries and skin burns. Eyes and skin have to be
protected from the radiation of the plasma arc therefore.

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 Safety measures:
• Wearing of total protective clothing (helmet, welding overall, possibly apron, gauntlet gloves, sa-
fety shoes).The protective clothing has to be insulated, dry and flame-resistant.
• Protection devices are safety goggles and hand shields, which must have a sufficient lens
shade.
• The cutting area should be prepared so that reflections and transmission of ultraviolet light is
reduced:
- use of protective walls
- arranging painting of walls with dark colour

Attention!
The user has to follow national and local regulations absolutely (e.g. Employer’s Liability
Insurance Association).

1.4.6 Endangerment through fumes, smoke and dust

Due to the plasma process itself hazardous substances may be produced. To avoid risks on health
the following has to be arranged:

• Keep cutting place well ventilated

• Remove fumes and smoke by exhaustion devices
• Removed all chlorinated and other solvents from the cutting area because they could form
phosgene gas when exposed to ultraviolet radiation
• Wear breathing mask when cutting galvanized materials
• Ensure that toxic limits become not exceeded

Attention!
The user has to follow national and local regulations (e.g. Employer’s Liability Insurance
Association)!

Attention!
In any case the user of the plasma cutting installation has to carry out measurements of the
concentration of toxic substances to proof the effectiveness of the exhaust equipment!

1.4.7 Measures for prevention of „Oxyhydrogen gas formation”

(Does only apply for plasma cutting of aluminium in combination with water)

The molten aluminium which is blown out of the cutting gap forms in water an aluminium
granule which is oxidizing in water very fast because of its large surface.
Hydrogen is generated due to the bond of oxygen of the water. The hydrogen raises in the
water table to the surface, is ignited during the cutting process and burns out (reddish fla-
me).

This reductive process can last for days in the slag of the water table. Mainly compressed
air is used for the automatic level control of the water table, and by that a hydrogen-air mix-
ture will be generated (oxyhydrogen gas).

Attention!
If such a mixture (highly explosive at a hydrogen content of 4 to 76 vol. %)
is formed in the displace chamber or below the plate and is ignited by the
plasma arc, a wasteful explosion possibly will happen.

For water tables with level control:

• Nitrogen (with lower purity) has to be used instead of air.

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 For water tables without level control it has to be ensured, that:
• hydrogen can escape freely everywhere and is burnt out,
• the inside contour of the water table is even so that no granule can gather at inac-
cessible spaces,
• the slag and the granule are removed from the water table without delay,
• that no hydrogen can gather below the plate which is placed on the table grating.
• The guiding machine has to be positioned after the cutting outside the water table to avoid,
that hydrogen or oxyhydrogen (hydrogen-air mixture) cangather in hollow spaces (like switch
boxes).
Attention!
It is not allowed to store the plates on the cutting grating for a longer time!

1.4.8 Endangerment through noise

Be aware that during the plasma cutting a high noise level is produced.
Depending on the technological process and the cutting parameters in a meter distance from the
pilot arc the following sound level is reached:

Process: Dry plasma cutting

max. sound level material technology
with a height of:
cutting material

FineFocus F
1m 3m 6m

HiFocusplus

HiFocus F
current* thickness

HiFocus
measured calculated
(A) (mm)
(dB(A)) (dB(A)) (dB(A))

20 1,5 90 80 75 5,2
60 8 92 82 77 9,5
80 20 102 92 87 8,5
mild steel
90 12 103 93 88 8,5
130 30 107 97 92 9,5
160 50 102 92 87 5,8
280 70 112 102 97 CrNi 6,5
300 10 113 103 98 mild steel 7,2
360 80 113 103 98 AlMg3 7,3
400 100 114 104 99 7,0
CrNi
600 150 122 112 107 7,0
cutting pressure
*depending on the type of the unit
(bar)

Therefore suitable protective measures have to be arranged in any case(ear protectors, muffs,etc.)
The user has to follow national and local regulations (e.g. employer’s liability insurance associa-
tion).
1.4.9 Endangerment to spatter
During plasma cutting sparks, slag and hot metal are produced. The risk of burns and fire exists!
To avoid endangerments the following has to be arranged:
• removal of all potential flammable materials from the cutting area, at least in a distance of 10 m
• cool down freshly cut material before handling or storing
• make fire extinguishers available in the cutting area

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1.4.10 Handling of pressure cylinders
Attention!
For the gas supply only high- quality, preferable two- step pressure regulators have to be
used, guaranteeing a constant supply pressure. The quality of the pressure reducer influences
the cutting quality and reliability of the complete unit. Pressure reducers that are conform to
the quality requirements are mentioned in the order specifications of Kjellberg.
Furthermore the user has to follow local and national standards.
For the plasma cutting process compressed gases are used. To avoid endangerments following
instructions have to be taken:

• place cylinders upright in secured position

• don’t use damaged cylinders, pressure reducers and armatures
• only employ the pressure reducer for corresponding gas
• never lubricate pressure reducers with grease or oil
• all parts, which coming with oxygen into contact, must be absolutely free of oil and grease.
• when using oxygen the pressure reducer must be furnished with an explosion protection
• perform gas pressure test acc. to chapter “Gas pressure test”

1.4.11 Handling of coolant „Kjellfrost“(only valid for liquid cooled torches and power sources)

For all liquide- cooled plasma cutting units Kjellberg Finsterwalde is using the coolant „Kjellfrost”,
suitable as anti- freezer as well.

„Kjellfrost” contains anti- corrosive inhibitors. Thereby all the components of the cooling device are
protected effective against corrosion.

Please notice following items particulary:

ƒ „Kjellfrost“ is classified as a hazardous substance in sense of the standard for hazardous sub-
stances, but not in the sense of the standard for the transportation of hazardous substances.
ƒ Danger dominant ingredient: Ethylenglykol (Ethandiol)
ƒ Never add water to the new„Kjellfrost“ (for dilution or filling up). Only pure „Kjellfrost“ has to be
used for filling up!
ƒ Safety regulations for handling, storing, etc. are given in a safety data sheet, which is available
on request (Tel. +49.3531.500203).

Attention!
All details given on the label of the new anti-freezer have to be followed consequently!

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 Caution if handling coolant Kjellfrost!

- „Kjellfrost“ is injurious to health

- Don’t drink Kjellfrost
- Keep it away from food, drinks and fodder.
- Avoid the contact with eyes and skin
- Safety goggles recommended during filling
- Always clean your hands after end of work.
- Wear protection suit
- Wear gloves from Nitril or Viton (see safety data sheet)
- Don’t wear contaminated clothes.
- Slippery when wet by spilled „Kjellfrost“
- Keep away from children

First aid measure!

- 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 which much water and soap

1.5 The plasma cutting process

The plasma is defined as a gas having atoms and molecules which are partly split into ions and e-
lectrons and having therefore a high electrically conductivity.
In the plasma torch this gas becomes heated up extremely and leaves it through the nozzle with a
high speed. Due to the high heat concentration all electrically conductive materials will melt and
due to the high speed and pressure of the plasma arc the molten material will be blown away form-
ing a very small kerf in the material.
The plasma arc hereby is transferred from the cathode, installed in the plasma torch and con-
ducted to the negative pole of the plasma power source, to the workpiece (transferred arc).
The plasma cutting is a technology for cutting of electrically conductive metals, like constructional
steels, stainless steels, aluminium, copper, etc. It is suitable for straight, profile, template and bevel
cutting. So plates, tubes, profiles, formed and casted parts can be cut or worked.

plasma cutting
process

dry cutting under water cutting

process process

without secondary with secondary gas with secondary gas

gas (conventional) (swirl gas technology) (swirl gas technology)

without enhanced with enhanced

constriction of the constriction of the
plasma arc plasma arc

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1.5.1 Dry cutting process

1.5.1.1 Plasma cutting without secondary gas

fig. 1-1: principle of plasma cutting
without secondary gas
Depending on the cutting task various cutting 1 pilot resistor
technologies can be used. The cutting without 2 HV-igniter
secondary gas is described with fig. 1-1. 3 gas supply
4 cathode
5 nozzle
6 plasma arc (main arc)
7 workpiece

A safe ignition of the pilot arc is granted when following subsequent points:
• If a plasma hand torch is available, then the central connector of the plasma hand torch must be
tightened to the limit stop.
• The proper mounting of the wearing parts.
• The cathode must always be firmly tightened.
• The nozzle end must always be kept clean of dirt, especially of metal spatter. A soft wire brush
can be used for cleaning.
• The required parameters in regard to gas pressure and mains voltage must be observed.
Attention!
By no means may pliers or other inappropriate tools be used, as this will inevitably damage
the wearing parts (creation of burrs that lead to malfunctioning).

The safe formation of the main arc (cutting arc) will be achieved through (see fig. 1-1):

• disconnection of HV-igniter just after ignition of pilot arc

• pilot arc current is limited by the pilot arc resistor
• Automatic power increase if pilot arc contactes the workpiece

Generally the workpiece cable must have full contact to the workpiece.
When using the hand torch the distance holder should be used.

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1.5.1.2 Dry cutting process with secondary gas (swirl gas technology)

Dry cutting process with secondary gas without enhanced constriction of the plasma arc

Plasma torches for the secondary gas technology are using a swirl gas for shielding the plasma arc
from the atmosphere. With the conventional dry plasma cutting the plasma arc is directly trans-
ferred from the nozzle to the workpiece. Spatter and upcoming material can lead to double arcing
and to reduced nozzle life and poor cutting quality. Plasma torches using the swirl-gas technology
are avoiding those disadvantages. The nozzle of the plasma torch effectively is protected by the
swirl-gas cap and the surrounding swirl gas against upcoming material, especially when cutting
starts by piercing. Flow rate and composition of the swirl gas can be optimised to obtain best cut-
ting results on different materials.

The figure shows the principle of the swirl gas technology in comparison to the conventional dry
plasma cutting.

A A
B B
C
fig. 1-2:
plasma torch with swirl gas
compared to conventional plasma
torch

A coolant circuit

B plasma gas

C swirl gas

ohne Wirbelgas
without swirl-gas

Dry cutting process with secondary gas and with enhanced constriction of the plasma arc (HiFo-
cus technology)

The former described cutting technologies are producing a cut with more or less inclination of the
cutting surfaces, especially at thin materials. On plates up to 5 mm the cut angle can amount to 5
to 10 degrees really. The new HiFocus technology reduces the inclination considerably. The cut-
ting surfaces in the thin sheet metal range (0.5 - 8.0 mm) are nearly perpendicular, resulting in
much higher part accuracy. The reason is the intensive constricted and stabilized plasma arc.

Reworking of the metallic clean and free-of-dross cut surface is normally not necessary.

Detailed cutting data to the kind of materials and qualities of material are to be found in the appen-
dix of the instruction manual.

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1.5.2 Under water cutting process

The under water cutting process reduces the pollution of the environment, the noise level of the
process and the light radiation considerably in comparison to the dry cutting process. The distortion
of the cutting material is very low.

But the consumption of electrical energy is higher.

One of the advantages of the swirl gas technology is the fact that the plasma torch is suitable for
the dry cutting and the underwater cutting as well without any adaptation to the torch.

Furthermore the cutting process grants highest stability, ensuring optimum cutting quality for both:
“dry” and “under water”..

1.6 Maintenance
Attention!
Before carrying out any maintenance or repair work, or opening cover plates the plasma
power source has to be disconnected visibly from the mains (unplug mains cable)!
Only under the advice of a licensed electrician the unit should be opened
(see VDE 0105 or follow national instructions)!

1.6.1 General

1.6.1.1 Intervals of maintenance

Following measures have to be taken regularly:

1. weekly:
visual inspection of the condition of the plasma power source, all system components and the
plasma torches, control of the filling level of the coolant (fill up on demand)

2. monthly:
by application of hydrogen and oxygen, Æ inspection of the gas supply, gas pressure test acc.
to chapter 1.6.2.1

3. after 4 to 6 months :
Cleaning the power source and all components

4. all 6 months :
electrical revision

5. yearly :
complete change of coolant („Kjellfrost“)

A 0002 - 01.09.2007 - page 1-12 - Kjellberg Finsterwalde

1.6.1.2 Cleaning
From the power source all dust and dirt which has collected inside by the fan have to be removed
in intervals of 4 to 6 months. Blowing out should be done carefully with dry compressed air, more
effective is to use a vacuum cleaner.
When working in shifts or under unfavourable conditions the regular cleaning should take place in
shorter intervalls.
For ensuring an effective cooling filter mattes, if existing, should be cleaned in water (approx. 40°C)
by using standard detergents.
Manual cleaning is useful as well (beating; exhausting; with compressed air, e.g.)
In the same way all components of the system have to be cleaned.

Filter regulators and micro filters have to be cleaned weekly. Condense water has to be drained;
filter inserts have to be replaced in time.

The small filter screws inside the gas connectors of the plasma gas control units have to be in-
spected every 4 to 6 months, and cleaned if necessary. For that reason the pressure reducers of
the gas cylinders have to be closed and the respective gas hose removed from the control unit.
The filter screws only can be taken out by a small screw driver.

1.6.1.3 Electrical revision

According to existing regulation an electrical revision of the plasma cutting unit has to be arranged:
• after 6 months, if the installation is changing the location permanently
• after one year, if the installation remains on the place

a) The visual inspection should concentrate to following conditions and ensuring, that

- the power source is in a good condition

- the touch protection to parts functionally not activated is granted
- main fuses or overcurrent protections are matching the line cross section
- cables and wirings are undamaged and have no burn marks

b) By measurement has to be proofed that the protection against excessive touch potential of
parts functionally not activated is granted (test of protective conductor):

- the transition resistance between marked protective conductor connection of the plasma cutting
unit and all touchable metallic, not alive parts has to be < 0.1 Ohm if line cross section is
2
> 6 mm (otherwise pay attention to EN 60204-1) !

c) The insulating capacity of winding and line insulation has to be proofed:

- insulation value between windings and housing (protective connector terminal) > 2.5 MOhm
(dry and cold condition)
- insulation value between primary and secondary coils of the transformer T1 > 5 MOhm (dry
and cold condition)

Noticed faults have to be rectified by an expert immediately.

A 0002 - 01.09.2007 - page 1-13 - Kjellberg Finsterwalde

1.6.1.4 Plasma torch

The plasma torches have to be handled with care. Powerful treatment and stress load have to be
avoided. All spare parts must be in clean condition and carefully changed in time (see instruction
manual of the plasma torch).

Damages of parts inside the torch, like nozzle holder and cathode tube have to be avoided.

Besides the change of consumable parts by using the special torch tools no other action to
the torch head is allowed! Plasma torches must be transported and stored at protected places
with full inserted parts on the torch head only!

Hose parcels have to be protected against damages, like sharp bending, twisting, over rolling, and
thermal damages as well. At the plasma torches of the PerCut 160-1 series the filter screws have
to be cleaned from time to time after unscrewing from the gas connector. (only valid for liquid cooled
torches)

Attention!
Plasma torches have to be water tight at any time! Defective torches generally will be re-
paired by the Kjellberg Service Centre or a licensed repair shop!

Attention!
All components and parts coming in touch with oxygen have to be kept free of oil and grea-
se! This refers specially to the torch head and the consumables!

Only O R I G I N A L Kjellberg spare parts and consumables may be used!

A 0002 - 01.09.2007 - page 1-14 - Kjellberg Finsterwalde

1.6.2 Special

1.6.2.1 Gas pressure test

When using oxygen, hydrogen or inflammable gas mixtures the check of the gas supply system is
particularly important. An unnoticed gas leakage can have serious consequences.

The following gas pressure test has to be carried out separately for hydrogen and oxygen and
every other inflammable gas mixture monthly:

1. Disconnect the supply lines from the gas solenoid valves of the plasma torch connection unit
in order to prevent the magnetic valves from being activated
2. Start plasma cutting unit and activate gas test switch to fill up the gas hoses
3. Close exit valves at the pressure reducers (gas test switch must remain switched on!)
4. Check the initial pressures of the attached gases at the respective plasma gas control unit (ma-
nometer or label "initial pressure" at PGC). The adjusted initial pressures must be kept con-
stant for at least 3 min on the adjusted value.

If any loss of pressure is noticed, the reason has to be found out and eliminated immediately! The
pressure test has to be repeated after then.

After a successful completion of the gas pressure test the following actions have to be carried out:

1. Turn off gas test switches

2. Switch off plasma unit
3. plug connector of the solenoid valves

Attention!
Only regularly performed gas pressure tests are the guarantee for a safe operation of the
gas supply system! Because of the existing risk of fire and explosion by oxygen, hydrogen
and inflammable gas mixtures, the gas pressure test has to be carried out carefully and
proofed by protocol.

Protocol about the monthly gas pressure test see enclosure

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1.6.2.2 cooling system

The coolant has to be changed yearly.

Losses of coolant during the change of consumables have to be replaced. Therefore weekly the fil-
ing level has to be checked. if the level has reached the red mark of the filling level indicator cool-
ant has to be filled up to the end mark.

Attention!
Opening the plasma unit may be
carried out only under responsibility of a qualified electrician. Before starting any mainte-
nance and repair work principally the power supply source has to be switched off and visi-
bly disconnected from the mains.

The used coolant has to be removed from the cooling circuit of the plasma unit as follows:

• unscrew the left side wall of the plasma cutting unit

• put a collecting vessel under the drain orifice (right below the back wall)
• open the drain tap and afterwards unscrew the inlet hose of plasma torch
• After the complete discharge of coolant circuit clean filter of dirt trap. For this purpose unscrew
the connecting hoses, unscrew G3/8“-lock-nut, take out the dirt trap and the filter.
• The mounting occurs in reverse sequence.
• screw the left side wall of the plasma cutting unit
• Afterwards close the drain tap and fill in the new coolant mixture "Kjellfrost- 15" resp. "Kjellfrost-
25" (purge the drain pipe)
• Screw on the inlet hose of plasma torch
• Check screw connections for tightness
• If there are any problems during the first suction process of the pump, the dirt trap has to be
placed as deeply as possible (on the floor board), in Order to facilitate suction

A 0002.04 -- 17.01.2005 - page 1- 15 - Kjellberg Finsterwalde

1.6.2.3 Preventive periodic maintenance - component change plan

To guarantee a high availability of the unit, the strict adherence of the stated maintenance measures is nec-
essary.

Depending on the existing individual operating conditions of the user, it can make sense to carry out a pre-
ventive periodic maintenance with component change in addition to these maintenance measures according
to the following plan:

preventive periodic maintenance - plasma power source:

component change plan HiFocus 160i
time interval component Article No. quantity
1 year or after coolant .12.62360 unit depending
1000 cutting hours
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
2 years or after coolant .12.62360 unit depending
2000 cutting hours
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
3 years or after coolant .12.62360 unit depending
3000 cutting hours
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
4 years or after coolant .12.62360 unit depending
4000 cutting hours
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
coolant pump .11.033.702.320 2
torch hose package by manufacturer or
authorised service
5 years or after coolant .12.62360 unit depending
5000 cutting hours
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
fan .10.535.611 1
6 years or after coolant .12.62360 unit depending
6000 cutting hours
ignition unit contactor .10.161.710.24 1
nozzle-workpiece contactor .10.161.722.24 1
relay for torch solenoid valve .10.110.459 4 (K1,K5,K7,K8)
coolant and gas cable condition depending
As of 7th. year repetition of the component change plan

A 0002.04 -- 17.01.2005 - page 1- 16 - Kjellberg Finsterwalde

2 Plasma power source HiFocus 160i

2.1 Technical data

Primary side
input voltage U1: 3x 400V +10/-10% 50Hz
connecting load, max.: 33 kVA (100% duty cycle)
fuse, slow / switch: T 50 A / 50 A „B“
2
cross section, Cu: 4 x 10mm
power factor cos phi: 0.94 (160 A)
efficiency: 0.87

secondary side:
switch of technology range HiFocus-range 1 HiFocus-range 2 HiFocus-range 3
open circuit voltage U0: 330 V 330 V 330 V
cutting current IS: 10 – 160 A 10 – 160 A 10 – 160 A
arc voltage US: (100 %) 160 V 160 V 160 V
cutting power PS: 25,6 kW 25,6 kW 25,6 kW
duty cycle X: 100 % at 160 A 100 % at 160 A 100 % at 160 A
cycle duration: 10 min 10 min 10 min
material thickness ds : 0.5 – 8 mm 3 – 50 mm flying cutting
pilot arc current IPB: max. 15 A max. 15 A max. 18 A

characteristic: drooping (CC)

ignition: pilot arc ignition by HV-igniter; main arc ignition by pilot arc
2
workpiece cable: 35 mm

weight m: 196 kg
dimensions (lxbxh): 960 x 540 x 1050 mm (with undercarriage „castors and wheels“)
protection class: IP22
insulation class: F
cooling: by fan

torch cooling: integrated circulating cooling

o
coolant: coolant mixture „Kjellfrost -15“ (freezing protection up to -15 C) or „Kjellfrost -25“
o
(up to -25 C) with integrated corrosion protection

pressure: 0.6 MPa (6.0 bar) at 3.1 l/min

tank capacity: approx. 11 l

table 2-1

2.2 Technical description

All components of the plasma power source are mounted into a movable housing. The control and
signalling elements are placed in the front panel together with the gratings for the cooling air intake.
The back wall contains the filler neck for the coolant, the connector for the workpiece cable, the
mains cable entry, the connectors for the remote control, CNC-interface, as well as the components
for the arc ingnition, plasma gas control and adjustment, and furthermore the gratings for the cooling
air exhaust.
The terminals for the plasma torches resp. the hose parcel extensions PZL-H 101 and PBL-160 and
the fuse board F1-F5 are accessible after opening a cover plate, placed in the back wall.
The internal cooling system consists of the pump, the coolant tank, the heat exchanger and the flow
controller for switching off the power source in case of insufficient flow rate.
The inverter module contains the main transformer, the IGBT-bridge, the cutting choke coil, the main
rectifier, the pilot resistors and the power contactors. A high volt igniter initiates the pilot arc.
The complete cutting process is controlled and monitored by means of a micro-processor control.

G 0001 - 01.03.2006 - page 2-1 - Kjellberg Finsterwalde

2.3 Characteristic features and advantages

By the application of the Plasma Fine-Focus-Principle acc. to Professor Manfred von Ardenne with
its extreme constriction of the plasma arc extraordinarily energy densities will be achieved, which will
be additionally increased in the HiFocus range with HiFocusplus technology, resulting in various
technological advantages.

These mainly are:

• plasma cutting with laser-like quality from 0.5 to 25.0 mm

• dross-free up to 25 mm (dependet on workpiece)
• precise cutting surfaces and excellent contour precision of the parts, less rework reduces costs
considerably
• low heat input
• low distortion

Technological advantages:

• longevity of consumables because of second gas ignition and nozzle-saving piercing with swirl
gas technology
• minimized consumption of gas and energy due to the highly constricted plasma arc
• reduced investment and operation costs compared with a laser installation
• flexible capability for various CNC-guiding systems and robots

Further features and advantages:

• stepless current adjustment from 10 - 160 A (100 % duty cycle) for cutting up to 50 mm
thickness (material depending)
• stepless adjustable marking current 4.0 - 25 A for optimal process adaptation
• nozzle saving piercing by adaptable pilot arc current
• optimal process sequence by micro processor control
• adjustable current down slope at corner-, start- and stop-signals
• automatic monitoring of all important processes (torch cooling, ignition time, pilot arc time, etc.)
• digital cutting current and arc voltage display
• automatic display of the preset cutting current value
• indication of process conditions and process faults by LED and display
• interface for adaptation to CNC or robot controls
• serial data transfer (RS 485) for control of the HiFocus 160i from CNC
• serial data transfer to PC for diagnostic purposes (RS 232)
• longevity of consumables due to extreme effective water cooling
• hose parcel extensions (10, 20, 30 or 40 m) and plasma ignition box for increasing the
operational radius to max. 55 m
• plasma machine torch PerCut 170 with quick-change head reduces downtime and increases
flexibility
• stepless dosage and measurement of the gases by means of flow control respectively
flowmeter enable optimum control of the cutting process
• special torches (robot cutting, with short or inclined shaft, tube inside cutting) are available on
request
• up-to-date industrial design, movable or transportable by crane
• various plasma gases like air, oxygen, nitrogen, and Ar/H2/N2-mixtures ensure optimal cutting
results on different materials
• plasma marking with argon for optimal marking operations; with air for notching and punching

2.4 Ranges of application

With the HiFocus 160i the user is in the position to receive laser-like qualities when cutting mild
steels, stainless steels and aluminium at thickness from 0.5 to 50.0 mm (material depending).
Normally no finish work is required because the cut is clean and nearly free of dross.

The plasma cutting system is recommended for following technologies (consider cutting tables):

G 0001 - 01.03.2006 - page 2-2 - Kjellberg Finsterwalde

 HiFocus-technology

material: mild steel and aluminium preferably for:

• narrow cutting gaps through small nozzle orifice
cutting current: 20 - 50 A • direct corner cutting
• high cutting quality acc. to DIN EN ISO 9013 „u“
material thickness:* 0.5 - 8.0 mm (mild steel) • cutting of inside contours
1.0 - 8.0 mm (aluminium) • very small heat effected zone
• longevity of cathode and nozzle
plasma gas / swirl gas: 0.5 MPa (5 bar) • minimized gas consumption
• dross-free plasma cutting

HiFinox-technology

material: high alloyed steel (1.4301) preferably for:

• narrow cutting gaps through small nozzle orifice
cutting current: 20 - 50 A • metallic clean surfaces (1.4301), slightly increased cutting
angle as at mild steel
material thickness:* 1.0 - 6.0 mm • cutting of inside contours
• very small heat effected zone
plasma gas / swirl gas: 0.5 MPa (5 bar) • a little dross, dross-free plasma cutting in the range 2-6 mm

HiFocusplus-technology

material: mild steel preferably for:

• high cutting performance because of 3 times higher
cutting current: 50 - 160 A cutting speed
• dross-free cutting over a wide range of parameters
material thickness:* 4.0 - 50.0 mm

plasma gas / swirl gas: 1.0 MPa (10 bar)

HiFocus F -technology

material: mild steel preferably for:

high alloyed steel • flying cutting start
aluminium • cutting up to max. 50.0 mm
• metallic clean surfaces, also at thicker materials
cutting current: 40 - 160 A • sometimes slightly increased cutting angle at the cutting
surfaces
material thickness:* 2.0 - 50.0 mm (mild steel)
5.0 - 45.0 mm (high alloyed steel)
6.0 - 40.0 mm (aluminium)

plasma gas / swirl gas: 0.6 MPa (6 bar)

HiFocus F PLUS-Technology

material: High alloyed steel preferably for:

• flying cutting start
cutting current: 100 – 160 A • cutting up to max. 35.0 mm
• metallic clean surfaces, also at thicker materials
material thickness:* 5 – 35 mm (high alloyed steel) • small cutting angle

Plasma gas / swirl gas: 0.65 MPa (6.5 bar)

* material depending, standard qualities, linear cuts

Cutting is possible in all positions and applicable for straight cutting (line or profile) and bevel cutting
as well, on plates, sheet metal, tubes and pipes, forced and forged parts, piled plates, casted parts
and scarp metal.

Because of the variable current setting the cutting power easily can be adapted to the process
requirements.

G 0001 - 01.03.2006 - page 2-3 - Kjellberg Finsterwalde

2.5 Plasma marking
The application of the "FineFocus Principle“ offers numerous technological advantages for the
marking process. These especially are:
• small marking lines
• low heat input
• low distortion
• high marking speed
• excellent marking quality
The direct transferred plasma arc enables the marking of all electrically conductive materials with no
regard to thickness and quality.
Mild steels, high alloyed steels, nonferrous metals and special alloys can be marked. Following
application of plasma gases is recommended:
• argon
excellent marking quality at all materials
• air
only for higher capacities at notching and punching
The marking process is applicable at all kind of material, like sheet metal, tubes, profiles, forged and
casted parts.
The marking current is stepless adjustable to conform with the marking requirements.

2.6 Putting into operation (see connection diagrams)

After the receipt of the plasma cutting unit verify by the delivery note that all components are
present. Contact the supplier if parts are damaged or missing.

2.6.1 Check out, placement and installation

The Plasma Cutting Unit is designed for a service in explosion-proofed rooms or in the free air by
using a roofing under following conditions:
• ambient temperature: -10°C up to +40°C
• relative moisture: max. 90% at 20oC
Place the power source so that the air flow is not blocked. The cooling air is drawn in through the
front and side wall and is exhausted through the rear and side wall. A free distance of at least
250 mm should be kept around the unit.

The Plasma Cutting Machine is designed acc. to the requirements of the protection class IP 22
(DIN EN 60529), that means :
• protection against penetration of solid parts above 12 mm size
• drip-proof protection against straight dropping water (without negative influence up to 15o
unit inclination).
Avoid that dust (especially metallic particles), acid damp, corrosive substances and gases can enter
the unit. The life time and the function of the plasma cutting will be influenced. The unit is movable
by hand. When transporting by forklift the unit has to be taken from the side.
Attention!
The centre point is near to the front of the unit! Danger of
tilting exists!
For crane transportation lifting eyes are provided.
Attention!
For crane transportation all four lifting eyes have to be used!
The angle between the ropes or chains should not exceed
45o! Pay attention for the weight of the unit (fig. 2-1)!

fig. 2-1: crane transportation

G 0001 - 01.03.2006 - page 2-4 - Kjellberg Finsterwalde

2.6.2 Installation

2.6.2.1 Mains connection

The plasma cutting unit is supplied with the ready installed mains cable (4 x 10 mm2, 5 m long) and
mains plug (CEE- 63A). The connection to the mains has to be carried out through a wall-mounted
power switch with a suitable wall socket for the power cable plug. Prior the power switch mains fuses
have to be arranged acc. to chapter 2.1.

2.6.2.2 Workpiece connection / current return line

For the connection of the workpiece cable a socket is provided in the rear wall of the power source.
The workpiece clamp has to be fastened firmly to the cutting job or the table on which the part to be
cut is placed.
Attention!
It is not allowed to use con-
ductive parts of building, like
steel construction, pipes, track
ways or similar devices for
conducting the power back to
the plasma cutting unit, as far
cutting is not performed at
those parts!

2.6.2.3 Earthing
Workpiece and cutting table have
to be correctly earthed. The
Plasma Cutting Unit HiFocus 160i,
the Plasma Ignition Box PZ-H and
the Plasma Torch Connection Unit
PBA-H 160 are provided with
marked terminals, size M8 for the
earthing. To avoid electromagnetic
disturbances, and for the safety of
the personnel the earthing of the
plasma power source and the
plasma components has to be
carried out very carefully. The size
of the earthing wire should have at
least 16 mm2.

2.6.2.4 Connection of the HiFocus 160i

All the connecting and control fig. 2-2: back wall of the power source HiFocus 160i
cables will be placed to the back
wall of the power source. All “live” 1 Connector control cable standard value 5pol. plug
parts and the fuses are accessible 2 Connector remote control 8pol. socket
3 Connector guiding system resp. height control 25pol. socket
only after opening the cover plate,
4 Connector PGE1-HM, PGE-HM, PGV 25pol. socket
which is protected by a safety 5 Connector control cable PZL-H101 10pol. socket
contact. 6 Fuses F1 - F15
7 Filler neck for coolant
Following components are suitable 8 Connector control cable PerCut 160-1, cable set PZL- 8pol. socket
for the connection to the HiFocus H101 or PBL-H160 G3/8”
160i: 9 Connector ”coolant return / cathode” G1/4”
10 Connector ”coolant entry / nozzle“ terminal M8
• the cable set PZL-H 101 for 11 Connector external cathode cable terminal M8
12 Connector earth hose parcels PG 29
extension of the operational 13 Mains cable entry socket
radius along with the PZ-H 14 Workpiece connection terminal M8
• the cable set PBL-H 160 for 15 Terminal earthing
the connection of the PBA-H 16 Cover flap 4pol. plug
160 17 Connector control cable PerCut 160-1, cable set PZL-
9pol. plug
• the plasma gas valve unit H101 or PBL-H160 9pol. plug
18 Connector serial interface RS 485 CNC Q2F 3A
PGV 1 in connection with the 19 Connector serial interface RS 485 PGC1
PGC 1 for the adjustment and 20 Motor circuit breaker of pumps
the dosage of the process
gases
• the plasma gas control unit PGE 1-HM for the adjustment and dosage of the process gases
• the remote control FB for the operation of the plasma machine torches

G 0001 - 01.03.2006 - page 2-5 - Kjellberg Finsterwalde

2.7 Control and display elements of the power source
Attention!
It is not allowed to operate the machine with any of the housing cover plates not in place! It is
hazardous to the operator and other people in the area, and prevents the equipment from
properly cooling the components! Generally the plasma cutting unit has to be switched OFF
and disconnected visibly from the mains (unplug supply cable) before opening any cover from
the power source or from other components!
The plasma unit only has to be operated with plasma torches of the PerCut 160 series!

fig. 2-3: control and display elements of the plasma cutting unit

1. red push button S3 "Emergency stop", (reset button) 7. LED-signal lamp green „cooling circuit o.k.“
- activated: plasma unit OFF (except control transformer - LED ON: cooling circuit operates (flow switch
and fan for heat exchanger) S10 activated)
- unlocked: plasma unit ready for operation
8. LED-signal lamp green „gas supply o.k.“
2. key switch S1 "Mains ON" - LED ON: gas pressure for plasma and swirl gas
- position 0: supply to control transformer and fan of heat > 0.3 MPa (3 bar)
exchanger OFF
- position 1: power to control transformer and fan of heat 9. LED-signal lamp green „temperature power source
exchanger ON, PGC on o.k.“ - LED ON: rectifier within thermal limit
- position 2: power for control transformer and fan of heat
exchanger ON, PGC on, device can be 10. LED-signal lamp yellow „pilot arc“
switched on by S2 - LED ON: pilot arc ON

3. illuminated button green S2 "stand-by" 11. LED-signal lamp „main arc“

- activated: - plasma unit ready for operation - LED ON: main arc ON
- power ON for main transformer, pump, fan
and controls 12. potentiometer "cutting current"
- signal lamp ON: plasma cutting unit ready for operation - cutting current adjustment, 10 – 160A

4. selector switch S5 "cutting technology" 13. potentiometer "current reduction"

- position 1: HiFocus-range 1 (plates 0.5-8 mm resp.1-6 mm thick) - current reduction during signal „corner“ from CNC
- position 2: HiFocus-range 2 (plates 3-50 mm thick) - read value on current display, after switch „gas
- position 3: HiFocus-range 3 (flying cutting of steel) test“ (5) is set to upper position (max. value: 30 %
of rated current)
5. tumbler switch "gas test"
- upper position: gas test ON 14. potentiometer "down slope"
- for adjusting the plasma gas pressure - for current reduction on the end of the cut in
- for measuring the flow rate of plasma gas connection with button (6)
- for current reduction at corner signal
- for water drain from torch head after change of spare parts 15. selector switch "up slope"
- LED “error” ON - position 1: (preferred value)
- plasma unit not ready for operation

6. button „down slope“ - selection

- time adjustment in connection with potentiometer (14)

G 0001 - 01.03.2006 - page 2-6 - Kjellberg Finsterwalde

 16. LED-signal lamp red „error“ 19. LED-signal lamp red „pilot time exceeded“
- LED ON: plasma cutting unit not ready for - LED ON: pilot arc was maintained for more than
operation 15 s, restart within this time not possible
- failure in cooling circuit
- gas pressure < 0,3 MPa (3 bar) 20. LED-signal lamp red „nozzle contact“
- tumbler switch "gas test" in ON - LED ON: nozzle has contacted the workpiece
position
- thermal overload on power source 21. arc voltage display
17. LED-signal lamp red „torch failure“ - indicates the arc voltage
– LED ON: not allowed connection between nozzle - indicates “gas test”
and cathode (torch short circuit)
- switch OFF power source 22. current display
- check torch (consumables, hose - indicates cutting current (actual value)
parcel), if failure repeats change the - indicates cutting current (pre-set value)
torch - indicates “error codes”
- indicates “down slope time” in ms
18. LED-signal lamp „ignition time exceeded"
- LED ON: - ignition time exceeded or pilot arc not 23. potentiometer „marking current“
ignited (only valid for HiFocus 160i + FlowControl)
- press OFF-button on remote control - adjustment of marking current (4-25A) after pre-
FB, or stop ON-signal from CNC selection switch 5 “cutting technology” or by pre-
selection from CNC interface (priority to selector
switch)

2.8 Cutting operation

Before cutting can start the following steps have to be taken:
Inspection of the plasma torches:
- the torch must be in a correct and undamaged condition
- the inserted consumables must match the intended cutting technology and have to be in a good
shape
Inspection of the plasma power source:
- the mains fuse are of the required size (see chapt. 2.1)
- the workpiece cable is correct connected (see chapt. 2.6.2.2)
Inspection of the installed plasma components:
- the gas supply system is correct installed, connections are safe and tight (see chapt. „connection
of gas supply”)
Attention!
Never direct the plasma torch towards the eyes or other parts of the body! Don’t touch
nozzle and nozzle cap if power is ON! High voltage ignition can create electrical
endangerment, the pilot arc can cause burns on eyes and skin! Wear protective clothes and
safety glasses!

Operation sequences
1. emergency stop (1) resetting (turn to left)
2. key switch (2) turn to position „I“ power to control transformer
switch to “PGC” when change display of consumables at operation screen “Record
consumables parameter” of the PGC (only for FlowControl)
3. green push button (3) switches ON: power source, pump and inspection:
controls - display (22) shows shortly „in 1“, software- no., “ini
2”, set current value
- pre flow
- illum. button green (3) “ON“
- LED red ERROR (16) “OFF“
- LED green cooling o.k. (7) “ON“
- LED green gas o.k. 8) “ON“
- CAN1-connection o.k.
- LED green term. o.k. (9) “ON“
Unit ready for start !
4. selector switch (4) dial technology range acc. cutting chart*
5. operation PGC 1 PGE-HM or PGE1- preselection plasma regime (acc. to
HM cutting program), switch on the plasma
(see corresponding instruction manual) gas and swirl gas (acc. to cutting table)
6. power potentiometer (12) current adjustment value shown at display (22)
7. marking current potentiometer (23) marking current adjustment value shown at display (22)
(only valid for HiFocus 160i + FlowControl)
8. potentiometer current reduction (13) current reduction at signal „corner“ from value shown at display (22) when activating tumbler
CNC (5) gas test

G 0001 - 01.03.2006 - page 2-7 - Kjellberg Finsterwalde

 9. potentiometer (14) "down slope" activate tumbler „down slope-time“ (6) and read
value (ms) on display (22)
10. selector switch (15) "up slope" position: 1 (preferred value)
11. tumbler switch (5) or adjust to symbol „gas test“ check:
activation of gas test switch on - gas test after change of consumables (water
power source resp. drain)
automatically when unit becomes - LED red cumulative error (16) “ON“
switched ON or - display “gas” on voltage display (21)
when changing gases
12. Plasma torch positioning into start position torch to work distance acc. to cutting chart; piercing
above the workpiece
running cutting start only possible when
HiFocus F- technology is selected
13. Pressing ON- button on remote Pilot arc ignition Plasma torch ON:
control or - LED yellow Pilot arc (10) “ON” automatically after
ON- signal from CNC control Main arc on pilot arc contacts workpiece
- LED yellow Main arc (11) “ON”
14. Cutting acc. to cutting job
15. Plasma torch “OFF” - when overrunning the workpiece or plasma arc extinguishes
- “OFF”-button on remote control
activated or
- “OFF”- signal from CNC
16. Plasma unit “OFF” - Turn Key switch (2) to “0” resp. switch Power source off, main arc extinguishes if activated
the PGC to “change of wearing parts”
or
- Press Emergency Stop (1)
table 2-2 * Die Schneidspannung ist abhängig von der Werkstückauflage und der Schlauchpaketlänge

Ignition of pilot arc

The pilot arc will be established when pressing the ON-button of the remote control FB or by the ON-
signal from the guiding system on (X102: B2, B3) after the gas preflow. The arc time is limited to 15
s. After contacting the workpiece the main arc automatically becomes ignited automatically and the
cutting process starts.

Pilot arc and main arc immediately will stop after the OFF signal from remote control FB or from the
guiding machine, or if the torch is overrunning the workpiece.

Running cutting start

(only possible in HiFocus F technology and if the selector switch S5 [4] “cutting technology range” is switched to HiFocus-
range 3!)

• ignite pilot arc 10 to 20 mm before the edge of the workpiece

• move plasma torch toward the workpiece
• as far as the pilot arc contacts the workpiece the main arc establishes
• at thin sheet metal the starting speed should be reduced
• the distance between swirl gas cap and workpiece should be in a range of 1.0 to 4.0 mm. The
respective torch distances are given in the cutting starts

Piercing

Attention! Upcoming hot material can lead to endangerments (risk of burns and fire!

• when piercing above the workpiece the distance for ignition has to be adjusted to approx. 6 mm,
depending on the plate thickness (values are given in the cutting chart)
• after the ignition of the pilot the main arc establishes immediately
• the torch should start movement simultaneously with the ignition to reduce the danger of
damaging torch parts. Upcoming material can effect nozzle, swirl gas nozzle or nozzle gas
• for thicker materials the following procedure is recommended:
- adjust ignition height acc. cutting chart (1.2 - 2 x cutting distance)
- piercing delay acc. cutting chart
- lift torch during transfer arc slightly to avoid that spatter can damage the torch head
- after the material is pierced through the torch returns to the optimum cutting distance

G 0001 - 01.03.2006 - page 2-8 - Kjellberg Finsterwalde

Fig. 2-4: schematic diagram of a cutting process with height control system

Sequence steps of height control

1 process ON / setting plasma torch to ignition height
2 torch ON / gas in / waiting for pilot arc
3 keep torch to ignition height / waiting for transfer arc, main arc
4 setting to cutting height or lifting up to pierce height temporary
(delay time for height control)
5 cutting with voltage-dependent height control
6 torch lifting to transitional position

Adjustment parameters
h1 reference position
h2 ignition height of plasma torch
h3 pierce height = elevated torch height at hole piercing (at larger material thicknesses)
h4 cutting height
h5 transitional height (torch height between several cuts)
h6 additional height = pierce height - ignition height (h6 = h3 - h2)
t1 pierce time
t2 control delay for the height control:
The dynamic process at the hole piercing has to be completed before the actual
value is taken for the height control.
P1 first setting
pSG / QSG pressure / flow rate of start gas
pWG / QWG pressure / flow rate of swirl gas
vs cutting speed

G 0001 - 01.03.2006 - page 2-9 - Kjellberg Finsterwalde

 Switching OFF the plasma cutting unit

The HiFocus 160i will be switched OFF by turning the key switch S1 (2) to position „0“. By that all
active components of the HiFocus 160i are switched off. When activating the red push button S3 (1)
“emergency-stop” all components become disenergized, with exception of the control transformer
and the fan of the heat exchanger.

Remark!
The red emergency stop acts as a reset-switch. For starting the power source by the green
push button S2 (3) the emergency stop must be reset by a left rotation. If the plasma cutting
unit is not used fore a longer period it should be disconnected visibly from the mains.

2.9 Remote control FB1

With the remote control FB the cutting process with the machine torch PerCut (ignition of pilot arc) can
be started and stopped. It is provided with an ON-(green) and OFF-(red) button. The 10 m control cable
becomes connected to the connector X132, placed on the back wall of the HiFocus 160i.

Attention!
If the remote control is plugged in not ignition of the plasma torch from the CNC control is
possible.

2.10 Filling up the coolant

The coolant has to be filled up before the plasma torch is connected.

For operation at temperatures below 0oC the use of antifreezer “Kjellfrost -15°” (resists freezing up
to -15oC) or “Kjellfrost -25°” (resists freezing up to -25oC) is recommended. These coolants are in
addition to the antifreezer for increasing of the life time of the pump and the packings, as well as
increasing of the service life of the cooling channels of the plasma torches.

Attention! No water should be added to those coolants (formation of acid) !

The filler neck is placed on the back of the power source HiFocus 160i. The tank capacity amounts
to approx. 11 l. Excessive coolant leaves the tank through the overflow and is guided to the floor.
The filling level can be checked visually (front wall).

When using the plasma ignition box PZ-H along with a hose parcel extension PZL-H 101 the filling
level has to be checked after the first start to compensate the volume for the water hoses.

Also the loss of coolant during the change of consumables or torches has to be compensated
weekly. After 12 month the complete coolant has to be replaced (depending on the working
conditions).

2.11 Combination of the HiFocus with CNC-controls of guiding systems and robots
The control cable for the combination of the HiFocus 160i with CNC-controls of guiding systems or
robots has to be connected to the 25 pole socket (system Wieland), placed in the back wall of the
power source. The respective cable the user has to prepare himself. The necessary materials can
be supplied on request from Kjellberg Finsterwalde.

The potential-free contacts are dimensioned for a current load of max. 500 mA DC at a control
voltage of 24 V. Relay contacts have to be furnished with a protective diode.
Remark!
Before connecting the control cable remove the link X102:C3-C4. It is not possible to
operate the HiFocus 160i without the link or without emergency signal from the guiding
system!

G 0001 - 01.03.2006 - page 2-10 - Kjellberg Finsterwalde

 X102 signal remarks
inputs
B2-B3 „torch ON“ from CNC potential free closing contact
B4-B5 „corner ON“ from CNC potential free closing contact
C3-C8 „data set O/I“ from CNC potential free closing contact (priority before selector switch of
HiFocus 160i)
A7 0...10V (= 10A...160A) Í active analogue input for active Í remote control
B6 GND (workpiece potential) Í control control (potential free Í potentio-
outlet from CNC required) Í meter
C5-C6 active control ON link
C3-C4 emergency stop from CNC potential-free break contact
remove wire link from 102
X102 signal remarks
outputs
A1-A2 „main arc ON“ from PA potential-free closing contact
A3-A4 „pilot arc ON“ from PA potential-free closing contact
C1-C2 emergency stop from CNC potential-free break contact
B7-C7 Plasma machine ready to start potential-free closing contact
B7-A8 Plasma machine ready for start potential-free closing contact
A9 cathode potential (...-200V) Í cutting
B8 nozzle potential (... -100V) Í nozzle
C9 workpiece potential ( 0V) Í potential Í voltage
table 2-3: signals between power source and CNC interface

Attention!
If the remote control is plugged in not ignition of the plasma torch from the CNC control is
possible.

X104 signal remarks

outputs
1 GND reference point
2 current actual value “I” is 0 - 10 V 1 V × 50 A
3 voltage actual value “U” is 0 - 10 V 1 V × 50 A
4 free
5 free
table 2-4: signals of current actual value and voltage actual value

Serial interface RS 485

By means of the serial interface RS 485 on the back side of the machine additional to the interface
X102 records can be read or transferred. The interface connectors have the following function:

X 4.1 Connection to CNC

X 4.2 Connection to PGC

Further information regarding received or transmitted parameters and their limits for communication
between CNC/PC and power source are shown in the description „Serial interface part 2“.

The descriptions part 1 - 3 can be ordered separately.

2.12 Start regime HiFocus 160i

2.12.1 Start by remote control

connection at socket X132

contact signal
4 FB-operation
1 +24V
2 FB ON
3 FB OFF
The link 1 - 4 switches into the operation mode with remote control (FB).
FB ON = ON button short pressing, plasma unit switches ON
FB OFF = OFF button pressing, switches plasma unit OFF

G 0001 - 01.03.2006 - page 2-11 - Kjellberg Finsterwalde

2.12.2 Start by CNC:
Connection at socket X102

contact signal
B2 ON from CNC
B3 ON from CNC
contact closed: switches plasma unit ON
contact closed: switches plasma unit OFF

2.12.3 Start from CNC with special function „separate ignition signal“
Connection to socket X102 (process start signal) and X132 (ignition signal)

plug contact signal

X132 1 +24V
2 FB ON
3 FB OFF
X102 B2 ON from CNC
B3 ON from CNC
• operation mode chosen by link X132 (1 - 3)
• “ON” activated by ON from CNC (X102 B2-B3)
• gas preflow activated (f.i. when lowering Z-axle)
• arc ignition after release impulse to socket X132 (1-2)
• OFF by opening contact X102 (B2-B3)

2.12.4 Start from CNC with special function (pre-impulse):

Connection to socket X102 (process signal) and X132 (ignition signal)

plug contact signal

X102 B2 ON from CNC
B3 ON from CNC
• operation mode available from program version 1.17
• ON is made through a short ON impulse from CNC (X120)

2.13 Protective facilities

The plasma cutting unit is ready for operation, if after actuating the key switch and the green
illuminated push button (stand-by) and the green LED-signal lamps
• "temperature power source o.k."
• "gas supply o.k." and
• "cooling circuit o.k." are ON,
and the red LED „error“ is OFF
• and the pre-set value of the cutting current is indicated.

The protection circuits are acting as described in the following and switching OFF the power source:
• emergency-stop, door contact, emergency-stop from CNC
• after using the key switch the power source will not start when pressing the green illuminated
button S2 (pump and fan do not run)
• pilot arc limitation
(protects pilot resistors and reduces consumption on nozzle and cathode)
- switches OFF pilot arc after 15 s
- red LED „Pilot time exceeded“ shows for 2 s, restart in this period not possible
• nozzle protection circuit
- interrupts main arc when upcoming material touches the nozzle
- red LED „nozzle contact“ lights (protection circuit can be deactivated by placing the jumper
JP3 to PCB LP 066501)

G 0001 - 01.03.2006 - page 2-12 - Kjellberg Finsterwalde

 Under following conditions the red LED „error“ is ON and the green signal lamp “stand-by” is OFF:
• coolant flow control
- switches OFF at a flow rate < 3,0 l/min
- green LED „cooling circuit o.k.“ OFF (if long extensions are in the circuit it can take 1 min to
have the cooling circuit activated)

• gas pressure control

- switches OFF if gas pressure is < 0,3 MPa (3 bar) and when swirl gas cap is missing
- green LED „gas supply o.k.“ OFF

• temperature control
- switches OFF the rectifier in case of thermal overload
- green LED “thermal overload” OFF

• motor circuit breaker

- switch-off at overload of the pump
- is again turned on by activating on the back wall (behind the door)

The cutting willingness is signalled if subsidiary to the standby the gas test is ended

2.14 Trouble shooting

If during the operation malfunctions are registered the cutting has to be stopped and the reason to
be found out.

Attention!
Before starting any repairs or maintenance on the installation generally the power source
has to be switched OFF and disconnected from the mains (unplug mains cable)! Only under
the advice of an licensed electrician or skilled personnel the unit should be opened (see
VDE 0105 or follow national instructions).
1. after activating the key switch S1 (2) on position 2 and the green push button S2 (3) the fan
and the pump do not start:
• emergency-stop S3 (1) activated (reset switch)
• link X102:C3/C4 (emergency stop from CNC) removed
• cover plate on back wall, side walls of PZ-H not closed resp. door of PBA-H 160 open
• control cable plasma torch not connected
• motor circuit breaker Q2F off
2. pump and fan move, red LED (16) „error“ ON, but green LED (8) „gas supply o.k.“ is OFF:
• gas pressure of the selected gas < 0.3 MPa (3 bar)
3. red LED (16) „error“ ON and green LED (7) „cooling circuit o.k.“ OFF:
• coolant flow < 1.6 l/min
• no or less coolant in the tank
• motor circuit breaker Q2F off

4. red LED (16) „error“ ON and green LED (9) „temperature power source o.k.“ OFF:
• thermal overload on rectifier, cool down with running fans
• eventually clean device and filter mats of the plasma machine fan behind the side walls
(corresponding the maintenance order)

5. no full cutting power (power source OFF), plasma cutting switches OFF after approx. 15 sec.
• workpiece cable not connected
• yellow LED (11) „main arc“ OFF

6. The plasma sequence control of the HiFocus 160i (PCB LP 066451) is displaying certain error
codes, if during service or operation errors are noticed. The current display indicates code
numbers from ER 1 - ER70 and additionally the respective LED light. The description of these
errors and the rectification is given in the following chart (numbers in quotation marks refer to
the pos. no. of fig. 5):

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error chart / error codes - plasma sequence control HiFocus 160i (LP 066451)

display condition LED-display description end resp. rectification

(19)

ER 1 gas-coolant- collected • gas missing settle disturbances see

chapt. 2. - 4.
temperature disturbance (16) • coolant missing
LED green „gas“
disturbance
„temp“ or • high temperature
„coolant“ OFF valid till V6.xx or from V7.xx
and J5 plugged

E43 coolant error LED signal lamp • coolant missing settle disturbances see chapt.2.4
red" sum error" (16)

LED green
„coolant“ OFF

E51 temperature error LED signal lamp • high temperature

red" sum error" (16) only valid from
V 7.xx
LED green „temp“ and
OFF J5 free
E70 gas error LED signal lamp • gas missing
red" sum error" (16)

LED green „gas“

OFF

ER2 source defect nozzle contact (20) • current relay pilot arc or - error correction
pilot arc time (19) • current relay main arc activated
- remote control:
ignition time (18) • voltage appears without ON signal press „FB OFF“
torch error (17) - CNC:
• the current from a module is stop "ON"
inform
the
bigger than 90 A in the cutting
service!
operation valid till V6.xx or from
V7.xx
and J5 plugged

E21 current Modul1 K7 LED signal lamp • current relay Modul2 - remote control:
red "sum error" (16) press „FB OFF“
- CNC:
E22 current Modul2 K3 shines and • current relay Modul2 stop "ON"
LED (17), (18),
(19), (20) flashes
E24 pilot arc current K2 • current relay pilot arc inform
the
only valid from
service!
E26 nozzle voltage • voltage at the torch without "ON" V 7.xx
signal and
J5 free

ER3 error torch torch error (17) • current flow during gas preflow switch OFF unit, check torch and
Îshort circuit at the torch consumables

valid till V6.xx or from V7.xx

and J5 plugged

E31 current Modul1 K7 LED signal lamp • current relay Modul2 switch OFF unit, check torch and
red "sum error" (16) consumables
torch error (17)
E32 current Modul2 K3 • current relay Modul2
only from
V 7.xx and
E34 pilot arc current K2 • current relay pilot arc J5 free

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 ER4 pilot arc time pilot arc time (19) • pilot arc time exceeded - remote control:
press „FB OFF“
- CNC:
stop "ON"

ER5 ignition time ignition time (18) • HV ignition time exceeded or no - remote control:
ignition press „FB OFF“
- CNC:
stop "ON"

ER6 main arc inter- none • arc interruption during cutting (main end after approx. 1 s
ruption source)

ER7 nozzle height nozzle contact (20) • arc voltage to low - remote control:
Îheidht nozzle-workpiece too press „FB OFF“
small - CNC:
stop "ON"

ER8 gas test period none • max. time exceeded, stop gas test tumbler switch "gas test" "OFF"
and start again if required

ER9 pilot arc interruption none • plasma arc interruption during end after approx. 1 s
ignition (main arc is not formed)

table 2-5

G 0001 - 01.03.2006 - page 2-15 - Kjellberg Finsterwalde

 Instruction Manual

Plasma machine torch

Type series

PerCut 160-2
PerCut 170-2
Article no.: .11.842.421 / .11.842.621 (PerCut 160)
.11.843.021 (PerCut 170)
3 Plasma Machine Torch of Type series PerCut 160-2 / 170-2

3.1 Technical data

PerCut 160-2 PerCut 170-2

(.11.842.421. …) (.11.843.021. …)

Max. open circuit voltage UO: 400 V

Max. cutting current IS: 160 A
Max. pilot arc current IPb: 18 A
Ignition: High-voltage ignition (max. 10 kV) with pilot arc

Max. cutting thickness: 50 mm

Clamping diametr: 44 mm 50 mm

o
Torch cooling: Coolant mixture „Kjellfrost -15“ (freezing protection up to -15 C) or
o
„Kjellfrost -25“ (up to -25 C) with integrated corrosion protection
Flow rate: ca. 2.5 l /min

Plasma gases: air, O2, Ar, N2, H2 and mixtures

(for quality, operating pressure and flow rates see cutting tables)

Swirl gases: O2, N2 and mixtures, N2/H2 (backing gas)

(for quality, operating pressure and flow rates see cutting tables)

Hose parcel lenght: 1 m; 1.5 m

Connections:
Coolant outlet / Cathode line G 3/8“
Coolant inlet / Pilot line G 1/4"
Control gas G 1/8“
Swirl gas hose PUN 6 x 1
Plasma gases hose PU-3
hose PU-3

Control line MV 1-4 -

MV 5 -

Weight 3,8 kg (1.5 m hose parcel) 3,6 kg (1.0 m hose parcel)

table 3-1

3.2 Technical description

Attention!
The plasma torches of the PerCut 160/170 may only be operated by the plasma cutting
systems HiFocus 80i, 130 and 160i.
So they compose a safety-related package with the plasma power source and a safety
operation is ensured in EN 60974-7.

Attention!
Before starting maintenance and installation works at the plasma torch, the Plasma Cutting
System must always be switched off and visibly disconnected from the mains (unplug the
mains cable)!

The plasma torches are used to cut with the plasma gases air, oxygen, argon, nitrogen and
hydrogen. Oxygen, nitrogen or a mixture of both gases and a backing gas are used as secondary
gas (swirl gas).

The cutting current is transferred to the cathode by a copper strand, which is inserted in the
electrically insulating water outlet hose. The pilot current is conducted to the nozzle by a copper
strand, which is inserted in the electrically insulating water inlet hose.

Z 0001.00 - 02.04.2008 - page 3-2 - Kjellberg Finsterwalde

 The cutting current is transferred to the cathode by a copper strand, which is inserted in the
electrically insulating water outlet hose. The pilot current is conducted to the nozzle by a copper
strand, which is inserted in the electrically insulating water inlet hose.

The nozzle is fastened by the unscrewable nozzle cap in the nozzle holder. The coolant circulates
between the nozzle and the nozzle cap and simultaneously flows through the cathode in a cooling
tube. The thermally highly stressed plasma torch parts are thus efficiently cooled.
Attention!
! Before operating the plasma torch, it must be checked whether the consumables for the
corresponding method are in the torch. After changing the consumables, blow the torch dry
by switching the flip switch “Gas test” on for approx. 20 sec., as residual coolant can lead to
the destruction of the torch tip during high-voltage ignition.

The operator is only allowed to change the consumables of the plasma torch!

Only original Kjellberg spare parts and consumables may be used!

All parts coming in contact with oxygen (including the consumables) must by all means be
kept free of oil and grease.

The Plasma Machine Torch PerCut 160/170 can be used for a cutting current of up to 160 A and
thus for an achievable cutting thickness of 50 mm. It mainly consists of the torch tip, the torch shaft,
the hose package and the consumables. The torch possesses 2 gas hoses for plasma gas supply,
one swirl gas hose, as well as one control gas hose.

For installation and replacement of the consumables, see point 3.4

3.3 Connection of the Plasma Torch (to the plasma-torch-connection-unit PBA-H160)

Attention!
! Before opening the Plasma Cutting System or the Plasma Ignition Box, the Plasma Cutting
System must always be switched off and visibly disconnected from the mains (unplug the
mains cable)!

The Plasma Torches Type PerCut 160-2/1/170-2 must principally be connected to the Plasma Torch
Connection Unit PBA-H160.

The torch must be attached isolated to the support of the guiding machine. A torch fastening device
produced by the firm Kjellberg Finsterwalde can be used for this purpose.

To connect the Plasma Torch to the PBA-H160, the hose package is to be lead to it from below.
Inside, the following hoses are to be connected:

• Coolant outlet G3/8"

• Coolant inlet G1/4"
• Control gas G1/8“

The plasma gas hoses ∅4 (PU-3) and the swirl gas hose ∅6 (PUN 6x1) are to be lead outside
through the corresponding holes on the side wall and connected laterally to the marked screw
fittings. To do so, loosen the union nut, plug the hose onto the nipple and fasten the nut firmly again.

The hose package is to be relieved of strain by means of the bottom green clamp.

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3.4 Consumables of the Plasma Machine Torch

fig. 3-2: Consumable overview of Type PerCut 160-2

Z 0001.00 - 29.01.2008 - page 3-4 - Kjellberg Finsterwalde

 fig. 3-3: Consumable overview of Type PerCut 170-2

Z 0001.00 - 29.01.2008 - page 3-5 - Kjellberg Finsterwalde

 Attention!
! Before starting maintenance and installation works at the plasma torches, the Plasma
Cutting System must always be switched off and visibly disconnected from the mains
(unplug the mains cable)!

When replacing consumables

at the plasma torch, the
plasma system must be
principally switched off in
such a way that it cannot be
accidentally switched on fig. 3-4:
(BGV D1, §44). Unauthorized
starting is prevented by Key-operated switch
pulling off the key-operated on the operating and
switch after the plasma display front of the
system has been switched off, plasma system
for example.
! Attention!
All parts coming in contact with oxygen must by all means be kept free of oil and grease.
When replacing consumables, the torch tip and the consumables must by all means be kept
free of oil and grease!

Used or damaged consumables must be replaced in due time. (Indication: visible change of cutting
quality).
The service life of the cathode depends on the cutting time and on the number of ignitions.

Ascertaining of the cathode wear with the meter

max. cathode
cathod plasma plasma position
article no. plasma unit burn-back
e gas torch no.
(mm)

for quality
cut

S 002 X .11.843.021.310 1,65 1,80

O2, Air 01.01, 02.01

neu!
S 002 Y .11.843.021.320 1,80 2,20
HiFocus 80i,
PerCut 160-2
HiFocus 130,
PerCut 170-2
HiFocus 160i

S 012 X .11.843.121.310 O2 03.01 1,65 1,80

*) … Attention: A higher cathode burn-back can lead to the destruction of the torch.

Table 3-2: max. cathode burn-back by cathodes with a flat head

Z 0001.00 - 29.01.2008 - page 3-6 - Kjellberg Finsterwalde

 to zero: to read off:

fig.3-5: Ascertaining of the cathode wear with the meter

Art.-Nr. .36.000.015

The service life of the nozzle mainly depends on the cutting time, the number of ignitions and the
handling of the torch (how piercing is carried out, spatter, etc.). Always make sure that the
consumables are suitable for the intended cutting process (fig. 3-1resp. fig. 3-2). The consumables
must be replaced with extreme care and only using the delivered installation tools: cathode puller
(10.01), nozzle/gas supply puller (10.02), and the socket spanner for nozzle caps (10.03).

When replacing consumables, the torch can remain clamped to the guiding machine.

Placement of consumables

1. screw in cooling tube (00.05) with slot directed to the cathode

2. insert cathode (0x.01), O-ring 6 x 2 must be placed well (sealing function)
3. adjust gas guide (0x.02)
4. slide in nozzle (0x.03)
5. place nozzle cap (0x.04) and screw it on hand tight with socket wrench (10.3)
6. adjust the swirl gas cap (0x.05) into the protective cap (0x.06) and screw both manually to the
torch head

Removal of consumables

1. turn off manually the protective cap (0x.06) together with the swirl gas cap (0x.05) (press out
swirl gas cap)
2. screw off nozzle cap (0x.04) with socket wrench (10.3)
3. pull out nozzle (0x.03) together with gas guide (0x.02) by using the nozzle- / gas guide puller
(10.02)
4. pull out gas guide (0x.02) from nozzle with nozzle- / gas guide puller (10.02)
5. pull out the cathode (0x.01) resp. the cathode (0x.01) along with the distance ring (0x.07)
(HiFocus F-Technology) by using the cathode puller (10.01)
6. the cooling tube (00.05) has to be inspected for damages

Z 0001.00 - 29.01.2008 - page 3-7 - Kjellberg Finsterwalde

 Attention!
! After screwing off the protective cap (0x.06) to replace the swirl gas cap (0x.05) without any
further replacement of consumables, the tightness of the nozzle cap must by all means be
checked and, if required, tightened again before mounting the protective cap!

Rings must only be replaced if they are deformed or damaged.

Attention!
! Make sure that all consumables are installed! The torch may only be operated with the cooling
tube, as it will otherwise be damaged through insufficient cooling of the cathode! Except for the
mentioned consumables, no other parts of the plasma torch may be replaced unauthorized.
Only original Kjellberg consumables may be used. If other consumables are used, no warranty
claims can be made! The plasma torch cannot be opened any further from the tip side!

When switching on the Plasma Cutting System after

replacing consumables, by all means observe the
following:
1. After pressing the green button S2:
• Automatic short gas blowing
• No coolant may escape formt the plama torch
(wait until there are no air bubbles in the
coolant hoses)
2. Switch the flip switch “Gas test” of the plasma
system to Blow gas for at least 20 s, or select the
automatic gas blowing time at the PGC1
accordingly:
• Blows residual coolant out of the plasma torch
• Drops can damage the torch during ignition
fig. 3-6: Green illuminated button S2
on the operating front of the
plasma system
3.5 PerCut 170 - Operating notes

Dismantling the change tip

Before opening the torch, the Plasma Power

Source must definitely be switched off and
prevented from being accidentally switched
on again!
1. Turn the sealing sleeve to the left all the
way to the limit stop
2. Lead the sealing sleeve downwards to
the limit stop of the housing
3. Turn the sealing sleeve to the left until
the change tip can be removed
Attention!
! Do not drop the change tip,
this could damage it!
4. Place the change tip on the “Station for
the tip PerCut 170” – (Art. no.
.11.843.021.830 – option for securely
storing and cleaning change tips
currently not being used)

Change of consumables
1. Removing the change tip from the tip
seat or directly from the torch shaft fig. 3-7: Station for the quick change torch tip
PerCut 170 (Art.-Nr.: 11.843.021.830)

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 2. Using the “Tool for VT change” Art.
no..11.839.021.840
3. Change of consumables acc. to point 3.4 of the operating instructions (like with PerCut 160)
4. Taking out the “Tool for VT change” and visual inspection of the inner components of the change
tip in regard to possible damages or wear of the ring
5. Placing the change tip on the station or installation on the torch shaft

Installing the change tip

1. Plug the change tip onto the torch shaft while slightly turning the change tip until the securing
screw fits into the shaft groove.
Attention!
!Do not jam the change tip, and plug it on all the way to the limit stop.
2. Turn the sealing sleeve until its grooves tie in with the screws of the shaft
3. Push on the sealing sleeve and lock the change tip by turning it to the right all the way to the limit
stop

Note!
! In case the sealing sleeve cannot be locked, the change tip is not plugged onto the shaft far
enough. It must then be checked whether all inner components are free of foreign matter
and whether all rings are okay. In case of doubt, the contact positions of the torch must be
cleansed with compressed air, and a further attempt is to be made WITHOUT USING
FORCE.

Maintenance and attendance

To prolong the service life of the rings, it is recommended to regularly wet the rings with an oxygen-
suitable lubricant that can be obtained from Kjellberg. Care must be taken that no lubricant
penetrates into the nipples.

Attention!
! The use of normal oil or grease leads to the destruction of the change tip.

The change tip is a high-quality precision part and must therefore be handled with care. To
prevent damages, it is recommended to store the change tip not being used in the optionally
available “Station for the tip PerCut 170”.

The connection for compressed air provides for the possibility of blowing out the residual
coolant and collecting it in a separate container.

Before blowing out the change tips with compressed air, they must be locked on the station to
prevent them from being unintentionally loosened during cleaning.

Hose connections (inside diameter 6 mm) are to be established between the hose nipples on the
back and an appropriate container, e.g. a tin box.

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 Instruction Manual

Plasma gas control unit

FlowControl
(PGC 1/ PGV 1)
Article no.: PGV 1 .11.825.150
PGC 1 .11.420.001 (version of software: 5.x and 6.x)
4 Plasma gas control unit FlowControl
(consisting of plasma gas valve unit PGV 1 and plasma gas adjustment unit PGC 1)

4.1 Technical data

PGV 1 - art. No.: .11.825.150

PGC 1 - art. No.: .11.420.001
operating voltage:
(magnet solenoids): 24 V AC, 50 / 60 Hz
Dimensions (lxbxh): (510x330x450) mm
Weight: approx. 30 kg
connecting plasma
gases: Air Oxygen Argon Hydrogen Nitrogen

(free of oil, (99.5%, dry, (99,996 %) (99,95 %) (99,999 %)

dirt, free of dirt,
moisture; use filter /
use filter / fine filter)
fine filter)

Flow rate to connected

torch,max.: 1400 l/h 1500 l/h 1400 l/h 300 l/h 5000 l/h
maximum pressure: 1,2 MPa 1,2 MPa 1,2 MPa 1,2 MPa 1,2 MPa
(12 bar) (12 bar) (12 bar) (12 bar) (12 bar)
3
connection: G ¼“ G ¼“ G ¼“ G /8” links G ¼“
ZG / PG1 PG2 ZG / PG1 PG3 ZG / WG1 /
WG2
connecting
swirl gases: Forming gas (N2/H2) Oxygen Nitrogen

(95% N2, (99.5%, dry, free of (99,999 %)

5% H2) dirt, use filter / fine
filter)

Flow rate to connected

torch,max.: 1800 l/h 1800 l/h 1800 l/h
maximum pressure: 1,2 MPa 1,2 MPa 1,2 MPa (12 bar)
(12 bar) (12 bar)
connection: G 3/8” links G ¼“ G ¼“
WG2 WG1 WG1 / WG2
Requirements on the Air
air quality
max. size of particles: 0,1 μm (category 1 acc. to ISO 8573)
max. rest oil content: 0,01 mg/m3 (category 1 acc. to ISO 8573)
max. pressure dew point: +3oC (category 4 acc. to ISO 8573)

table 4-1

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4.2 Technical description plasma gas control unit FlowControl
Depending on the cutting technology the FlowControl is required for the adjustment and dosage of
the plasma gases and swirl gases (consisting of PGV 1 and PGC 1).

The PGV 1 contains the connectors for the gases, the pressure switches, solenoid valves and the
FlowController for the plasma gases PG1, PG2 and PG3, as well as the connectors for the swirl
gases WG1 and WG2.

With the gas-button on the PGC 1 the “Gas test” can be selected. Thereby the gas flow starts for all
preselected gases.

The cutting technology has to be selected acc. to the respective program at the PGC 1.

4.2.1 Operation PGC 1

When switching ON the power source the gas control is furnished with the supply voltage. The micro
processor of the PGC 1 becomes initialised and performs the connection to the other components of
the system. On the display panel the start screen appears.

The control board of the PGV 1 contains a data base with all the necesary parameters for the cutting
process.

This data base has a managing capacity up to 15,000 different cutting data sets. It is divided into
15 ranges, which are assigned to different plasma torches. To each plasma torch up to 1,000 data
sets can be attached.

The storages 1 - 499 contain preset data sets. They are suitable for the cutting process. If
modifications on those cutting parameters are carried out, they can be stored as USER data sets on
the storages 500 - 999.

Structure of the data bank:

• data set numbers per torch 1 up to 999

• per torch two data set ranges are available

1. data set range 2. data set range

thousand digit from 1 up to 499 from 500 up to 999
(predefined) (USER data base)
0 comparative data for CNC ----------------------
1 preset data PerCut 101/110 with HiFocus 100 user data PerCut 101/110 with HiFocus 100
2 preset data PerCut 160/170 with HiFocus 160i user data PerCut 160/170 with HiFocus 160i
3 preset data PerCut 160/170 with HiFocus 100 plus user data PerCut 160/170 with HiFocus 100 plus
4 preset data PerCut 160/170 – 3D – with HiFocus 160i user data PerCut 160/170 – 3D – with HiFocus 160i
6 preset data (reserve) user data (reserve)
7 special range special range
8 - 15 preset data (reserve) user data (reserve)
table 4-2

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4.2.2 Start screen

The start screen will be displayed immediately after applying

the current supply. After a fixed time it automatically changes
to the working screen.
This change takes place:
• automatically after a preset time
(under the provision - from version 5.4 - that the components
connected to the CAN bus will be recognised from the
PGC 1) or
• by pressing the page-down button
(the components required for the CAN bus must not be available for that
purpose)
The field Language allows the selection for the service of the unit in the desired
language (German / English / French …). The selection of the language is done
with the buttons FIELD right/left.

In the field Torch the desired range of data can be selected. The selection of the
data field range is carried out with the buttons FIELD right/left.
fig. 4-1:
Change between language and data field range by key FIELD up/down. details from
front panel
In the 3 fields of the software versions the state of the software of the of the PGC1
components gas PGC1, gas preselection valves and control block will be
displayed.
If no display of the version numbers is given, than the PGC 1 has not found components at the CAN
bus.
In this case „ERROR“ will be
displayed and the power
KJELLBERG FINSTERWALDE source indicates „gas fault“.
THE FINE FOCUS COMPANY
PLASMA FLOW CONTROL selection of language (V6.1)

torches/ power source/

Language: english V6.1 type of
gas preselection (V7)
Torch: PerCut 160,170 V: 07
HiFocus 160i PGV 1
version of control software
Software-Version
Control : 06.01 version of gas preselection
Gas presel.: 04.00 OK
software-version of gas block
Valve : 05.04 Typ PFC
fig. 4-2: start screen (from version 6.0)

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4.2.3 Operation screen „Cutting“

1 2 3 4 5 6 7
1 set number
2 plate thickness
3 material
4 nozzle
5 remark / technology
line 1

line 2
1 1.0330
0.5 mm
St12 HiFocus
Nozzle: S2006 more: F1
20A 6 key for further information on
the data record
7 cutting current

PG1 PG2 PG3 WG1 WG2 8 to a kind of gas assigned gas

line 3
9 flow rate in scale units
10 command display
line 4 Air O2 O2 8
11 cutting speed
line 5 12 report
3 7 9
13 cutting-gas actual pressure
14 cutting-gas reference pressure
line 6 Create a new data: < COPY >
line 7 Select data set: < ENTER > 10
line 8
fig. 4-3:
line 9 OK or error message
line 10 Pressure: p1 5,2 p2 5,2 bar v : 5000 mm/min operation screen
“cutting”

14 13 12 11

In the field CUTTING the required data of the gas control for the cutting process will be displayed.
Hint!
In case of changes safe the value in the with * marked arrays with ENTER. Otherwise after
10 seconds the former value will be reset.

line 1 1 set number: 1 - 999 only set numbers covered with data will be displayed
3 description kind of material
5 designation of technology, description
7* required cutting current (only in manual operation and PGC 1 is master)
line 2 2 thickness of material to be cut
4 employed nozzle for the cutting process
6 after using the key F1 - display of the record parameter opens itself (notice about employed
consumables and further cutting parameters)
line 3 - 5* In these lines the cutting and swirl gases will be displayed.
Three different cutting gases PG1, PG2, PG3 and two swirl gases WG1, WG2 are possible.
If one data set is selected the respective windows indicates the valid gases (line 4) for this set, as well as
the gas flow rate given in scale units (line 5). For gases that are not used the fields of the respective gas
path are blank. In this case the pilot arc becomes ignited with the gas of the path PG 1, but this gas isn’t
used for the cutting process.
line 6 - 7 Command line
Indications are given for possible commands, like: copying of the data set, repeated transmission of the
values of the flow rates to the control valves, gas purge and process runs etc.
line 8 Error indication
“no record on I/O” or “no free userrecord available”

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 line 9 Error display
In this line errors will be displayed in different groups.
• Group 1
- Transmission error in CAN bus
CAN-GVW - Connection to gas preselection group is interrupted
or - invalid software on PCB of gas purge (from version 6.0)
CAN-REG - Connection to gas control block is interrupted
or - invalid software in gas control block (from version 6.0)
GVW not sync. - GVW has an other gas combination as PGC 1 (from version 6.0)
Current - PGC 1 is master and haven´t a RS 485-connection to power source
• Group 2
- cap (torch isn’t mounted according to regulation)
- inlet pressure of the used gases is not in the permissible range
- inlet pressure of the used gases is too low ; e.g. (“Error: pressure pg1”) (from version 6.0)
- inlet pressure of the used gases is too high; e.g. (“Error pressure PG1”) (form verson 6.0)

• Group 3
- tightness failure (only for information) pPG 1 / 2, pPG 3

line 10 14* p1 cutting-gas reference pressure

The necessary torch gas pressure for the cutting process is shown.
13 p2 cutting-gas actual pressure
The actual torch gas pressure in the cutting process is shown.
11 recommended cutting speed

Switching operation action

possibilities data set selection hand wheel (present data sets)
data set confirmation Enter
flow rate selection * hand wheel (scale units 0 - 99)
cutting flow selection * hand wheel (current in A)
torch set pressure change * hand wheel (2.5 - 9.9 bar)
to start screen Page-up
to data set survey Page-down
creation new data set Copy
view technology data F1
confirmation new data set Enter
deletion user data set Del
edition new set
field to field FIELD right / left
sign to sign CHAR right / left
sign selection hand wheel
to field of data set number F2
gas test gas purge
Choosing stored set key O/I (from version 6.0)
to the last data set F3 (up to version 5.x)
key O memory for data set 0 (from version 6.0)
key I memory for data set I (from version 6.0)
activate the data-set-choice of key O/I F3 (from version 6.0)
finish the data-set-choice of key O/I F2 (from version 6.0)

table 4-3

4.2.4 Operation screen „Record parameters“

By operating the button F1 it is possible to switch from the screen „Cutting“ into the screen “Record
parameter”. Information regarding torch consumables have to be used and recommended
technological parameters fort he cutting process are shown. This screen can not be modified. Return
to the screen „Cutting“ is possible by second operation of the F1 button.
After pressing the COPY button during screen „Cutting“ is shown, it switches into screen „Record
parameter“, too. Now overwriting of arrays is possible.
At first the PGC 1 shows the next free user record (500 – 999). With the rotating knob a record
number can be choosed. Select the changeable arrays with the FIELD keys and go with the CHAR
keys within this arrays from sign to sign. With the rotating knob values and signs can be choosed or
changed.

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 1

2
3
4
5
6

7
8

10
9

(up to version 5.x)

11

2
4
5
6

7
8

12
10 (from version 6.0)

11

fig. 4-4: display „record parameters”

1 plasma torch hints of the adjusted torch (Percut 160,170)
2 record display display of record number (1 – 499 preset data sets)
(500 – 999 user data sets)
3 data version display of the record version number / structure version number
4 plate thickness thickness of the material to be cut
5 material kind of material
6 comment display of the remark or technology
7 cutting voltage value of cutting voltage, that is to be expected in the cutting process
8 technology range position of the technology range switch (e.g. 1)
9 torch consumables display of the necessary consumables
10 technology display of the recommended cutting parameters for the guiding machine
parameter
11 cutting speed recommended speed of the torch in the stable cutting process
12 marking set hint of the accompanying marking data set

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 Switching operation action
possibilities with F1-button to record parameters
back to operation screen F1

with COPY-button to record parameters

select a new data set hand wheel
cursor field-by-field FIELD up / down
cursor field-by-field FIELD right / left
save records (only in range 500 - 999) Enter
cursor sign-by-sign CHAR right / left
change the sign and/or value hand wheel
to the operation screen Page-up
table 4-4

4.2.5 Operation screen „Data Survey“

1 1. 0330 St 12 , 0. 5mm, 20A, Hi Focus 1 set number

2 1. 0330 St 12 , 0. 8mm, 20A, Hi Focus 2 kind of material or gas combination
3 1. 0330 St 12 , 1. 0mm, 20A, Hi Focus 3 plate thickness
4 1. 0330 St 12 , 1. 0mm, 25A, Hi Focus 4 cutting current
5 1. 0330 St 12 , 1. 0mm, 30A, Hi Focus 5 technology
6 1. 0330 St 12 , 1. 0mm, 35A, Hi Focus
7 1. 0330 St 12 , 2. 0mm, 35A, Hi Focus fig. 4-5: display “data survey”
8 1. 0330 St 12 , 3. 0mm, 35A, Hi Focus
9 1. 0330 St 12 , 4. 0mm, 35A, Hi Focus
10 1. 0330 St 12 , 5. 0mm, 35A, Hi Focus
11 1. 0330 St 12 , 6. 0mm, 35A, Hi Focus
12 1. 0330 St 12 , 2. 0mm, 50A, Hi Focus fig. 4-6: detail from front panel of
13 1. 0330 St 12 , 3. 0mm, 50A, Hi Focus the PGC 1
14 1. 0037 St 37 , 5. 0mm, 50A, Hi Focus
15 1. 0037 St 37 , 6. 0mm, 50A, Hi Focus

1 2 3 4 5

Changing into this operation screen from the operation screen „cutting“ is
possible pressing the button „PAGE down“.

A list of all in the PGC 1 installed data sets is available (for the respective
torch) in the operation screen „Data Survey“. It will be displayed ascending
to the respective data set number.

A overview of all in the PGC 1 unlocked gas combinations is in the data survey of the torch range
“CNC data sets”. Only these combinations are released in CNC-operation by the PGC 1.

switching operation action

possibilities selection data set Enter
cursor set wise scroll FIELD up / down
sidewise scroll FIELD right / left
erasure data set Del
(only for set range 500 - 999)
to operation screen “Cutting” Page-up
to configuration screen (up to version 5.x) Page-down
To “Input pressure” screen (from version 6.0) Page-down
table 4-5

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4.2.6 Operation screen „Input pressure“
1 2 3 4 5 The input pressures of gases are
shown in this operation screen,
which are needed for the
selected data record.
1 1.0330
0.5 mm
St12 HiFocus
20A
Input Pressure 1 number of data set
2 thickness
PG1 PG2 PG3 WG1 WG2 3 material
4 technology (comment)
6
Air O2 O2 5
6
cutting current
required gases for selected
7 5.5 9.5 min 9.5 data set
7 minimal adjusted flow pressure
current value 8 current flow pressure
8 10.0 10.0 bar 10.0 9 maximal adjusted flow pressure

9 12.0 12.0 max 12.0 fig. 4-7: display “input

pressure”

switching operation action

possibilities to operation screen “data survey” Page-up
to operation screen “Configurazione dati” Page-down
table 4-6

4.2.7 Operation screen „Configuration data“

Configuration data
1 Corr. Flow: 0 Gas purge

2 RS232/RS485 * 9.6 kBit/s PG1 99 Skt.

3 Device: 1 PG2 99 Skt.
4 Device is Master PG3 99 Skt.
5 T Torch pressure 30 s
6
# Torch pressure 10 WG1 99 Skt. 10
T Start display 10 s WG2 99 Skt.
T Gas purge 1 21 s
7
T Gas purge 2 5 s Start Gas
8 29.03.2005 11:02:58 STG1 99 Skt.
STG2 99 Skt.
CAN data rate
9
* 100 kBit/s
(up to version 5.x)

Configuration data
1 Fast Rec. Sw.: CNC

2 RS232/RS485 * 9.6 kBit/s

3 Device: 1
4 Device is Slave Start Gas
5 T Torch pressure 30 s
6 # Torch pressure 10 STG1 99 Skt. 10
T Start display 10 s STG2 99 Skt.
T Gas purge 1 21 s
7
T Gas purge 2 5 s

9 CAN data rate * 100 kBit/s

(from version 6.0)

fig. 4-8: display “configuration data”

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 1 correction gas flow: If the flow rate of the gases are incorrect selected, the PGC 1
automatically performs correction.
Default setting = 0 (up to version 5.x)

1 fast record Choice of data set with key F3 or by CNC with the interface X102 in
switching: manual operation
(from version 6.0)
HiFocus 160i: from Bon-no.: 134 275
PGV 1: from Bon-no.: 133 730

2 data rate RS232/485: Here the transfer rate for the serial transfer can be selected.
Possible variations are: 9,6 / 14,4 / 19,2 / 28,8 / 57,6 / 115,2
kBit/s. Verify the value with ENTER.
standard setting: 9,6 kBit/s
3 device serial number
If several PGC 1 are operated with one Bus RS485 a distinction is
possible by the serial number of the equipment.
Standard setting is equipment number 1 (possible settings are 1 - 4
devices.
4 device is Master
only for manual operation with internal data base possible. The PGC
takes the value for the cutting current from the internal data base and
adjusts the current of the plasma unit correspondingly. A change of
that value has to be carried out at the PGC always.
Slave (standard)
for CNC or manual operation. The receives instruction of a
superordinated control (CNC).
5 T torch pressure Check time for the actual torch pressure
within this time the torch pressure p1 in the gas hose has to be reached.
Otherwise the hose is possibly leaky.
Standard value: 30s
# torch pressure Maximum number of the refilling intervals to hold the pressure within the
check time. Is the set point reached quickly but frequently filling up, the
gas hoses are leaky.
Standard 10 fill ups / check interval.
Hint: The monitoring of the leakage is only for information, but does not
switch off the system in case of defects.
6 T start screen This value is defining the time delay for the automatic change from
the start screen to the working screen.
7 T gas purge 1 This time determines the duration of the gas purge after each change
of the gas between two different cutting proceses.

Standard setting purge time 1 = 30 s or higher

(the value for the purge time after switching on the unit is fixed)
T gas purge 2 This time determines the duration of the gas purge between a
cutting proces and a marking proces.
If cutting gas and marking-gas are identical (f. e. argon), is not blown
through.
Standard setting purge time 2 = 5 s or higher
8 date / time display of actual date and time (adjust the time with the PC).
(from version 6.00 no more available)

9 CAN-Baud rate The Baud rate defines the transfer speed in the internal data bus.
Following transfer speeds are possible: 10, 20, 50, 100, 125, 250,
500 and 1000 kBit/s. Verify the value with ENTER.

standard setting: 100 kBit/s

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 10 parameters of gas Shows the used gas flow rate during gas purge after gas change or
purge as start gas i technology range 2. From version 6.0 – only the start gas is adjustable.

Switching operation action

possibilities
cursor to the next value FIELD up / down
FIELD right / left
value change hand wheel
to screen “Data survey” (from version 5.x) Page-up
to screen “Input Pressure” (from version 6.0) Page-up
to screen “Support” Page-down
table 4-7

4.2.8 Operation screen „Support“

The screen contains information

Adress: for contacting the Kjellberg Finster-
walde Company.
Kjellberg Finsterwalde
Plasma und Maschinen GmbH
Leipziger Straße 82

03238 Finsterwalde
Germany
Tel. : +49.3531.500-345
Fax : +49.3531.8510/500335
Email : [email protected]
WWW : www.kjellberg.de
Support for device: # 700701/1: device-number
Service department: +49.3531.500-345 SERVICE-PHONE
(primary use - please)

fig. 4-9: display „Support“

4.2.9 Selection of data sets for the cutting process

The selection of data sets for the cutting process can be performed manually at the PGC 1 as well
as remotely through the serial interface of the guiding machine.

4.2.9.1 Manual selection of cutting data at the PGC 1

With the manual selection of cutting data sets at the PGC 1 a cutting data set suitable for the
respective cutting operation will be chosen from the data bank integrated in the PGC 1. This cutting
data set contains the cutting data necessary for the cutting process. The required gas parameter will
be transferred to the PGV 1 just after the data set was selected.

The technology selector switch of the power source has to be switched manually to the position
shown in the technological data sheet. If no serial interface connection between PGC 1 and Power
Source HiFocus is existing, then the current value indicated at the display has to be adjusted with
the potentiometer “Cutting or Marking Current”. An automatic takeover of the cutting current from the
data set under the below stated conditions takes place, if the PGC 1 and the power source are
connected by a serial 9 pole sub-D cable (RS485).

After the confirmation of a data set at the PGC 1 simultaneously with the adjustment of the gas
parameters at the PGV 1 the cutting current will be transferred to the power source. The current
display of the power source shows the desired current and the arc voltage display indicates during
the cutting break “cnc”. Necessary corrections of the cutting current take place in the operation
screen of the PGC 1.

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 Necessary conditions for the automatic current set point passing are:

• Serial connection between PGC 1 and the power source, 9 pole interface cable
• At the power source and the PGC 1 the same data rate is selected. Adjustment 9,6 kBit/s
(standard) at the configuration side of the PGC 1.
• PGC 1 and power source are working as the same device (standard adjustment: Equipment 1)
Power source: Jumper 7 and 8 of the sequence control not placed (Delivery condition).
PGC 1: Adjustment at configuration side “Equipment”.
• The power source supplies the current for the data bus. The switch for the bus current supply is
set to PGC 1; resp. available from the terminals 2 and 6, connection X4.2 of the bus connection,
24 VDC. *** The switch (bus current supply) is installed only in HiFocus 160i from bon 131054 to 134010.***.
• The PGC 1 has to be the master. PGC 1 adjustment at the configuration side “Device no. is”
• No serial connection to the guiding machine is existing, or the communication to the guiding
machine is switched off.

4.2.9.2 Selection of a data set of the PGC 1

The PGC 1 possesses an own internal data set with the optimised data for the respective cutting
process.

This data set are included in the internal data banks, listed at torch types. In the start screen the
selection of torches is carried out, with limitation of the valid data set for the respective torch.

In the operation screen the data sets can be selected by using the hand wheel. Record numbers
are opened by key F2.

After confirming the requested data set by the Enter button, the data set is activated and
information will be transferred from the PGC 1 to the PGV 1. The respective gas valves of the PGV
will open and are starting the automatic gas purge process.

After the purge action the gas control is ready for the cutting process.

The selection of a data set can be performed in the working screen Data Survey too.

When switching off the plasma power source (for changing consumables, or at shift end) the gas
control simultaneously becomes switched off. Has the power source a 2-step start mode for
changing spare parts of the plasma torch at first the power source has to be switched into position
“PGC 1 on”. Now the power source is switched off, but the power supply of the PGC 1 keeps on
and the parameters of the file are still readable.

After the restart of the power source the PGC 1 (in both variants) at first is activating the Start
Screen, is testing then the connection to the components at the CAN BUS and is initiating after that
the operation screen, when it is o.k.

In the working screen the PGC 1 recognizes the last used data set and activates it automatically.

Changes on the parameters displayed in the operation screen are possible by the hand wheel. The
changes become operative after performing with the Enter button. If no performing is done after a
short delay the previous value will be displayed.

4.2.9.3 Fast data set selection by using the keys “0” and “I” (from version 6.x)

The fast data set selection is possible only during the manual operation, controlled by the key F3 or
through the serial interface X102 contacts C3/C8. At first the source for the data set switching is
selected at the configuration side. Set selection is done with key F3 or from CNC through interface
X102 of the power source HiFocus.

Z 0002 - 14.03.2005 - page 4-12 - Kjellberg Finsterwalde

 o Possibilities of selecting a data set and its storage

1. Press key “F2”

select set and press “ENTER” Æ to data set selection
purge procedure starts.

Press key “0” or “I” shortly.

after then press “ENTER” shortly Æ Set will be stored in “0” or “I”

2. With key “Page” into technology data summary.

select set and press “ENTER”, Æ into operations picture Parameter
purge procedure runs.

Press key “0” or “I”.

after then press “ENTER” Æ stores set in storage “0” resp. “I”

If under condition “Plasma Stop” the key “O” or “I” is pressed longer, then the data set, stored
under this position will be displayed. The display is available as long as the key is pressed.

o Possibilities of switching between two data sets

The fast data set selection will be activated by key “F3”, and deactivated by key “F2”.

1. Set selection by key “F3”

In the configuration picture the set selection “F3” is active.

The storages “0” and “I” have been covered with the respective data sets.
(preferably “0” with the cutting set, and “I” with the marking set)

When pressing first time key “F3”, then the fast data set selection will be activated. Always
the set of the storage “I” will be loaded at first. The purge process takes place. After pressing
“F3” again the set of storage “0” will be loaded and purging starts. Further activating of key
“F3” causes changes between the sets “0” and “I”. No data set change takes place, if “F3” is
activated under the conditions “Cutting, Purge or Purge error”. Alterations of the stored data
sets “0” and “I” are not possible. For that the mode fast data set selection has to be stopped
with “F2”.

The display fast data set selection, activated by “F3”, will be shown in the field between the
plasma and swirl gases.

Set change with “F3” / Set “I” active Set change with “F3” / Set “0” active
1 1.0330
0.5 mm
St12 HiFocus
Düse : S2006 mehr :F1
20A 1 1.0330
0.5 mm
St12 HiFocus
Düse : S2006 mehr :F1
20A
PG1 PG2 PG3 P WG1 WG2 PG1 PG2 PG3 P WG1 WG2

Air O2 G O2 Air O2 G O2
C C
3 7 3 0 7
Neuen Satz erstellen: < COPY >
1 Neuen Satz erstellen: < COPY >
Satz auswählen: < ENTER > Satz auswählen: < ENTER >
OK oder Fehlermeldung OK oder Fehlermeldung
Druck :p1 5,2 p2 5,2 bar v : 5000 mm/min Druck :p1 5,2 p2 5,2 bar v : 5000 mm/min

Fig. 4-10: Display „set change F3“

Z 0002 - 14.03.2005 - page 4-13 - Kjellberg Finsterwalde

 2. Set selection through control cable of the CNC

In the configuration picture at first the “fast set switch over CNC” must be active. The stores
“0” and “I” have been covered with the respective data sets (preferably “0” with the cutting
set, and “I” with the marking set).

With the first pressure of the key “F3” the fast data set selection will be active. From the
guiding machine a potential-free contact is required. At the interface X102 of the HiFocus

C3/C8 = connected, set of storage “I” loaded and

C3/C8 = interrupted, set of storage “0” loaded.

Purging takes place. If the input assignment of the entry X102 C3/C8 will be changed, then
the respective data set will be loaded and purging takes place. Changes during the condition
“Cutting, Purging and Purge error” do not effect a data set change. The data set change
takes place only at the condition Plasma stop. Alterations of the stored data sets are not
possible. For that the mode fast data set selection has to be stopped with “F2”.

The display fast data set selection, activated by “F3”, will be shown in the field between the
plasma and swirl gases.

Set change with CNC/ Entry Power Source Set change with CNC/ Entry Power Source
X102 C3/C8 connected X102 C3/C8 disconnected
1 1.0330
0.5 mm
St12 HiFocus
Düse : S2006 mehr : F1
20A 1 1.0330
0.5 mm
St12 HiFocus
Düse : S2006 mehr :F1
20A
PG1 PG2 PG3 C WG1 WG2 PG1 PG2 PG3 C WG1 WG2

Air O2 N O2 Air O2 N O2
C C
3 7 3 0 7
Neuen Satz erstellen: < COPY >
1 Neuen Satz erstellen: < COPY >
Satz auswählen: < ENTER > Satz auswählen: < ENTER >
OK oder Fehlermeldung OK oder Fehlermeldung
Druck :p1 5,2 p2 5,2 bar v : 5000 mm/min Druck :p1 5,2 p2 5,2 bar v : 5000 mm/min

Fig. 4-11: Display “Set change CNC”

4.2.9.4 Safe of user data sets

If preset data sets was changed for the cutting process, it is possible to safe them as user data sets
in the record range 500 - 999.
At first press the COPY-button under the operational display. The existant gas combination with its
values is safed now and the display changes into the operational display “record parameter”.

This display is adjustable.. With the FIELD-buttons a field can be selected and with the CHAR-buttons
changed from character to character. Changes of values or characters can be made with the rotating
knob. If ready, the record is safed by pressing ENTER. By operating the DEL-button all changes can be
deleted.

Existing data sets are not changeable later. Moreover only existing gas combinations can be
changed.

If all free storage spaces are engaged, the operations picture shows the notice “no storage space
available”.

Z 0002 - 14.03.2005 - page 4-14 - Kjellberg Finsterwalde

4.2.9.5 Delete of data sets

Deleting of records can be performed in display „data survey“. Data sets in the range 1 - 499 are not
removable. User data sets in the range 500 - 999 can be deleted.

At first the cursor will be placed to the data set to be deleted by the FIELD- Keys. Then the DEL-
Key should be pressed. After the deleting the cursor jumps back to the 1.data set (This procedure
can take some time at large data amounts. During this procedure the equipment must not switched
off). The deleted set is not available more.

4.2.9.6 Preselection of gas parameters from the external control

If the PGC 1 should be controlled from an external data bank, then this is performed by the serial
interface (RS485) connector X4.
The internal data bank of the PGC 1 for the cutting parameters in this case is not active.

The cutting data will be taken from the data bank, included in the guiding machine and transferred
to the PGC 1 through the serial connection.

Following system configurations are possible:

• The guiding machine determines the gas parameters for the cutting process through the serial
connection. Then the current parameters will be adjusted manually at the cutting power
source.
• The guiding machine determines the gas parameters for the cutting process through the serial
connection. The current parameters will be determined from the guiding machine through the
conventional interface X102.
• The guiding machine determines the gas parameters and the current parameters for the
cutting process through the serial connection.
In this case the guiding machine is the master, controlling the two slaves connected to the
serial bus.
Nevertheless the connection of the guiding machine with the power source through the
interface X102 is besides the serial connection necessary.
The signals, like “Torch ON”, or “Emergency OFF” will be transferred by safety reasons
furthermore through the connection X102.

Following conditions for the function of the serial connection are necessary:

ƒ Serial connection between guiding machine, power source and PGC1 by a 9-pole
connecting cable
ƒ Same data rate selected at guiding machine, power source and PGC1: 9.6 kBit/s (standard),
adjustment at “Configuration side” PGC1 (RS 232/485)

The guiding machine transmits the data to the as the same devices defined PGC1 and power
source (Standard: Device 1).

ƒ Power source: Jumper 7 and 8 of the sequence control are not placed (condition at delivery)
ƒ PGC1: Adjustment at configuration side “Device”
ƒ The current supply for the data bus is carried out from the guiding machine or the power
source (see chapt. 4.2.9.1).
ƒ Switch “bus current supply “(power source) in position PGC (the bus converters of the power
source and the PGC1 have the same power supply); respectively
ƒ the “switch bus current supply” (power source) is in position “guiding machine” (power
source and PGC1 will be supplied from the guiding machine).
ƒ The PGC1 must be the slave.
ƒ PGC1 adjustment at configuration side “Device is” slave

Z 0002 - 14.03.2005 - page 4-15 - Kjellberg Finsterwalde

 Attention!
After switching on the PGC 1 in the start screen under ”Torch” the operation mode “Pre-
selection from CNC” will be selected (f.e.: CNC Control V4). In the operation screen the
cursor is placed on the last used gas combination.

The PGC 1 is waiting for data from the serial interface. The mode of the data transfer is defined in
the document “Serial Interface” - part 1-3.

If a data set was transferred from an external source the PGC 1 is checking the content. When it is
found OK the data set becomes activated. The parameters will be displayed in the operation
screen and the required values transferred from the PGC 1 to the PGV 1. This transfer is
performed like the operation with internal data sets.

When switching off the plasma unit the PGC 1 is storing the last transferred data set from the
external source. After the restart the gas control automatically is activating this set. The gas control
is ready for operation again without transmission of a data set.

The external control has no direct access to the data sets of the internal data bank of the PGC 1.
4.3 Service and display elements of the PGC 1
1 button for gas test
2 display gas control signal
3 display error - gas failure / CAN connection error
4 LCD display
5 F1-button “record parameters”
6 F2-button „to data set selection“
7 F3-button „change of data set“
8 del-button “delete button”
9 copy-button „new data set“
10 enter-button „input confirmation“
11 page-buttons „change display pages“
12 field-buttons „position change field“
13 char-buttons „position change sign alternation“
14 LED-power - power supply ON
15 contrast adjustment display
16 hand wheel for parameter selection
17 serial interface RS 232
18 switch of interfaces RS 232 and RS 485
19 connection to guiding system RS 485
20 CAN1 spare position
21 CAN1 signal connection to PGV 1
22 socket current supply PGC 1
23 store key of data set O (from version 6.0)
24 store key of data set I (from version 6.0)

fig. 4-12: service and display elements of PGC 1

Z 0002 - 14.03.2005 - page 4-16 - Kjellberg Finsterwalde

4.4 Connection of the plasma gas valve unit PGV 1
The PGV 1 will be connected by a
25 pole control cable to the socket
X110 (placed on the plasma machine).
The gas supply hoses for the plasma
gas have to be fitted to connectors (4)
to (8), the hoses for the swirl gas to the
connectors (1) to (3).
The connectors (10) to (14) are
provided for the supply hoses to the
plasma gas connection unit PGA-HM or
plasma torch connection unit PBA-H
resp. for the hoses of the torch hose
parcel.
The PGV 1 is at direct torch connection
fixed at the top of the plasma machine.
At other configurations a suitable
placement has to be arranged.

fig. 4-13: connections of the plasma gas valve unit PGV 1

1 inlet swirl gas WG2 N2H2 (backing gas) G3/8“ - left 11 torch connection cutting gas PG1/PG2 G1/4“ - left
2 inlet swirl gas WG1/2 N2 G1/4“ 12 torch connection cutting gas PG3 G3/8“ - left
3 inlet swirl gas WG1 O2 G1/4“ 13 torch connection swirl gas M12x1
4 inlet plasma gas PG3 H2 G3/8“ - left 14 torch connection control gas G1/8“
5 inlet plasma gas PG2 O2 G1/4“ 15 gas flow filter
6 inlet plasma gas PG1/2 N2 G1/4“ 16 fuse control circuit 24 V AC
7 inlet plasma gas PG1 Ar G1/4“ 17 circuit 24 V DC
8 inlet plasma gas PG1 Air G1/4“ 18 socket current supply (X1) 4 pole socket
9 connection X110 - to power source 25 pole plug 19 connection CAN1 - signal to PGC1 (X2) Sub D 9pole
10 torch connection ignition gas PG1 G1/4“ 20 service socket RS232 (X3)

4.5 Connection of the gas hoses between PGV 1, PGA-HM and PBA-H
The length of the gas hoses for the connection of the components of the Plasma Cutting Complex
have to arranged according to the system configuration. The following hoses are used:
Plasma gas PG1 (Air, N2 ,Ar) :Oxyacetylene hose 4x3,5 blue -G1/4“ (marked grey)
Plasma gas PG2 (O2, N2 ) : Oxyacetylene hose 4x3,5 blue-G1/4“-left
Plasma gas PG3 (H2) : Oxyacetylene hose 4x3,5 red-G3/8“-left
Swirl gas (O2, N2, N2/H2) : Oxyacetylene hose 4x3,5 blue- M12x1
Control gas (N2 , O2) : Oxyacetylene hose 4x3,5 blue- G1/8“
For connecting the PGV1 with the PGA-HM all the 5 hoses have to be used, for the connection of
the PGA-HM with the PBA-H only the hoses { - ~.

Z 0002 - 14.03.2005 - page 4-17 - Kjellberg Finsterwalde

4.6 Connection of the gas supply
Attention!
For the gas supply only high- quality, preferable two- step pressure regulators have to be
used, guaranteeing a constant supply pressure. The quality of the pressure reducer influences
the cutting quality and reliability of the complete unit. Pressure reducers that are conform to
the quality requirements are mentioned in the order specifications of Kjellberg.
Furthermore the user has to follow local and national standards.
4.6.1 Plasma gases
The connectors for the plasma gas supply hoses are placed on the back of the plasma gas valve
unit PGV1 (fig.4-13):

Ensure the quality of the plasma gases absolutely (see section “Technical data - plasma cutting
unit). Dirty gases can cause double arcing, increased wear of nozzles and cathodes and damage of
torch or within the PGV1.

Against coarse dirt all gas connectors of the plasmagas control units, plasmagas connection units
and the plasma torches are equipped with micro filters. They can be unscrewed by a little
screwdriver and if necessary cleaned.

For the gas supply the followng hoses have to be used.

plasma gases colour code connectors
air black, grey marked G1/4"
oxygen blue G1/4"
argon black G1/4"
hydrogen red G3/8" left
nitrogen black, green marked G1/4"

table 4-8

Attention!
The inlet pressure should not exceed 1.2 MPa (12 bar), but should be at least 1,0 MPa (10 bar).
Please follow strictly the regulations for handling gas cylinders and pressure reducers!

Plasma gas air

quality requirements:
• size of particles, max. 0,1 μm class 1 acc. to ISO 8573
• remaining oil content, max. 0,01 mg/m3 class 1 acc. to ISO 8573
• dew point, max. +3oC class 4 acc. to ISO 8573
supply from pressure cylinder:
• check the cylinder valves (must be free of oil and grease), clean it if required
• open shortly the valve for removing dust
• adjust the pressure reducer to the cylinder
• connect the gas hoses (black/grey marked, G1/4”-G1/4”) between pressure reducer (with
filter/micro filter) and inlet connector “Air” (with filter / micro filter) at the PGV 1
• open the valve and adjust the pressure between min. 10 bar and max. 12 bar
supply from the shop line or compressor:
• arrange oil and water separator in the supply line, or dry freezer, to be connected the shop line
and the PGV 1
• the oil separator is not required if the compressor works “oil free”
• adjust the pressure at the compressor between min. 10 bar and max. 12 bar

Z 0002 - 14.03.2005 - page 4-18 - Kjellberg Finsterwalde

 Plasma gas oxygen

Attention!
All components coming in touch with oxygen have to be free of oil and grease! Pressure
reducers for oxygen have to provided with explosion protectors (fire protection). Install
micro filters between gas supply and PGV 1

• check the cylinder valves (must be free of oil and grease), clean it if required
• open shortly the valve for removing dust
• adjust the pressure reducer with explosion protection to the supply (cylinder, shop line)
• connect the gas hoses (blue marked, G1/4“-G1/4“) between pressure reducer (with filter / micro
filter) and inlet connector “O2” (with filter / micro filter) at the PGV 1
• open the valve and adjust the pressure between min. 10 bar and max 12 bar.
Hint!
If the plasma ignition box PZ-H is in the circuit it is recommended to place a second
explosion protection directly to the gas entry of the PZ-H. (available from Kjellberg
Finsterwalde on request)

Plasma gases argon, hydrogen, nitrogen

• check the cylinder valves (must be free of oil and grease), clean it if required
• open shortly the valve for removing dust
• adjust the pressure reducer to the respective cylinders
• connect gas hose (black colour, G1/4“-G1/4“) between pressure reducer argon and the inlet
connector „Ar“ at the PGV 1
• connect gas hose (black/green, G1/4”-G1/4”) between pressure reducer nitrogen and the inlet
connector “N2” at the PGV 1
• connect gas hose (red colour, G3/8“ left - G3/8“ left) between pressure reducer hydrogen and the
inlet connector „H2“ of the PGV 1
• open the valve and adjust the pressure between min. 10 bar and max. 12 bar

4.6.2 Swirl gases (oxygen, nitrogen, backing gas)

The connectors for the supply hoses of the swirl gases are placed on the back of the plasma gas
valve unit PGV 1 (fig. 4-13).
For the gas supply following hoses are required:

swirl gas colour code connectors

oxygen blue G1/4"
nitrogen black, green marked G1/4"
N2/H2 (backing gas) red, green marked G3/8" left

table 4-9
• check the cylinder valves (must be free of oil and grease), clean them if required
• open shortly the valves for removing dust
• adjust the pressure reducers to the respective cylinders
• connect the gas hoses (blue, G1/4“-G1/4“) between pressure reducer oxygen (with filter / micro
filter) and the inlet connector (with filter / micro filter) „O2“ of the PGV 1
• connect the gas hoses (black/green, G1/4“-G1/4“) between pressure reducer nitrogen and the
inlet connector „N2“ of the PGV 1
• connect the gas hoses (red/green, G3/8“left - G3/8“left) between the pressure reducer hydrogen
and the inlet connector „N2/H2“ of the PGV 1
• open the valves and adjust the pressure between min. 10 bar and max. 12 bar.
Attention!
All components coming in touch with oxygen have to be free of oil and grease!

When using oxygen the pressure reducer has to be furnished with an explosion protection
(fire protection)!

Z 0002 - 14.03.2005 - page 4-19 - Kjellberg Finsterwalde

 Instruction Manual

Plasma Gas Ignition Box

PZ-H
Article no.: .11.821.931
5 Plasma gas ignition box PZ-H

5.1 Technical data PZ-H

article no.: .11.821.931

operating voltage : 24 V AC, 50 / 60 Hz
dimensions (lxbxh): 450 x 185 x 240 mm
weight: 8.5 kg
connection to: HiFocus with hose parcel extension PZL-H101

table 5-1

5.2 Technical description

5.2.1 Cable set PZL-H 101

For various applications the standard lengths of the torch hose parcels with 6, 10 or 15 meters are
sufficient for the operation. But in special cases it is possible to enlarge the operational radius up to
55 m by using the hose parcel extension PZL-H101 in connection with an plasma ignition box PZ-H
and PGA-HM.

The PZL-H101 consists of:

• coolant outlet hose with cathode cable

• coolant inlet hose with pilot cable
• 10 pole supply cable
• 9 pole control cable
• protective conductor
• cathode cable

5.2.2 Plasma ignition box PZ-H

The plasma ignition box

PZ-H is the connecting
point for the plasma
torch hose parcel resp.
the cable set PBA-H
160 with the supply
hoses and cables to the
plasma cutting unit
(PZL-101). The PZ-H
contains the connectors
for the water inlet and
outlet hoses of the
torch hose parcel and
the hose parcel
extension PZL-H 101,
and the torch solenoid
valve supply cables as
well. All terminals are
accessible after
opening the side walls
which are protected by
safety contacts.

fig. 5-1: plasma ignition box with plasma gas connection unit

Z 0005 - 18.08.2005 - page 5-2 - Kjellberg Finsterwalde

5.3 Connection of the plasma ignition box PZ-H
For connecting the plasma ignition box with the
HiFocus 160i the hose parcel extension PZL-H 101 up
to 40 m is required.

fig. 5-2: detail of back wall

The following connections have to be carried out:

back wall of power source fig.5-2 cable set PZL-H101 PZ-H terminal board
coolant return / cathode 9 coolant return hose coolant return / G3/8"
coolant inlet / nozzle 10 coolant inlet hose coolant inlet / G1/4"
2
terminal bolt M8 11 cathode cable 35 mm coolant return / M8
connection control cable X121 8 control cable / 8 pole plug X121A
connection control cable X114 5 control cable / 12 pole plug X114A
terminal bolt M8 12 protective conductor / 1 pole housing M8

table 5-2: connection PZL-H101

Additionally the 2 pole control cable (art.no. 11.500.700.47x) has to be connected to the cable set
PBL-H160 (table 5-3).

back wall of power source fig.5-2 control cable 11.500.700.47x cable set PBL-H160
connection control cable X122 17 control cable / 2 pole plug X122A

table 5-3: connection PZL-H101

Works on the plasma ignition box:

• remove side walls

• open green stress relief clamp
• insert water hoses and control cable of the plasma torch through the “PZL”-marked entry (back
side) and connect them to the terminals resp. 8 pole plug

Works on the plasma cutting unit:

• open cover plate on the back wall (use screw drive)

• connect coolant hoses, control cable and protective conductor of the cable set (table 5-3)

The cable set has to be fixed properly by the green stress relief clamp! The cables and hoses have
to be placed untwisted and without sharp bends.

Attention!
After the connections are carried out the plasma cutting unit and the ignition box have to be
closed carefully! If the installed safety contacts (cover plate of power source / side walls
PZ-H) are not closed, the power source can’t be operated.

Z 0005 - 18.08.2005 - page 5-3 - Kjellberg Finsterwalde

 Instruction Manual

Plasma Gas Connection Unit

PGA-HM
Article no.: .11.825.106
6 PGA-HM
6.1 Technical data PGA-HM
art. no.: .11.825.106
dimensions (lxwxh): 180 x 185 x 240 mm
weight: 4.0 kg
employed gas: plasma gas: air, O2, N2, H2, Ar (see chapter „connection of gas supply“ in
the instruction manual of the plasma gas
connection to: swirl gas: O2, N2, N2/H2 (backing gas) control unit / - controller)
control gas: O2, N2
PGV 1 / PGE-HM / PGE1-HM by gas hoses
table 6-1

6.2 Technical description

6.2.1 Technical description PGA-HM

For extending the operational radius along with the plasma ignition box PZ-H the plasma gas
connection unit PGA-HM is required. All connectors and terminals for the plasma gases, the swirl
gases and the control gases are placed on the back side, connecting the PGA-HM and the PGV1 /
PGE-HM / PGE 1-HM and the plasma torches resp. with the plasma torch connection unit.

The PGA-HM is fixed on the top of the PZ-H.

6.2.2 Cable set PBL-H 160

The cable set is required for connecting the plasma torch connection unit PBA-H with the plasma
ignition box PZ-H, resp. with the plasma cutting unit HiFocus 160i. The cable set PBL-H160 consists
of:

• coolant inlet hose with inserted pilot cable 2.5 mm2

• coolant return hose with inserted cathode cable 6 mm2
• control gas hose
• 8 pole control cable
• 4 pole control cable

Furthermore the connection hoses for the PG1 - PG3 and the swirl gas of the PGA-HM resp. PGV 1
/ PGE-HM / PGE 1-HM have to be connected.

Z 0006 - 03.05.2004 - page 6-2 - Kjellberg Finsterwalde

 Instruction Manual

Plasma Torch Connection Unit

PBA-H160
Article no.: .11.802.243
7 Plasma torch connection unit PBA-H160
7.1 Technical data PBA-H160
art. no.: .11.820.243 (5 solenoids valves)
input voltage (solenoids): 24 V AC, 50 / 60 Hz
dimensions (lxwxh): 170 x 237 x 280 mm
weight: 3.3 kg
employed gas: plasma gas: air, O2, N2, H2, Ar (see chapter „connection of gas supply“ in
the instruction manual of the plasma gas
swirl gas: O2, N2, N2/H2 (backing gas) control unit / - controller)
control gas: O2, N2
connection to: PZ-H and PGA-HM160 resp. PA and PGV 1, PGE-HM or PGE1-HM with cable set PBL-H160

table 7-1

7.2 Technical description PBA-H160

The plasma torch connection unit PBA-H160 is the intersection between the plasma torches
PerCut 160-2 and the power source resp. the plasma ignition box PZ-H/Plasma gas connection unit
PGA-HM. After opening the safety-contact protected cover plate the connectors for water
inlet/nozzle, water outlet/cathode and control gas are accessible. The connectors for the plasma
gases { to } and the swirl gas ~ are placed sideward on the PBA-H.

The PBA-H is provided with stress relief clamps for the hose parcel of the PBL-H 160 and the PerCut 160-2.

2 spacers M6
in the bottom

X122 X121

1 2 3 4

blue
black

fig. 7-1: plasma torch connection unit PBA-H 160

Z 0007 - 28.09.2004 - page 7-2 - Kjellberg Finsterwalde

7.3 Connection of the PBA-H160
The plasma torch connection unit has to be fixed to the guiding system the customer is using. For
the correct fastening the back wall of the PBA-H160 is furnished with two distance pieces (with
threads M6 inside/outside).

Afterthen cables of the hose parcel PBL-H160 will be inserted from the upper side into the PBA-
H160 and fastened there. The connecting hoses for the gas supply have to be installed gas tight to
the respective connectors. The hose parcel has to be secured by the green stress relief clamp.

power source/Flow Control PZ-H/PGA-HM cable set PBL-H160 PBA-H

coolant return / cathode coolant return / PVC-10x2 coolant return / G3/8"

coolant inlet / nozzle coolant inlet / PVC-6.5x2 coolant inlet / G1/4"
connector control cable X121 control cable / 8pole plug X121C
connector control cable X122 control cable / 4pole plug X122C
terminal bolt M8 protective conductor / 1pole housing M8
control gas/G1/8“ gas hose 4x3,5 blue G1/8“

table 7-2: connection PBL-H160

After the connection work is finished the cover plate with the safety switch has to be closed properly,
otherwise the start of the plasma power source is blocked. Depending on the configuration the
PBA-H 160 will be connected by the PBL-H160 to the combination plasma unit - FlowControl resp.
PGE-HM / PGE1-HM or to the plasma ignition box PZ-H / PGA-HM 160.

Z 0007 - 30.09.2004 - page 7-3 - Kjellberg Finsterwalde

cutting tables
Pos: 1.1 /Überschriften/1/Schneidtabellen @ 0\mod_1197468480017_19.doc @ 1555

1 cutting tables
Pos: 1.2 /Überschriften/1.1/Schneidtabellen PerCut 160/170 @ 0\mod_1217425105315_19.doc @ 5018

1.1 Cutting tables PerCut 160/170

Pos: 1.3 /Anlagen/Schneidtabellen/HiFocus160i/Deckblatt_HiFo160i @ 0\mod_1216379990286_19.doc @ 4721

HiFocus 160i Overview

FlowControl 1
data version: 11 - valid from: 17.07.2008

torch material thickness cutting current commentary #

PerCut 160/170 1.0330 St12 0,5 - 1.5 mm 20 - 25 A HiFocus 1
1.0330 St12 1- 6 mm 35 - 50 A HiFocus 2

1.0037 St37 5- 6 mm 50 A HiFocus 3

1.0037 St37 4 - 10 mm 60 A HiFocus+ 4
1.0037 St37 6 - 15 mm 100 A HiFocus+ 5
1.0037 St37 10 - 30 mm 115 - 130 A HiFocus+ 6
1.0037 St37 12 - 25 mm 160 A HiFocus+ 7
1.0037 St37 20 - 50 mm 160 A HiFocus F 8
1.0037 St37 5 - 12 A marking 9

1.4301 CrNi 1- 3 mm 20 - 30 A HiFocus 10

1.4301 CrNi 1 mm 30 A HiFinox 11
1.4301 CrNi 4- 6 mm 45 - 50 A HiFocus 12
1.4301 CrNi 2- 6 mm 55 - 60 A HiFinox 13
1.4301 CrNi 6 - 25 mm 115 - 130 A HiFocus F 14
1.4301 CrNi 6 - 12 mm 130 A HiFocus F+ 15
1.4301 CrNi 10 - 35 mm 160 A HiFocus F 16
1.4301 CrNi 12 - 30 mm 160 A HiFocus F+ 17
1.4301 CrNi 6 - 14 A marking 18

1.4571 CrNiTi 5 - 15 mm 130 A HiFocus F 19

1.4571 CrNiTi 6- 8 mm 130 A HiFocus F+ 20
1.4571 CrNiTi 10 - 30 mm 160 A HiFocus F 21

3.3536 AlMg3 1- 8 mm 35 - 50 A HiFocus 22

3.3536 AlMg3 6 - 25 mm 115 - 130 A HiFocus F 23
3.3536 AlMg3 8 - 10 mm 130 A HiFocus F+ 24
3.3536 AlMg3 10 - 35 mm 160 A HiFocus F 25

Consumable part overview of the plasma torch type PerCut 160/170

Pos: 1.4 /Anlagen/Schneidtabellen/HiFocus160i/SD 1 HiFo 160i FC PerCut 160/170 - St12 0,5-1,5mm @ 0\mod_1216380247563_19.doc @ 4725
 cutting tables
HiFocus 160i #1
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus - 1.0330 St12 ( 0.5 - 1.5 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] O2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

1 0,5 20 - S002 Z101 S2006X S3004 - Z4015 Z501 - 1 0 3 0 7 0 5,2 2 1,5 2 0 105 5400 * 1,2 450 200 30

2 0,8 20 - S002 Z101 S2006X S3004 - Z4015 Z501 - 1 0 3 0 8 0 5,2 2 1,5 2 0 108 4300 * 1,2 450 200 30

3 1 20 - S002 Z101 S2006X S3004 - Z4015 Z501 - 1 0 3 0 8 0 5,2 2 1,5 2 0 110 3700 * 1,3 450 200 30

4 1,5 25 - S002 Z101 S2006X S3004 - Z4015 Z501 - 1 0 3 0 8 0 5,2 2 2 2 0 112 3000 * 1,3 450 200 30

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

450 0 5 - S002 Z101 S2006X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 81 3000 * 0 0 200 4

1
0.5 mm
1.0330 St12
nozzle : S2006x more : F1
HiFocus
20A
PG1 PG2 PG3 WG1 WG2

Air O2 O2
3 7
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure:p1 5.2 p2 5.2 bar v : 5400 mm/min

Pos: 1.5 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.6 /Anlagen/Schneidtabellen/HiFocus160i/SD 2 HiFo 160i FC PerCut 160/170 - St12 1-6mm @ 0\mod_1216380422618_19.doc @ 4729
cutting tables
HiFocus 160i #2
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus - 1.0330 St12 ( 1 - 6 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] O2, N2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

5 1 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 5 0 20 1 5,2 2 2 2 0 113 2400 * 1,4 451 200 30

6 1,5 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 7 0 20 1 5,2 2 1,5 2 0,1 115 2000 * 1,4 451 200 30

7 2 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 7 0 20 1 5,2 2,5 1,5 2,5 0,1 116 1600 * 1,4 451 200 30

8 3 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 7 0 20 1 5,2 3 2 3 0,1 118 1200 * 1,4 451 200 30

9 4 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 7 0 20 1 5,2 3 2 3 0,1 119 950 * 1,5 451 200 30

10 5 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 7 0 20 1 5,2 3,5 2 3,5 0,2 119 800 * 1,5 451 200 30

11 6 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 7 0 20 2 5,2 3,5 2,5 3,5 0,2 120 700 * 1,6 451 200 30

12 2 50 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 8 0 20 1 5,2 2,5 2 2,5 0,1 112 2600 * 1,4 452 200 50

13 3 50 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 8 0 20 1 5,2 2,5 2 2,5 0,1 112 2200 * 1,6 452 200 50

14 4 50 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 8 0 20 1 5,2 2,5 2 2,5 0,1 115 1000 * 2 452 200 50

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

451 0 5 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 82 3000 * 0 0 200 4

452 0 5 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

5
1.0 mm
1.0330 St12 HiFocus
nozzle : S2007x more : F1
35A
PG1 PG2 PG3 WG1 WG2

Air O2 O2 N2
5 20 1
New Data : < COPY >
Select record: < ENTER >
OK or Error
Pressure :p1 5.2 p2 5.2 bar v : 2400 mm/min

Pos: 1.7 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.8 /Anlagen/Schneidtabellen/HiFocus160i/SD 3 HiFo 160i FC PerCut 160/170 - St37 5-6mm @ 0\mod_1216380605470_19.doc @ 4733
 cutting tables
HiFocus 160i #3
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus - 1.0037 St37 ( 5 - 6 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] O2, N2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

15 5 50 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 8 0 20 2 5,2 3,5 2 3,5 0,2 120 850 * 2 452 200 50

16 6 50 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 8 0 20 2 5,2 3,5 2,5 3,5 0,2 125 750 * 2,1 452 200 50

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

452 0 5 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

15
5.0 mm
1.0037 St37
nozzle : S2008x more :
HiFocus
F1
50A
PG1 PG2 PG3 WG1 WG2

Air O2 O2 N2
8 20 2
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.2 p2 5.2 bar v : 850 mm/min

Pos: 1.9 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.10 /Anlagen/Schneidtabellen/HiFocus160i/SD 4 HiFo 160i FC PerCut 160/170 - St37 4-10mm @ 0\mod_1216380746148_19.doc @ 4737
cutting tables
HiFocus 160i #4
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus+ - 1.0037 St37 ( 4 - 10 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] N2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

50 4 60 - S002 Z102 S2008X S3028 - Z4020 Z501 - 1 0 20 0 0 50 9,5 3 1,5 3 0,2 118 2600 * 1,4 453 200 50

51 5 60 - S002 Z102 S2008X S3028 - Z4020 Z501 - 1 0 20 0 0 40 9,5 3 2 3 0,3 122 2400 * 1,6 453 200 50

52 6 60 - S002 Z102 S2008X S3028 - Z4020 Z501 - 1 0 20 0 0 45 9,5 3 2 3 0,3 125 1800 * 1,8 453 200 50

53 8 60 - S002 Z102 S2008X S3028 - Z4020 Z501 - 1 0 50 0 0 60 9,5 3,5 2 3,5 0,4 130 1550 * 1,8 453 200 50

54 10 60 - S002 Z102 S2008X S3028 - Z4020 Z501 - 1 0 50 0 0 45 9,5 3,5 2 3,5 0,4 127 1000 * 1,9 453 200 50

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

453 0 5 - S002 Z102 S2008X S3028 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

50
4.0 mm
1.0037 St37
nozzle : S2008x
HiFocus+
more : F1
60A
PG1 PG2 PG3 WG1 WG2

Air O2 N2
20 50
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 9.5 p2 9.5 bar v : 2600 mm/min

Pos: 1.11 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.12 /Anlagen/Schneidtabellen/HiFocus160i/SD 5 HiFo 160i FC PerCut 160/170 - St37 6-15mm @ 0\mod_1217483785530_19.doc @ 5030
 cutting tables
HiFocus 160i #5
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus+ - 1.0037 St37 ( 6 - 15 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] N2, O2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

55 6 100 - S002 Z102 S2011X S3028 - Z4020 Z501 - 1 0 50 0 0 60 9,5 3,5 2 3,5 0,2 125 2700 * 2 456 200 100

56 8 100 - S002 Z102 S2011X S3028 - Z4020 Z501 - 1 0 50 0 0 50 9,5 3,5 2 3,5 0,4 132 2000 * 2 456 200 100

57 8 100 - S002 Z102 S2011X S3028 - Z4022 Z501 - 1 0 50 0 0 50 9,5 3,5 2 3,5 0,4 130 2400 * 2 456 200 100

58 10 100 - S002 Z102 S2011X S3028 - Z4022 Z501 - 1 0 25 0 0 50 9,5 3,5 2 3,5 0,5 132 2000 * 2,2 456 200 100

59 12 100 - S002 Z102 S2011X S3028 - Z4022 Z501 - 1 0 50 0 10 50 9,5 4 2 4 0,5 133 1750 * 2,4 456 200 100

60 15 100 - S002 Z102 S2011X S3028 - Z4022 Z501 - 1 0 50 0 10 50 9,5 4,5 2 4,5 0,6 134 1300 * 2,7 456 200 100

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

456 0 6 - S002 Z102 S2011X S3028 - Z4022 Z501 - 1 0 0 0 0 0 3 3 2 3,5 0 74 3200 * 0 0 200 4

55
6.0 mm
1.0037 St37 HiFocus+
nozzle : S2011x more : F1
100A
PG1 PG2 PG3 WG1 WG2

Air O2 N2
50 60
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 9.5 p2 9.5 bar v : 2700 mm/min

Pos: 1.13 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.14 /Anlagen/Schneidtabellen/HiFocus160i/SD 6 HiFo 160i FC PerCut 160/170 - St37 10-30mm @ 0\mod_1217484828607_19.doc @ 5034
cutting tables
HiFocus 160i #6
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus+ - 1.0037 St37 ( 10 - 30 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] N2, O2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

61 10 115 - S002 Z102 S2012X S3028 - Z4022 Z501 - 1 0 50 0 0 50 9,5 4 2 4 0,4 132 2200 * 1,9 457 200 100

62 10 130 - S002 Z102 S2012X S3028 - Z4022 Z501 - 1 0 60 0 0 60 9,5 4 2 4 0,4 131 2600 * 2 457 200 150

63 12 130 - S002 Z102 S2012X S3028 - Z4022 Z501 - 1 0 60 0 0 75 9,5 4 2 4 0,4 132 2200 * 2 457 200 150

64 15 130 - S002 Z102 S2012X S3028 - Z4022 Z501 - 1 0 60 0 0 80 9,5 4,5 2 4,5 0,4 137 1800 * 2,4 457 200 150

65 18 130 - S002 Z102 S2012X S3028 - Z4022 Z501 - 2 0 60 0 0 85 9,5 5 2,5 6 0,5 146 1200 * 2,6 457 200 150

66 20 130 - S002 Z102 S2012X S3028 - Z4022 Z501 - 2 0 60 0 0 90 9,5 5 2,5 7 0,6 148 850 * 2,8 457 200 150

67 25 130 - S002 Z102 S2012X S3028 - Z4025 Z501 - 2 0 60 0 10 99 9,5 5 3 8 0,8 158 600 * 3 457 200 150

68 30 130 - S002 Z102 S2012X S3028 - Z4030 Z501 - 2 0 60 0 25 99 9,5 5 3,5 9 1 164 450 * 3,2 457 200 150

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

457 0 8 - S002 Z102 S2012X S3028 - Z4025 Z501 - 1 0 0 0 0 0 3 3 2 3,5 0 60 3400 * 0 0 200 4

61
10 mm
1.0037 St37 HiFocus+
nozzle : S2012x more : F1
115A
PG1 PG2 PG3 WG1 WG2

Air O2 N2
50 50
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 9.5 p2 9.5 bar v : 2200 mm/min

Pos: 1.15 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.16 /Anlagen/Schneidtabellen/HiFocus160i/SD 7 HiFo 160i FC PerCut 160/170 - St37 12-25mm @ 0\mod_1216382077254_19.doc @ 4749
 cutting tables
HiFocus 160i #7
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus+ - 1.0037 St37 ( 12 - 25 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] N2, O2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

69 12 160 - S002 Z102 S2014X S3028 - Z4022 Z501 - 2 0 60 0 0 50 9,5 4 2 4 0,4 135 2400 * 2,4 458 200 200

70 15 160 - S002 Z102 S2014X S3028 - Z4022 Z501 - 2 0 60 0 0 60 9,5 4,5 2 4,5 0,4 136 2000 * 2,6 458 200 200

71 18 160 - S002 Z102 S2014X S3028 - Z4022 Z501 - 2 0 60 0 0 80 9,5 5 2,5 6 0,5 142 1800 * 2,8 458 200 200

72 20 160 - S002 Z102 S2014X S3028 - Z4025 Z501 - 2 0 60 0 10 80 9,5 5 2,5 7 0,6 146 1400 * 3 458 200 200

73 25 160 - S002 Z102 S2016X S3028 - Z4025 Z501 - 2 0 60 0 10 90 9,5 5 2,5 7 0,8 150 1200 * 3,2 459 200 200

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

458 0 10 - S002 Z102 S2014X S3028 - Z4030 Z501 - 2 0 0 0 0 0 3 3 2 3,5 0 60 3600 * 0 0 200 4

459 0 12 - S002 Z102 S2016X S3028 - Z4030 Z501 - 2 0 0 0 0 0 3 3 2 3,5 0 62 3600 * 0 0 200 4

69
12 mm
1.0037 St37
nozzle : S2014x more : F1
HiFocus+
160A
PG1 PG2 PG3 WG1 WG2

Air O2 N2
60 50
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure:p1 9.5 p2 9.5 bar v : 2400 mm/min

Pos: 1.17 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.18 /Anlagen/Schneidtabellen/HiFocus160i/SD 8 HiFo 160i FC PerCut 160/170 - St37 20-50mm @ 0\mod_1216382489960_19.doc @ 4753
cutting tables
HiFocus 160i #8
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F - 1.0037 St37 ( 20 - 50 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] O2, N2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

115 20 160 - S012 Z111 S2116X S3008 - Z4140 Z501 Z111A 2 0 98 0 20 70 5,8 6 3 8 0,5 142 1000 * 3 464 200 200

116 25 160 - S012 Z111 S2116X S3008 - Z4140 Z501 Z111A 2 0 98 0 20 85 5,8 6 4 9 0,8 144 650 * 3,2 464 200 200

117 30 160 - S012 Z111 S2116X S3008 - Z4140 Z501 Z111A 2 0 98 0 20 99 5,8 0 4 0 0 145 550 * 3,4 464 200 200

118 35 160 - S012 Z111 S2116X S3008 - Z4140 Z501 Z111A 2 0 98 0 20 99 5,8 0 4 0 0 148 450 * 3,6 464 200 200

119 40 160 - S012 Z111 S2116X S3008 - Z4140 Z501 Z111A 2 0 98 0 20 99 5,8 0 4 0 0 149 400 * 4 464 200 200

120 45 160 - S012 Z111 S2116X S3008 - Z4140 Z501 Z111A 2 0 98 0 20 99 5,8 0 4 0 0 150 300 * 4,2 464 200 200

121 50 160 - S012 Z111 S2116X S3008 - Z4140 Z501 Z111A 2 0 98 0 20 99 5,8 0 4 0 0 152 200 * 4,4 464 200 200

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

464 0 10 - S012 Z111 S2116X S3008 - Z4140 Z501 Z111A 2 0 0 0 0 0 3 4 2,5 4 0 64 3000 * 0 0 200 4

115
20 mm
1.0037 St37
nozzle : S2116x more :
HiFocus F
160A
F1

PG1 PG2 PG3 WG1 WG2

Air O2 O2 N2
98 20 70
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure:p1 5.8 p2 5.8 bar v : 1000 mm/min

Pos: 1.19 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.20 /Anlagen/Schneidtabellen/HiFocus160i/SD 9 HiFo 160i FC PerCut 160/170 - St37 M @ 0\mod_1216382713564_19.doc @ 4757
 cutting tables
HiFocus 160i #9
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 marking - 1.0037 St37

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

450 0 5 - S002 Z101 S2006X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 81 3000 * 0 0 200 4

451 0 5 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 82 3000 * 0 0 200 4

452 0 5 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

453 0 5 - S002 Z102 S2008X S3028 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

456 0 6 - S002 Z102 S2011X S3028 - Z4022 Z501 - 1 0 0 0 0 0 3 3 2 3,5 0 74 3200 * 0 0 200 4

457 0 8 - S002 Z102 S2012X S3028 - Z4025 Z501 - 1 0 0 0 0 0 3 3 2 3,5 0 60 3400 * 0 0 200 4

458 0 10 - S002 Z102 S2014X S3028 - Z4030 Z501 - 2 0 0 0 0 0 3 3 2 3,5 0 60 3600 * 0 0 200 4

459 0 12 - S002 Z102 S2016X S3028 - Z4030 Z501 - 2 0 0 0 0 0 3 3 2 3,5 0 62 3600 * 0 0 200 4

464 0 10 - S012 Z111 S2116X S3008 - Z4140 Z501 Z111A 2 0 0 0 0 0 3 4 2,5 4 0 64 3000 * 0 0 200 4

450
0 mm
1.0037 St37
nozzle : S2006x more : F1
Marking
5A
PG1 PG2 PG3 WG1 WG2

Ar

New Data: < COPY >

Select Record: < ENTER >
OK or Error
Pressure:p1 3.0 p2 3.0 bar v : 3000 mm/min

Pos: 1.21 /Anlagen/Schneidtabellen/Text unter Schneidtabellen für Markieren @ 0\mod_1198072577197_19.doc @ 2202

Information
− adjust pierce delay to the value "zero" at profile-cutting-machine
− don't enlarge the ignition height
− the parameters for marking vary depending on material and kind of surface
− the compliance of the determined cutting height is very important
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel
Pos: 1.22 /Anlagen/Schneidtabellen/HiFocus160i/SD10 HiFo 160i FC PerCut 160/170 - CrNi 1-3mm @ 0\mod_1216618347709_19.doc @ 4770
cutting tables
HiFocus 160i #10
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus - 1.4301 CrNi ( 1 - 3 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2, Air - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

250 1 20 - S002 Z101 S2006X S3004 - Z4015 Z501 - 1 0 2 0 0 90 5,4 2 1,5 2 0 120 2500 * 1,4 450 200 4

251 1,5 20 - S002 Z101 S2006X S3004 - Z4020 Z501 - 1 0 3 0 0 90 5,4 2,5 1,5 2,5 0,2 122 1800 * 1,5 450 200 4

252 2 25 - S002 Z101 S2006X S3004 - Z4020 Z501 - 1 0 3 0 0 95 5,5 2,5 1,5 2,5 0,2 123 1450 * 1,6 450 200 4

270 2 30 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 10 0 0 0 85 5,2 2,5 1,5 2,5 0,2 124 1300 * 1,5 451 200 4

271 3 30 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 10 0 0 0 85 5,2 3 1,5 3 0,2 126 1100 * 1,5 451 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

450 0 5 - S002 Z101 S2006X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 81 3000 * 0 0 200 4

451 0 5 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 82 3000 * 0 0 200 4

250
1.0 mm
1.4301 CrNi
nozzle : S2006x more : F1
HiFocus
20A
PG1 PG2 PG3 WG1 WG2

Air O2 N 2
2 90
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.4 p2 5.4 bar v : 2500 mm/min

Pos: 1.23 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.24 /Anlagen/Schneidtabellen/HiFocus160i/SD11 HiFo 160i FC PerCut 160/170 - CrNi 1mm @ 0\mod_1216618516350_19.doc @ 4774
 cutting tables
HiFocus 160i #11
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFinox - 1.4301 CrNi ( 1 mm )

cutting records ZG [ignition gas] N2 - PG [cutting gas] N2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

200 1 30 - S042 Z101 S2007X S3008 - Z4020 Z501 - 1 95 0 0 99 80 7 3 2,5 3 0 120 5000 * 1 460 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

460 0 6 - S042 Z101 S2007X S3008 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3600 * 0 0 200 4

200
1.0 mm
1.4301 CrNi
nozzle : S2007x more : F1
HiFinox
30A
PG1 PG2 PG3 WG1 WG2

N2 N2 N /H
2 2

95 99 80
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure:p1 7.0 p2 7.0 bar v : 5000 mm/min

Pos: 1.25 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.26 /Anlagen/Schneidtabellen/HiFocus160i/SD12 HiFo 160i FC PerCut 160/170 - CrNi 4-6mm @ 0\mod_1216618791631_19.doc @ 4778
cutting tables
HiFocus 160i #12
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus - 1.4301 CrNi ( 4 - 6 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] Air - WG [swirl gas] N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

272 4 45 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 10 0 0 0 85 5,2 3 1,5 3 0,2 140 1350 * 1,7 452 200 4

273 5 45 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 10 0 0 0 85 5,2 3 2 3 0,2 142 1300 * 1,7 452 200 4

274 6 50 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 10 0 0 0 90 5,2 3 2 3 0,3 144 1200 * 1,8 452 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

452 0 5 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

272
4.0 mm
1.4301 CrNi
nozzle : S2008x more : F1
HiFocus
45A
PG1 PG2 PG3 WG1 WG2

Air N 2/H 2
10 85
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure:p1 5.2 p2 5.2 bar v : 1350 mm/min

Pos: 1.27 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.28 /Anlagen/Schneidtabellen/HiFocus160i/SD13 HiFo 160i FC PerCut 160/170 - CrNi 2-6mm @ 0\mod_1216618969166_19.doc @ 4782
 cutting tables
HiFocus 160i #13
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFinox - 1.4301 CrNi ( 2 - 6 mm )

cutting records ZG [ignition gas] N2 - PG [cutting gas] N2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

201 2 55 - S042 Z101 S2008X S3008 - Z4020 Z501 - 1 95 0 0 99 60 7,4 3 2 3 0,1 127 4000 * 1,1 461 200 4

202 3 55 - S042 Z101 S2008X S3008 - Z4020 Z501 - 1 95 0 0 99 60 7,4 3 2 3 0,2 124 2600 * 1,2 461 200 4

203 4 60 - S042 Z101 S2008X S3008 - Z4020 Z501 - 1 95 0 0 90 60 7,4 3 2 3 0,2 125 2200 * 1,3 461 200 4

204 5 60 - S042 Z101 S2008X S3008 - Z4020 Z501 - 1 95 0 0 99 80 7,4 3,5 2 3,5 0,3 127 2000 * 1,4 461 200 4

205 6 60 - S042 Z101 S2008X S3008 - Z4020 Z501 - 1 95 0 0 99 80 7,4 4 3 4 0,4 128 1800 * 1,5 461 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

461 0 6 - S042 Z101 S2008X S3008 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 84 3000 * 0 0 200 4

201
2.0 mm
1.4301 CrNi
nozzle : S2008x more : F1
HiFinox
55A
PG1 PG2 PG3 WG1 WG2

N2 N 2 N 2/H 2
95 99 60
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 7.4 p2 7.4 bar v : 4000 mm/min

Pos: 1.29 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.30 /Anlagen/Schneidtabellen/HiFocus160i/SD14 HiFo 160i FC PerCut 160/170 - CrNi 6-25mm @ 0\mod_1216619264307_19.doc @ 4786
cutting tables
HiFocus 160i #14
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F - 1.4301 CrNi ( 6 - 25 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

300 6 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 73 0 30 99 90 5,1 4 3 4 0,2 116 2000 * 2 466 200 4

301 8 120 - S052 Z111 S2514X S3008 - Z4530 Z501 - 2 73 0 30 99 95 5,1 4 3 4 0,2 118 1350 * 2,2 465 200 4

302 8 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 73 0 30 99 95 5,1 4 3 4 0,3 116 1600 * 2,2 466 200 4

303 10 115 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 73 0 30 99 95 5,1 4 3 4 0,3 126 900 * 2,4 466 200 4

304 10 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 73 0 30 99 95 5,1 4 3 4 0,4 128 1200 * 2,5 466 200 4

305 12 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 73 0 30 99 99 5,1 4 3 5 0,5 129 1000 * 2,6 466 200 4

306 16 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 73 0 30 99 99 5,1 5 3 6 0,7 127 950 * 2,8 466 200 4

307 20 130 - S052 Z111 S2516X S3008 - Z4540 Z501 - 2 73 0 30 99 99 5,1 5 3,5 8 0,9 136 550 * 3,2 466 200 4

308 25 130 - S052 Z111 S2516X S3008 - Z4540 Z501 - 2 73 0 30 99 99 5,2 6 4 9 1 138 400 * 3,4 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

465 0 10 - S052 Z111 S2514X S3008 - Z4530 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 56 3000 * 0 0 200 4

466 0 12 - S052 Z111 S2516X S3008 - Z4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

300
6.0 mm
1.4301 CrNi
nozzle : S2516x more : F1
HiFocus F
130A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
73 30 99 90
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure:p1 5.1 p2 5.1 bar v : 2000 mm/min

Pos: 1.31 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.32 /Anlagen/Schneidtabellen/HiFocus160i/SD15 HiFo 160i FC PerCut 160/170 - CrNi 6-12mm @ 0\mod_1216619687893_19.doc @ 4790
 cutting tables
HiFocus 160i #15
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F+ - 1.4301 CrNi ( 6 - 12 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

320 6 130 - S052 Z111 S2516X S3018 - Z4530 Z501 - 2 95 0 25 99 95 6,3 4 3 4 0,4 124 1600 * 2,4 466 200 4

321 8 130 - S052 Z111 S2516X S3018 - Z4530 Z501 - 2 95 0 25 99 95 6,3 4 3 4 0,4 126 1400 * 2,5 466 200 4

322 10 130 - S052 Z111 S2516X S3018 - Z4535 Z501 - 2 95 0 30 99 95 6,3 4,5 3 4,5 0,5 127 1150 * 2,6 466 200 4

323 12 130 - S052 Z111 S2516X S3018 - Z4535 Z501 - 2 95 0 30 99 95 6,3 4,5 3 4,5 0,5 128 950 * 2,8 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

466 0 12 - S052 Z111 S2516X S3008 - Z4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

320
6.0 mm
1.4301 CrNi
nozzle : S2516x more : F1
HiFocus F+
130A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
95 25 99 95
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure:p1 6.3 p2 6.3 bar v : 1600 mm/min

Pos: 1.33 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.34 /Anlagen/Schneidtabellen/HiFocus160i/SD16 HiFo 160i FC PerCut 160/170 - CrNi 10-35mm @ 0\mod_1216619898237_19.doc @ 4794
cutting tables
HiFocus 160i #16
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F - 1.4301 CrNi ( 10 - 35 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

309 10 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 75 0 35 99 99 5,2 4 4 4 0,2 130 1400 * 2,5 467 200 4

310 12 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 75 0 35 99 99 5,2 4 4 4 0,3 132 1100 * 2,7 467 200 4

311 15 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 75 0 35 99 99 5,2 4 4 4 0,4 133 950 * 2,8 467 200 4

312 18 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 75 0 35 99 99 5,2 5 4 5 0,4 136 850 * 2,9 467 200 4

313 20 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 75 0 35 99 99 5,2 5 4,5 6 0,6 138 700 * 3 467 200 4

314 25 160 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 75 0 35 99 99 5,2 5 5 8 0,9 140 550 * 3,2 467 200 4

315 30 160 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 75 0 35 99 99 5,2 0 5 0 0 142 400 * 3,4 467 200 4

316 35 160 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 75 0 45 99 99 5,2 0 5,5 0 0 145 250 * 3,8 467 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

467 0 14 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

309
10 mm
1.4301 CrNi
nozzle : S2518x more : F1
HiFocus F
160A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
75 35 99 99
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.2 p2 5.2 bar v : 1400 mm/min

Pos: 1.35 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.36 /Anlagen/Schneidtabellen/HiFocus160i/SD17 HiFo 160i FC PerCut 160/170 - CrNi 12-30mm @ 0\mod_1216620027426_19.doc @ 4798
 cutting tables
HiFocus 160i #17
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F+ - 1.4301 CrNi ( 12 - 30 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

324 12 160 - S052 Z111 S2518X S3018 - Z4540 Z501 - 2 98 0 35 99 99 6,5 4,5 3,5 4,5 0,5 125 1100 * 2,8 467 200 4

325 15 160 - S052 Z111 S2518X S3018 - Z4540 Z501 - 2 98 0 35 99 99 6,5 5 3,5 5 0,6 126 950 * 2,8 467 200 4

326 18 160 - S052 Z111 S2518X S3018 - Z4540 Z501 - 2 98 0 35 99 99 6,5 5 3,5 6 0,7 128 850 * 2,9 467 200 4

327 20 160 - S052 Z111 S2518X S3018 - Z4545 Z501 - 2 98 0 35 99 99 6,5 5 3,5 7 0,8 130 700 * 3 467 200 4

328 25 160 - S052 Z111 S2518X S3018 - Z4545 Z501 - 2 98 0 35 99 99 6,5 5,5 4 8 0,9 134 500 * 3,2 467 200 4

329 30 160 - S052 Z111 S2518X S3018 - Z4545 Z501 - 2 98 0 35 99 99 6,5 0 4 0 0 142 350 * 3,6 467 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

467 0 14 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

324
12 mm
1.4301 CrNi
nozzle : S2518x
HiFocus F+
more : F1
160A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
98 35 99 99
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 6.5 p2 6.5 bar v : 1100 mm/min

Pos: 1.37 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.38 /Anlagen/Schneidtabellen/HiFocus160i/SD18 HiFo 160i FC PerCut 160/170 - CrNi M @ 0\mod_1216620165983_19.doc @ 4802
cutting tables
HiFocus 160i #18
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 marking - 1.4301 CrNi

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

460 0 6 - S042 Z101 S2007X S3008 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3600 * 0 0 200 4

461 0 6 - S042 Z101 S2008X S3008 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 84 3000 * 0 0 200 4

465 0 10 - S052 Z111 S2514X S3008 - Z4530 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 56 3000 * 0 0 200 4

466 0 12 - S052 Z111 S2516X S3008 - Z4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

467 0 14 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

460 1.4301
0 mm
CrNi
nozzle : S2007x more : F1
Marking
6A
PG1 PG2 PG3 WG1 WG2

Ar

New Data : < COPY >

Select Record: < ENTER >
OK or Error
Pressure :p1 3.0 p2 3.0 bar v : 3600 mm/min

Pos: 1.39 /Anlagen/Schneidtabellen/Text unter Schneidtabellen für Markieren @ 0\mod_1198072577197_19.doc @ 2202

Information
− adjust pierce delay to the value "zero" at profile-cutting-machine
− don't enlarge the ignition height
− the parameters for marking vary depending on material and kind of surface
− the compliance of the determined cutting height is very important
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel
Pos: 1.40 /Anlagen/Schneidtabellen/HiFocus160i/SD19 HiFo 160i FC PerCut 160/170 - CrNiTi 5-15mm @ 0\mod_1216620284042_19.doc @ 4806
 cutting tables
HiFocus 160i #19
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F - 1.4571 CrNiTi ( 5 - 15 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

350 5 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 70 0 40 99 50 5,1 3,5 2,5 3,5 0,2 121 1750 * 1,8 466 200 4

351 6 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 70 0 40 99 60 5,1 4 2,5 4 0,2 123 1650 * 2 466 200 4

352 8 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 70 0 40 99 70 5,1 4 2,5 4 0,3 124 1550 * 2,2 466 200 4

353 10 130 - S052 Z111 S2516X S3008 - Z4540 Z501 - 2 70 0 40 99 70 5,1 4 2,5 4 0,3 125 1300 * 2,5 466 200 4

354 12 130 - S052 Z111 S2516X S3008 - Z4540 Z501 - 2 70 0 40 99 70 5,1 4 3 5 0,4 127 1200 * 2,6 466 200 4

355 15 130 - S052 Z111 S2516X S3008 - Z4540 Z501 - 2 70 0 40 99 80 5,1 4 3 6 0,4 132 900 * 2,8 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

466 0 12 - S052 Z111 S2516X S3008 - Z4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

350
5.0 mm
1.4571 CrNiTi
nozzle : S2516x more :
HiFocus F
130A
F1

PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
70 40 99 50
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.1 p2 5.1 bar v : 1750 mm/min

Pos: 1.41 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.42 /Anlagen/Schneidtabellen/HiFocus160i/SD20 HiFo 160i FC PerCut 160/170 - CrNiTI 6-8mm @ 0\mod_1216620889330_19.doc @ 4810
cutting tables
HiFocus 160i #20
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F+ - 1.4571 CrNiTi ( 6 - 8 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

370 6 130 - S052 Z111 S2516X S3018 - Z4530 Z501 - 2 98 0 50 99 90 6,5 4 3 4 0,4 126 1650 * 2 466 200 4

371 8 130 - S052 Z111 S2516X S3018 - Z4530 Z501 - 2 98 0 50 99 90 6,5 4 3 4 0,4 127 1400 * 2,2 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

466 0 12 - S052 Z111 S2516X S3008 - Z4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

370
6.0 mm
1.4571 CrNiTi
nozzle : S2516x more :
HiFocus F+
130A
F1

PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
98 50 99 90
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 6.5 p2 6.5 bar v : 1650 mm/min

Pos: 1.43 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.44 /Anlagen/Schneidtabellen/HiFocus160i/SD21 HiFo 160i FC PerCut 160/170 - CrNiTi 10-30mm @ 0\mod_1216620986455_19.doc @ 4814
 cutting tables
HiFocus 160i #21
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F - 1.4571 CrNiTi ( 10 - 30 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

356 10 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 75 0 50 99 99 5,5 4 4 4 0,2 132 1500 * 2,2 467 200 4

357 12 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 75 0 50 99 99 5,5 4 4 5 0,3 134 1200 * 2,4 467 200 4

358 15 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 75 0 50 99 99 5,5 4 4 5 0,4 136 1000 * 2,8 467 200 4

359 20 160 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 75 0 50 99 99 5,5 4,5 5 6 0,7 138 750 * 3,2 467 200 4

360 25 160 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 75 0 50 99 99 5,5 5 4,5 8 0,9 140 550 * 3,4 467 200 4

361 30 160 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 75 0 50 99 99 5,5 0 4,5 0 0 144 400 * 3,8 467 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

467 0 14 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

356
10 mm
1.4571 CrNiTi
nozzle : S2518x more : F1
HiFocus F
160A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
75 50 99 99
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.5 p2 5.5 bar v : 1500 mm/min

Pos: 1.45 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.46 /Anlagen/Schneidtabellen/HiFocus160i/SD22 HiFo 160i FC PerCut 160/170 - Alu 1-8mm @ 0\mod_1216621065642_19.doc @ 4818
cutting tables
HiFocus 160i #22
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus - 3.3536 AlMg3 ( 1 - 8 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] Air - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

400 1 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 8 0 0 95 0 5,5 3 2 3 0,1 139 3800 * 1,5 450 200 30

401 2 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 8 0 0 85 0 5,5 3 2 3 0,1 141 2600 * 1,5 451 200 30

402 3 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 8 0 0 95 0 5,5 3 2 3 0,1 145 2300 * 1,6 451 200 30

403 4 35 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 10 0 0 70 0 5,6 3,5 2 3,5 0,1 140 1100 * 1,6 451 200 30

404 4 45 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 10 0 0 0 90 5,6 3,5 2 3,5 0,1 143 1500 * 1,6 452 200 50

405 5 50 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 10 0 0 0 85 5,6 3,5 2 3,5 0,1 146 1400 * 1,9 452 200 50

406 6 50 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 10 0 0 0 85 5,6 3,5 2 3,5 0,2 148 1300 * 1,8 452 200 50

407 8 50 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 12 0 0 0 85 5,6 3,5 2 3,5 0,2 150 1100 * 1,6 452 200 50

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

450 0 5 - S002 Z101 S2006X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 81 3000 * 0 0 200 4

451 0 5 - S002 Z101 S2007X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 82 3000 * 0 0 200 4

452 0 5 - S002 Z101 S2008X S3004 - Z4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

400
1.0 mm
3.3536 AlMg3
nozzle : S2007x
HiFocus
more : F1
35A
PG1 PG2 PG3 WG1 WG2

Air N2
8 95
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.5 p2 5.5 bar v : 3800 mm/min

Pos: 1.47 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.48 /Anlagen/Schneidtabellen/HiFocus160i/SD23 HiFo 160i FC PerCut 160/170 - Alu 6-25mm @ 0\mod_1216621181580_19.doc @ 4822
 cutting tables
HiFocus 160i #23
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F - 3.3536 AlMg3 ( 6 - 25 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

420 6 115 - S052 Z111 S2514X S3008 - Z4530 Z501 - 2 70 0 30 99 70 5,5 4 2,5 4 0,1 138 2400 * 2,5 465 200 4

421 6 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 70 0 30 99 75 5,5 4 2,5 4 0,1 140 3200 * 2,7 466 200 4

422 8 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 75 0 35 99 75 5,5 4 2,5 4 0,2 138 2200 * 2,9 466 200 4

423 10 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 75 0 35 99 75 5,5 4 2,5 4 0,3 140 1600 * 3 466 200 4

424 12 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 75 0 35 99 80 5,5 4 2,5 5 0,4 140 1400 * 3,1 466 200 4

425 16 130 - S052 Z111 S2516X S3008 - Z4530 Z501 - 2 75 0 35 99 80 5,5 4 3 6 0,5 142 1000 * 3,3 466 200 4

426 20 130 - S052 Z111 S2516X S3008 - Z4540 Z501 - 2 80 0 35 99 80 5,5 5 3,5 8 0,6 146 800 * 3,5 466 200 4

427 25 130 - S052 Z111 S2516X S3008 - Z4540 Z501 - 2 80 0 35 99 80 5,5 6 3,5 9 0,9 155 600 * 3,8 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

465 0 10 - S052 Z111 S2514X S3008 - Z4530 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 56 3000 * 0 0 200 4

466 0 12 - S052 Z111 S2516X S3008 - Z4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

420
6.0 mm
3.3536 AlMg3
nozzle : S2514x more : F1
HiFocusF
115A
PG1 PG2 PG3 WG1 WG2

Ar H2 N2 N2 /H2
70 30 99 70
New Data : < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.5 p2 5.5 bar v : 2400 mm/min

Pos: 1.49 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.50 /Anlagen/Schneidtabellen/HiFocus160i/SD24 HiFo 160i FC PerCut 160/170 - Alu 8-10mm @ 0\mod_1216621332892_19.doc @ 4826
cutting tables
HiFocus 160i #24
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F+ - 3.3536 AlMg3 ( 8 - 10 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

440 8 130 - S052 Z111 S2516X S3018 - Z4530 Z501 - 2 90 0 45 99 75 7 4 3 4 0,4 126 1850 * 2,9 466 200 4

441 10 130 - S052 Z111 S2516X S3018 - Z4530 Z501 - 2 98 0 50 99 75 7 4 3 4 0,5 128 1600 * 3 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

466 0 12 - S052 Z111 S2516X S3008 - Z4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

440
8.0 mm
3.3536 AlMg3
nozzle : S2516x more : F1
HiFocusF+
130A
PG1 PG2 PG3 WG1 WG2

Ar H2 N2 N2 /H2
90 45 99 75
New Data: < COPY >
Select Record : < ENTER >
OK or Error
Pressure :p1 7.0 p2 7.0 bar v : 1850 mm/min

Pos: 1.51 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.52 /Anlagen/Schneidtabellen/HiFocus160i/SD25 HiFo 160i FC PerCut 160/170 - Alu 10-35mm @ 0\mod_1216621493767_19.doc @ 4830
 cutting tables
HiFocus 160i #25
FlowControl 1 - PerCut 160/170
data version: 11 - valid from: 17.07.2008 HiFocus F - 3.3536 AlMg3 ( 10 - 35 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

428 10 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 80 0 35 99 85 5,6 4 3 4 0,2 140 1800 * 2,5 467 200 4

429 12 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 80 0 40 99 85 5,6 4 3 4 0,3 142 1650 * 2,7 467 200 4

430 15 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 80 0 40 99 90 5,6 4 3 5 0,3 145 1250 * 2,9 467 200 4

431 20 160 - S052 Z111 S2518X S3008 - Z4530 Z501 - 2 80 0 40 99 95 5,6 4 3,5 6 0,5 148 1000 * 3 467 200 4

432 25 160 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 80 0 40 99 99 5,6 5 3,5 8 0,6 150 800 * 3,1 467 200 4

433 30 160 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 80 0 40 99 99 5,6 0 4 0 0 152 600 * 3,3 467 200 4

434 35 160 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 85 0 45 99 99 5,6 0 4 0 0 156 400 * 3,5 467 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

467 0 14 - S052 Z111 S2518X S3008 - Z4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

428
10 mm
3.3536 AlMg3
nozzle : S2518x mehr : F1
HiFocusF
160A
PG1 PG2 PG3 WG1 WG2

Ar H2 N2 N2 /H2
80 35 99 85
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.6 p2 5.6 bar v : 1800 mm/min

Pos: 1.53 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.54 /Plasmabrenner/PerCut 160/170/VT-Übersicht-PerCut160/170 @ 0\mod_1217417532225_19.doc @ 5000

cutting tables

Pos: 1.55 /Überschriften/1.1/Schneidtabellen PerCut 160/170 3D @ 0\mod_1217425235824_19.doc @ 5023

 cutting tables
Cutting tables PerCut 160/170 3D
Pos: 1.56 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/Deckblatt_HiFo160i - 3D @ 0\mod_1216621713127_19.doc @ 4835

HiFocus 160i Overview

FlowControl 1
data version: 4 - valid from: 19.04.2007

torch material thickness cutting current commentary #

PerCut 160/170 3D 1.0330 St12 0,5 - 1.5 mm 20 - 25 A HiFocus 1
1.0330 St12 1- 6 mm 35 - 50 A HiFocus 2

1.0037 St37 5- 6 mm 50 A HiFocus 3

1.0037 St37 4 - 10 mm 60 A HiFocus+ 4
1.0037 St37 6 - 15 mm 80 - 100 A HiFocus+ 5
1.0037 St37 10 - 25 mm 115 - 130 A HiFocus+ 6
1.0037 St37 2 - 25 mm 120 - 130 A HiFocus F 7
1.0037 St37 5 - 10 A marking 8

1.4301 CrNi 1- 3 mm 20 - 30 A HiFocus 9

1.4301 CrNi 1 mm 30 A HiFinox 10
1.4301 CrNi 4- 6 mm 45 - 50 A HiFocus 11
1.4301 CrNi 2- 6 mm 55 - 60 A HiFinox 12
1.4301 CrNi 6 - 25 mm 115 - 130 A HiFocus F 13
1.4301 CrNi 6 - 12 mm 130 A HiFocus F+ 14
1.4301 CrNi 10 - 20 mm 160 A HiFocus F 15
1.4301 CrNi 12 - 20 mm 160 A HiFocus F+ 16
1.4301 CrNi 6 - 14 A marking 17

1.4571 CrNiTi 5 - 15 mm 130 A HiFocus F 18

1.4571 CrNiTi 6- 8 mm 130 A HiFocus F+ 19
1.4571 CrNiTi 10 - 20 mm 160 A HiFocus F 20

3.3536 AlMg3 1- 8 mm 35 - 50 A HiFocus 21

3.3536 AlMg3 6 - 25 mm 115 - 130 A HiFocus F 22
3.3536 AlMg3 8 - 10 mm 130 A HiFocus F+ 23
3.3536 AlMg3 10 - 25 mm 160 A HiFocus F 24

Consumable part overview of the plasma torch type PerCut160/170

with 3D consumables
Pos: 1.57 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD 1 HiFo 160i FC PerCut 160/170 - St12 0,5-1,5mm @ 0\mod_1216622264033_19.doc @ 4840
cutting tables
HiFocus 160i #1
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus - 1.0330 St12 ( 0.5 - 1.5 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] O2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

1 0,5 20 - R002 Z101 R2006 R3004 - Y4015 Z501 - 1 0 3 0 7 0 5,2 2 1,5 2 0 106 5000 * 1,2 450 200 30

2 0,8 20 - R002 Z101 R2006 R3004 - Y4015 Z501 - 1 0 3 0 8 0 5,2 2 1,5 2 0 108 4000 * 1,2 450 200 30

3 1 20 - R002 Z101 R2006 R3004 - Y4015 Z501 - 1 0 3 0 8 0 5,2 2 1,5 2 0 110 3500 * 1,3 450 200 30

4 1,5 25 - R002 Z101 R2006 R3004 - Y4015 Z501 - 1 0 3 0 8 0 5,2 2 2 2 0 112 3000 * 1,3 450 200 30

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

450 0 5 - R002 Z101 R2006 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 81 3000 * 0 0 200 4

1
0.5 mm
1.0330 St12
nozzle : R2006
HiFocus
more : F1
20A
PG1 PG2 PG3 WG1 WG2

Air O2 O2
3 7
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure:p1 5.2 p2 5.2 bar v : 5000 mm/min

Pos: 1.58 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.59 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD 2 HiFo 160i FC PerCut 160/170 - St12 1-6mm @ 0\mod_1216622399205_19.doc @ 4844
 cutting tables
HiFocus 160i #2
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus - 1.0330 St12 ( 1 - 6 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] O2, N2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

5 1 35 - R002 Z101 R2007 R3004 - Y4020 Z501 - 1 0 5 0 20 1 5,2 2 2 2 0 113 2400 * 1,4 451 200 30

6 1,5 35 - R002 Z101 R2007 R3004 - Y4020 Z501 - 1 0 7 0 20 1 5,2 2 1,5 2 0,1 115 2000 * 1,4 451 200 30

7 2 35 - R002 Z101 R2007 R3004 - Y4020 Z501 - 1 0 7 0 20 1 5,2 2,5 1,5 2,5 0,1 116 1600 * 1,4 451 200 30

8 3 35 - R002 Z101 R2007 R3004 - Y4020 Z501 - 1 0 7 0 20 1 5,2 3 2 3 0,1 118 1200 * 1,4 451 200 30

9 4 35 - R002 Z101 R2007 R3004 - Y4020 Z501 - 1 0 7 0 20 1 5,2 3 2 3 0,1 119 900 * 1,5 451 200 30

10 5 35 - R002 Z101 R2007 R3004 - Y4020 Z501 - 1 0 7 0 20 1 5,2 3,5 2 3,5 0,2 119 750 * 1,5 451 200 30

11 6 35 - R002 Z101 R2007 R3004 - Y4020 Z501 - 1 0 7 0 20 2 5,2 3,5 2,5 3,5 0,2 120 650 * 1,6 451 200 30

12 2 50 - R002 Z101 R2008 R3004 - Y4020 Z501 - 1 0 8 0 20 1 5,2 2,5 2 2,5 0,1 112 2600 * 1,4 452 200 50

13 3 50 - R002 Z101 R2008 R3004 - Y4020 Z501 - 1 0 8 0 20 1 5,2 2,5 2 2,5 0,1 112 2200 * 1,6 452 200 50

14 4 50 - R002 Z101 R2008 R3004 - Y4020 Z501 - 1 0 8 0 20 1 5,2 2,5 2 2,5 0,1 115 1000 * 2 452 200 50

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

451 0 5 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 82 3000 * 0 0 200 4

452 0 5 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

5 1.0330
1.0 mm
St12
nozzle : R2007
HiFocus
mehr : F1
35A
PG1 PG2 PG3 WG1 WG2

Air O2 O2 N2
5 20 1
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.2 p25.2 bar v : 2400 mm/min

Pos: 1.60 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.61 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD 3 HiFo 160i FC PerCut 160/170 - St 37 5-6mm @ 0\mod_1216622517642_19.doc @ 4848
cutting tables
HiFocus 160i #3
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus - 1.0037 St37 ( 5 - 6 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] O2, N2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

15 5 50 - R002 Z101 R2008 R3004 - Y4020 Z501 - 1 0 8 0 20 2 5,2 3,5 2 3,5 0,2 120 800 * 2 452 200 50

16 6 50 - R002 Z101 R2008 R3004 - Y4020 Z501 - 1 0 8 0 20 2 5,2 3,5 2,5 3,5 0,2 125 750 * 2,1 452 200 50

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

452 0 5 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

15 1.0037
5 mm
St37
nozzle : R2008
HiFocus
mehr : F1
50A
PG1 PG2 PG3 WG1 WG2

Air O2 O2 N2
8 20 2
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.2 p2 5.2 bar v : 800 mm/min

Pos: 1.62 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.63 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD 4 HiFo 160i FC PerCut 160/170 - St37 4-10mm @ 0\mod_1216622699767_19.doc @ 4852
 cutting tables
HiFocus 160i #4
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus+ - 1.0037 St37 ( 4 - 10 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] N2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

50 4 60 - R002 Z102 R2008 R3028 - R4020 Z501 - 1 0 20 0 0 50 9,5 3 1,5 3 0,2 119 2200 * 1,4 453 200 50

51 5 60 - R002 Z102 R2008 R3028 - R4020 Z501 - 1 0 20 0 0 30 9,5 3 2 3 0,3 123 1800 * 1,6 453 200 50

52 6 60 - R002 Z102 R2008 R3028 - R4020 Z501 - 1 0 20 0 0 40 9,5 3 2 3 0,3 125 1700 * 1,8 453 200 50

53 8 60 - R002 Z102 R2008 R3028 - R4020 Z501 - 1 0 50 0 0 60 9,5 3,5 2 3,5 0,4 130 1550 * 1,8 453 200 50

54 10 60 - R002 Z102 R2008 R3028 - R4020 Z501 - 1 0 50 0 0 45 9,5 3,5 2 3,5 0,4 127 1000 * 1,9 453 200 50

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

453 0 5 - R002 Z102 R2008 R3028 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

50
4.0 mm
1.0037 St37
nozzle : R2008
HiFocus+
more : F1
60A
PG1 PG2 PG3 WG1 WG2

Air O2 N2
20 50
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 9.5 p2 9.5 bar v : 2200 mm/min

Pos: 1.64 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.65 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD 5 HiFo 160i FC PerCut 160/170 - St 37 6-15mm @ 0\mod_1216622897861_19.doc @ 4856
cutting tables
HiFocus 160i #5
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus+ - 1.0037 St37 ( 6 - 15 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] N2, O2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

55 10 80 - R002 Z102 R2009 R3028 - R4022 Z501 - 1 0 25 0 0 50 9,5 3,5 2 3,5 0,3 135 1700 * 2 454 200 70

56 6 100 - R002 Z102 R2011 R3028 - R4020 Z501 - 1 0 50 0 0 60 9,5 3,5 2 3,5 0,2 125 2700 * 2 456 200 100

57 8 90 - R002 Z102 R2010 R3028 - R4020 Z501 - 1 0 50 0 0 50 9,5 3,5 2 3,5 0,4 132 1800 * 2 455 200 100

58 8 100 - R002 Z102 R2011 R3028 - R4022 Z501 - 1 0 50 0 0 50 9,5 3,5 2 3,5 0,4 130 2400 * 2 456 200 100

59 10 100 - R002 Z102 R2011 R3028 - R4022 Z501 - 1 0 25 0 0 50 9,5 3,5 2 3,5 0,5 132 2000 * 2,2 456 200 100

60 12 100 - R002 Z102 R2011 R3028 - R4022 Z501 - 1 0 50 0 10 50 9,5 4 2 4 0,5 133 1750 * 2,4 456 200 100

61 15 100 - R002 Z102 R2011 R3028 - R4022 Z501 - 1 0 50 0 10 50 9,5 4,5 2 4,5 0,6 134 1700 * 2,7 456 200 100

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

454 0 5 - R002 Z102 R2009 R3028 - R4020 Z501 - 1 0 0 0 0 0 3 3 2 3 0 83 3000 * 0 0 200 4

455 0 6 - R002 Z102 R2010 R3028 - R4020 Z501 - 1 0 0 0 0 0 3 3 2 3 0 78 3000 * 0 0 200 4

456 0 6 - R002 Z102 R2011 R3028 - R4022 Z501 - 1 0 0 0 0 0 3 3 2 3,5 0 74 3200 * 0 0 200 4

55
10 mm
1.0037 St37
nozzle : R2009
HiFocus+
more : F1
80A
PG1 PG2 PG3 WG1 WG2

Air O2 N2
25 50
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 9.5 p2 9.5 bar v : 1700 mm/min

Pos: 1.66 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.67 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD 6 HiFo 160i FC PerCut 160/170 - St 37 10-25mm @ 0\mod_1216623411611_19.doc @ 4860
 cutting tables
HiFocus 160i #6
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus+ - 1.0037 St37 ( 10 - 25 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] N2, O2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

62 10 115 - R002 Z102 R2012 R3028 - R4022 Z501 - 1 0 50 0 0 30 9,5 4 2 4 0,4 132 2200 * 1,9 457 200 100

63 10 130 - R002 Z102 R2012 R3028 - R4022 Z501 - 1 0 60 0 0 45 9,5 4 2 4 0,4 133 2400 * 2 457 200 150

64 12 130 - R002 Z102 R2012 R3028 - R4022 Z501 - 1 0 60 0 0 75 9,5 4 2 4 0,4 132 2000 * 2 457 200 150

65 15 130 - R002 Z102 R2012 R3028 - R4022 Z501 - 1 0 60 0 0 80 9,5 4,5 2 4,5 0,4 137 1600 * 2,4 457 200 150

66 18 130 - R002 Z102 R2012 R3028 - R4022 Z501 - 2 0 60 0 0 85 9,5 5 2,5 6 0,5 146 1100 * 2,6 457 200 150

67 20 130 - R002 Z102 R2014 R3028 - R4022 Z501 - 2 0 60 0 0 90 9,5 5 2,5 7 0,6 148 850 * 2,8 458 200 150

68 25 130 - R002 Z102 R2014 R3028 - R4025 Z501 - 2 0 60 0 10 99 9,5 5 3 8 0,8 158 600 * 3 458 200 150

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

457 0 8 - R002 Z102 R2012 R3028 - R4025 Z501 - 1 0 0 0 0 0 3 3 2 3,5 0 60 3400 * 0 0 200 4

458 0 10 - R002 Z102 R2014 R3028 - R4030 Z501 - 2 0 0 0 0 0 3 3 2 3,5 0 60 3600 * 0 0 200 4

62 1.0037
10 mm
St37
nozzle : R2012
HiFocus+
more : F1
115A
PG1 PG2 PG3 WG1 WG2

Air O2 N2
50 30
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 9.5 p2 9.5 bar v : 2200 mm/min

Pos: 1.68 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.69 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD 7 HiFo 160i FC PerCut 160/170 - St 37 2-25mm @ 0\mod_1216623553814_19.doc @ 4864
cutting tables
HiFocus 160i #7
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F - 1.0037 St37 ( 2 - 25 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2 - WG [swirl gas] O2, N2

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

100 2 120 - R012 Z111 R2112 R3008 - R4030 Z501 Z111A 2 0 60 0 10 70 5,8 3 2 3 0,1 116 7000 * 1,9 461 200 50

101 3 130 - R012 Z111 R2114 R3008 - R4030 Z501 Z111A 2 0 60 0 10 70 5,4 3 2 3 0,1 111 6000 * 1,8 462 200 50

102 6 130 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 70 0 10 70 5,4 4 2,5 4 0,2 119 3200 * 2 462 200 50

103 8 130 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 70 0 20 70 5,6 4 3 4 0,3 125 2200 * 2,2 462 200 100

104 10 130 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 70 0 20 75 5,6 4 3 4 0,3 127 1800 * 2,4 462 200 150

105 12 130 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 70 0 20 75 5,6 4 3 5 0,4 128 1600 * 2,5 462 200 150

106 16 130 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 75 0 20 75 5,6 5 3 6 0,5 132 1200 * 2,7 462 200 150

107 18 130 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 75 0 20 85 5,7 5 3,5 6 0,6 136 1000 * 2,8 462 200 150

108 20 130 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 75 0 20 85 5,7 6 4 8 0,8 138 750 * 3 462 200 150

109 25 130 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 80 0 20 85 5,8 6 4 9 1 140 600 * 3,4 462 200 150

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

461 0 8 - R012 Z111 R2112 R3008 - R4030 Z501 Z111A 2 0 0 0 0 0 3 3,5 2 3,5 0 68 3000 * 0 0 200 4

462 0 8 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 0 0 0 0 3 4 2,5 4 0 65 3000 * 0 0 200 4

100
2.0 mm
1.0037 St37
nozzle : R2112
HiFocus F
more : F1
120A
PG1 PG2 PG3 WG1 WG2

Air O2 O2 N2
60 10 70
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.8 p2 5.8 bar v : 7000 mm/min

Pos: 1.70 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.71 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD 8 HiFo 160i FC PerCut 160/170 - St37 M @ 0\mod_1216624522264_19.doc @ 4868
 cutting tables
HiFocus 160i #8
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 marking - 1.0037 St37

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

450 0 5 - R002 Z101 R2006 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 81 3000 * 0 0 200 4

451 0 5 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 82 3000 * 0 0 200 4

452 0 5 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

453 0 5 - R002 Z102 R2008 R3028 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

454 0 5 - R002 Z102 R2009 R3028 - R4020 Z501 - 1 0 0 0 0 0 3 3 2 3 0 83 3000 * 0 0 200 4

455 0 6 - R002 Z102 R2010 R3028 - R4020 Z501 - 1 0 0 0 0 0 3 3 2 3 0 78 3000 * 0 0 200 4

456 0 6 - R002 Z102 R2011 R3028 - R4022 Z501 - 1 0 0 0 0 0 3 3 2 3,5 0 74 3200 * 0 0 200 4

457 0 8 - R002 Z102 R2012 R3028 - R4025 Z501 - 1 0 0 0 0 0 3 3 2 3,5 0 60 3400 * 0 0 200 4

458 0 10 - R002 Z102 R2014 R3028 - R4030 Z501 - 2 0 0 0 0 0 3 3 2 3,5 0 60 3600 * 0 0 200 4

461 0 8 - R012 Z111 R2112 R3008 - R4030 Z501 Z111A 2 0 0 0 0 0 3 3,5 2 3,5 0 68 3000 * 0 0 200 4

462 0 8 - R012 Z111 R2114 R3008 - R4140 Z501 Z111A 2 0 0 0 0 0 3 4 2,5 4 0 65 3000 * 0 0 200 4

463 0 10 - R012 Z111 R2116 R3008 - R4140 Z501 Z111A 2 0 0 0 0 0 3 4 2,5 4 0 64 3000 * 0 0 200 4

450
0 mm
1.0037 St37
nozzle : R2006
Marking
more : F1
5A
PG1 PG2 PG3 WG1 WG2

Ar

New Data: < COPY >

Select Record: < ENTER >
OK or Error
Pressure :p1 3.0 p2 3.0 bar v : 3000 mm/min

Pos: 1.72 /Anlagen/Schneidtabellen/Text unter Schneidtabellen für Markieren @ 0\mod_1198072577197_19.doc @ 2202

Information
− adjust pierce delay to the value "zero" at profile-cutting-machine
− don't enlarge the ignition height
− the parameters for marking vary depending on material and kind of surface
− the compliance of the determined cutting height is very important
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel
Pos: 1.73 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD 9 HiFo 160i FC PerCut 160/170 - CrNi 1-3mm @ 0\mod_1216624628691_19.doc @ 4872
cutting tables
HiFocus 160i #9
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus - 1.4301 CrNi ( 1 - 3 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] O2, Air - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

250 1 20 - R002 Z101 R2006 R3004 - R4015 Z501 - 1 0 2 0 0 90 5,4 2 1,5 2 0 120 2500 * 1,4 450 200 4

251 1,5 20 - R002 Z101 R2006 R3004 - R4020 Z501 - 1 0 3 0 0 90 5,4 2,5 1,5 2,5 0,2 122 1800 * 1,5 450 200 4

252 2 25 - R002 Z101 R2006 R3004 - R4020 Z501 - 1 0 3 0 0 95 5,5 2,5 1,5 2,5 0,2 123 1450 * 1,6 450 200 4

270 2 30 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 10 0 0 0 85 5,2 2,5 1,5 2,5 0,2 124 1300 * 1,5 451 200 4

271 3 30 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 10 0 0 0 85 5,2 3 1,5 3 0,2 126 1100 * 1,5 451 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

450 0 5 - R002 Z101 R2006 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 81 3000 * 0 0 200 4

451 0 5 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 82 3000 * 0 0 200 4

250
1.0 mm
1.4301 CrNi
nozzle : R2006
HiFocus
more :
20A
F1

PG1 PG2 PG3 WG1 WG2

Air O2 N 2
2 90
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.4 p2 5.4 bar v : 2500 mm/min

Pos: 1.74 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.75 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD10 HiFo 160i FC PerCut 160/170 - CrNi 1mm @ 0\mod_1216624826824_19.doc @ 4876
 cutting tables
HiFocus 160i #10
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFinox - 1.4301 CrNi ( 1 mm )

cutting records ZG [ignition gas] N2 - PG [cutting gas] N2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

200 1 30 - R042 Z101 R2007 R3008 - R4020 Z501 - 1 95 0 0 99 80 7 3 2,5 3 0 120 5000 * 1 459 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

459 0 6 - R042 Z101 R2007 R3008 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3600 * 0 0 200 4

200
1.0 mm
1.4301 CrNi
nozzle : R2007
HiFinox
more : F1
30A
PG1 PG2 PG3 WG1 WG2

N2 N2 N /H
2 2

95 99 80
New Data: < COPY >
Selecct Record: < ENTER >
OK or Error
Pessure :p1 7.0 p2 7.0 bar v : 5000 mm/min

Pos: 1.76 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.77 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD11 HiFo 160i FC PerCut 160/170 - CrNi 4-6mm @ 0\mod_1216625279430_19.doc @ 4880
cutting tables
HiFocus 160i #11
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus - 1.4301 CrNi ( 4 - 6 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] Air - WG [swirl gas] N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

272 4 45 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 10 0 0 0 85 5,2 3 1,5 3 0,2 140 1350 * 1,7 452 200 4

273 5 45 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 10 0 0 0 85 5,2 3 2 3 0,2 142 1300 * 1,7 452 200 4

274 6 50 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 10 0 0 0 90 5,2 3 2 3 0,3 144 1200 * 1,8 452 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

452 0 5 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

272
4.0 mm
1.4301
nozzle : R2008
CrNi HiFocus
more : F1
45A
PG1 PG2 PG3 WG1 WG2

Air N 2/H 2
10 85
New Data : < COPY >
Select Record: < ENTER >
OK or Error
Pessure :p1 5.2 p2 5.2 bar v : 1350 mm/min

Pos: 1.78 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.79 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD12 HiFo 160i FC PerCut 160/170 - CrNi 2-6mm @ 0\mod_1216625370178_19.doc @ 4884
 cutting tables
HiFocus 160i #12
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFinox - 1.4301 CrNi ( 2 - 6 mm )

cutting records ZG [ignition gas] N2 - PG [cutting gas] N2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

201 2 55 - R042 Z101 R2008 R3008 - R4020 Z501 - 1 95 0 0 99 60 7,4 3 2 3 0,1 127 4000 * 1,1 460 200 4

202 3 55 - R012 Z101 R2008 R3008 - R4020 Z501 - 1 95 0 0 99 60 7,4 3 2 3 0,2 124 2600 * 1,2 460 200 4

203 4 60 - R042 Z101 R2008 R3008 - R4020 Z501 - 1 95 0 0 90 60 7,4 3 2 3 0,2 125 2200 * 1,3 460 200 4

204 5 60 - R042 Z101 R2008 R3008 - R4020 Z501 - 1 95 0 0 99 80 7,4 3,5 2 3,5 0,3 127 2000 * 1,4 460 200 4

205 6 60 - R042 Z101 R2008 R3008 - R4020 Z501 - 1 95 0 0 99 80 7,4 4 3 4 0,4 128 1800 * 1,5 460 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

460 0 6 - R042 Z101 R2008 R3008 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 84 3000 * 0 0 200 4

201
2.0 mm
1.4301 CrNi
nozzle : R2008
HiFinox
more : F1
55A
PG1 PG2 PG3 WG1 WG2

N2 N 2 N 2/H 2
95 99 60
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 7.4 p2 7.4 bar v : 4000 mm/min

Pos: 1.80 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.81 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD13 HiFo 160i FC PerCut 160/170 - CrNi 6-25mm @ 0\mod_1216626465618_19.doc @ 4888
cutting tables
HiFocus 160i #13
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F - 1.4301 CrNi ( 6 - 25 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

300 6 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 73 0 30 99 90 5,1 4 3 4 0,2 116 2000 * 2 465 200 4

301 8 120 - R052 Z111 R2514 R3008 - R4530 Z501 - 2 73 0 30 99 95 5,1 4 3 4 0,2 118 1350 * 2,2 464 200 4

302 8 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 73 0 30 99 95 5,1 4 3 4 0,3 116 1600 * 2,2 465 200 4

303 10 115 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 73 0 30 99 95 5,1 4 3 4 0,3 126 900 * 2,4 465 200 4

304 10 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 73 0 30 99 95 5,1 4 3 4 0,4 128 1200 * 2,5 465 200 4

305 12 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 73 0 30 99 99 5,1 4 3 5 0,5 129 1000 * 2,6 465 200 4

306 16 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 73 0 30 99 99 5,1 5 3 6 0,7 127 950 * 2,8 465 200 4

307 20 130 - R052 Z111 R2516 R3008 - R4540 Z501 - 2 73 0 30 99 99 5,1 5 3,5 8 0,9 136 550 * 3,2 465 200 4

308 25 130 - R052 Z111 R2516 R3008 - R4540 Z501 - 2 73 0 30 99 99 5,2 6 4 9 1 138 400 * 3,4 465 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

464 0 10 - R052 Z111 R2514 R3008 - R4530 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 56 3000 * 0 0 200 4

465 0 12 - R052 Z111 R2516 R3008 - R4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

300
6.0 mm
1.4301 CrNi
nozzle : R2516
HiFocus F
more : F1
130A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
73 30 99 90
New Data : < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.1 p2 5.1 bar v : 2000 mm/min

Pos: 1.82 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.83 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD14 HiFo 160i FC PerCut 160/170- CrNi 6-12mm @ 0\mod_1216626625593_19.doc @ 4892
 cutting tables
HiFocus 160i #14
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F+ - 1.4301 CrNi ( 6 - 12 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

320 6 130 - R052 Z111 R2516 R3018 - R4530 Z501 - 2 95 0 25 99 95 6,3 4 3 4 0,4 124 1600 * 2,4 465 200 4

321 8 130 - R052 Z111 R2516 R3018 - R4530 Z501 - 2 95 0 25 99 95 6,3 4 3 4 0,4 126 1400 * 2,5 465 200 4

322 10 130 - R052 Z111 R2516 R3018 - R4540 Z501 - 2 95 0 30 99 95 6,3 4,5 3 4,5 0,5 127 1150 * 2,6 465 200 4

323 12 130 - R052 Z111 R2516 R3018 - R4540 Z501 - 2 95 0 30 99 95 6,3 4,5 3 4,5 0,5 128 950 * 2,8 465 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

465 0 12 - R052 Z111 R2516 R3008 - R4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

320
6.0 mm
1.4301 CrNi
nozzle : R2516
HiFocus F+
more : F1
130A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
95 25 99 95
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 6.3 p2 6.3 bar v : 1600 mm/min

Pos: 1.84 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.85 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD15 HiF o160i FC PerCut 160/170 - CrNi 10-20mm @ 0\mod_1216626758172_19.doc @ 4896
cutting tables
HiFocus 160i #15
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F - 1.4301 CrNi ( 10 - 20 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

309 10 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 75 0 35 99 99 5,2 4 4 4 0,2 130 1400 * 2,5 466 200 4

310 12 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 75 0 35 99 99 5,2 4 4 4 0,3 132 1100 * 2,7 466 200 4

311 15 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 75 0 35 99 99 5,2 4 4 4 0,4 133 950 * 2,8 466 200 4

312 18 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 75 0 35 99 99 5,2 5 4 5 0,4 136 850 * 2,9 466 200 4

313 20 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 75 0 35 99 99 5,2 5 4,5 6 0,6 138 700 * 3 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

466 0 14 - R052 Z111 R2518 R3008 - R4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

309
10 mm
1.4301 CrNi
nozzle : R2518
HiFocus F
more : F1
160A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
75 35 99 99
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.2 p2 5.2 bar v : 1400 mm/min

Pos: 1.86 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.87 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD16 HiFo 160i FC PerCut 160/170 - CrNi 12-20mm @ 0\mod_1216627005633_19.doc @ 4900
 cutting tables
HiFocus 160i #16
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F+ - 1.4301 CrNi ( 12 - 20 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

324 12 160 - R052 Z111 R2518 R3018 - R4540 Z501 - 2 98 0 35 99 99 6,5 4,5 3,5 4,5 0,5 125 1100 * 2,8 466 200 4

325 15 160 - R052 Z111 R2518 R3018 - R4540 Z501 - 2 98 0 35 99 99 6,5 5 3,5 5 0,6 126 950 * 2,8 466 200 4

326 18 160 - R052 Z111 R2518 R3018 - R4540 Z501 - 2 98 0 35 99 99 6,5 5 3,5 6 0,7 128 850 * 2,9 466 200 4

327 20 160 - R052 Z111 R2518 R3018 - R4540 Z501 - 2 98 0 35 99 99 6,5 5 3,5 7 0,8 130 700 * 3 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

466 0 14 - R052 Z111 R2518 R3008 - R4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

324
12 mm
1.4301 CrNi
nozzle : R2518
HiFocus F+
more :
160A
F1

PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
98 35 99 99
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Presure :p1 6.5 p2 6.5 bar v : 1100 mm/min

Pos: 1.88 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.89 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD17 HiFo 160i FC PerCut 160/170 - CrNi M @ 0\mod_1216627117070_19.doc @ 4904
cutting tables
HiFocus 160i #17
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 marking - 1.4301 CrNi

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

459 0 6 - R042 Z101 R2007 R3008 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3600 * 0 0 200 4

460 0 6 - R042 Z101 R2008 R3008 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 84 3000 * 0 0 200 4

464 0 10 - R052 Z111 R2514 R3008 - R4530 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 56 3000 * 0 0 200 4

465 0 12 - R052 Z111 R2516 R3008 - R4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

466 0 14 - R052 Z111 R2518 R3008 - R4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

459
0 mm
1.4301 CrNi
nozzle : R2007
Marking
more : F1
6A
PG1 PG2 PG3 WG1 WG2

Ar

New Data: < COPY >

Select Record: < ENTER >
OK or Error
Pressure :p1 3.0 p2 3.0 bar v : 3600 mm/min

Pos: 1.90 /Anlagen/Schneidtabellen/Text unter Schneidtabellen für Markieren @ 0\mod_1198072577197_19.doc @ 2202

Information
− adjust pierce delay to the value "zero" at profile-cutting-machine
− don't enlarge the ignition height
− the parameters for marking vary depending on material and kind of surface
− the compliance of the determined cutting height is very important
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel
Pos: 1.91 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD18 HiFo 160i FC PerCut 160/170 - CrNiTi 5-15mm @ 0\mod_1216627180831_19.doc @ 4908
 cutting tables
HiFocus 160i #18
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F - 1.4571 CrNiTi ( 5 - 15 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

350 5 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 70 0 40 99 50 5,1 3,5 2,5 3,5 0,2 121 1750 * 1,8 465 200 4

351 6 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 70 0 40 99 60 5,1 4 2,5 4 0,2 123 1650 * 2 465 200 4

352 8 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 70 0 40 99 70 5,1 4 2,5 4 0,3 124 1550 * 2,2 465 200 4

353 10 130 - R052 Z111 R2516 R3008 - R4540 Z501 - 2 70 0 40 99 70 5,1 4 2,5 4 0,3 125 1300 * 2,5 465 200 4

354 12 130 - R052 Z111 R2516 R3008 - R4540 Z501 - 2 70 0 40 99 70 5,1 4 3 5 0,4 127 1200 * 2,6 465 200 4

355 15 130 - R052 Z111 R2516 R3008 - R4540 Z501 - 2 70 0 40 99 80 5,1 4 3 6 0,4 132 900 * 2,8 465 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

465 0 12 - R052 Z111 R2516 R3008 - R4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

350
5.0 mm
1.4571 CrNiTi
nozzle : R2516
HiFocus F
more : F1
130A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
70 40 99 50
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.1 p2 5.1 bar v : 1750 mm/min

Pos: 1.92 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.93 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD19 HiFo 160i FC PerCut 160/170 - CrNiTi 6-8mm @ 0\mod_1216627279957_19.doc @ 4912
cutting tables
HiFocus 160i #19
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F+ - 1.4571 CrNiTi ( 6 - 8 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

370 6 130 - R052 Z111 R2516 R3018 - R4530 Z501 - 2 98 0 50 99 90 6,5 4 3 4 0,4 126 1650 * 2 465 200 4

371 8 130 - R052 Z111 R2516 R3018 - R4530 Z501 - 2 98 0 50 99 90 6,5 4 3 4 0,4 127 1400 * 2,2 465 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

465 0 12 - R052 Z111 R2516 R3008 - R4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

370
6.0 mm
1.4571 CrNiTi
nozzle : R2516
HiFocus F+
more : F1
130A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
98 50 99 90
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 6.5 p2 6.5 bar v : 1650 mm/min

Pos: 1.94 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.95 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD20 HiFo 160i FC PerCut 160/170 - CrNiTi 10-20mm @ 0\mod_1216627659832_19.doc @ 4916
 cutting tables
HiFocus 160i #20
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F - 1.4571 CrNiTi ( 10 - 20 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

356 10 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 75 0 50 99 99 5,5 4 4 4 0,2 132 1500 * 2,2 466 200 4

357 12 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 75 0 50 99 99 5,5 4 4 5 0,3 134 1200 * 2,4 466 200 4

358 15 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 75 0 50 99 99 5,5 4 4 5 0,4 136 1000 * 2,8 466 200 4

359 20 160 - R052 Z111 R2518 R3008 - R4540 Z501 - 2 75 0 50 99 99 5,5 4,5 5 6 0,7 138 750 * 3,2 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

466 0 14 - R052 Z111 R2518 R3008 - R4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

356
10 mm
1.4571 CrNiTi
nozzle : R2518
HiFocus F
more : F1
160A
PG1 PG2 PG3 WG1 WG2

Ar H2 N 2 N 2/H 2
75 50 99 99
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.5 p2 5.5 bar v : 1500 mm/min

Pos: 1.96 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.97 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD21 HiFo 160i FC PerCut 160/170 - Alu 1-8mm @ 0\mod_1216627818216_19.doc @ 4920
cutting tables
HiFocus 160i #21
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus - 3.3536 AlMg3 ( 1 - 8 mm )

cutting records ZG [ignition gas] Air - PG [cutting gas] Air - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

400 1 35 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 8 0 0 95 0 5,5 3 2 3 0,1 139 3800 * 1,5 451 200 30

401 2 35 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 8 0 0 85 0 5,5 3 2 3 0,1 141 2600 * 1,5 451 200 30

402 3 35 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 8 0 0 95 0 5,5 3 2 3 0,1 145 2300 * 1,6 451 200 30

403 4 35 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 10 0 0 70 0 5,6 3,5 2 3,5 0,1 140 1100 * 1,6 451 200 30

404 4 45 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 10 0 0 0 90 5,6 3,5 2 3,5 0,1 143 1500 * 1,6 452 200 50

405 5 50 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 10 0 0 0 85 5,6 3,5 2 3,5 0,1 146 1400 * 1,9 452 200 50

406 6 50 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 10 0 0 0 85 5,6 3,5 2 3,5 0,2 148 1300 * 1,8 452 200 50

407 8 50 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 12 0 0 0 85 5,6 3,5 2 3,5 0,2 150 1100 * 1,6 452 200 50

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

451 0 5 - R002 Z101 R2007 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 82 3000 * 0 0 200 4

452 0 5 - R002 Z101 R2008 R3004 - R4020 Z501 - 1 0 0 0 0 0 3 2,5 2 2,5 0 83 3000 * 0 0 200 4

400
1.0 mm
3.3536 AlMg3
nozzle : R2007
HiFocus
more : F1
35A
PG1 PG2 PG3 WG1 WG2

Air N2
8 95
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.5 p2 5.5 bar v : 3800 mm/min

Pos: 1.98 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.99 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD22 HiFo 160i FC PerCut 160/170 - Alu 6-25mm @ 0\mod_1216628026647_19.doc @ 4924
 cutting tables
HiFocus 160i #22
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F - 3.3536 AlMg3 ( 6 - 25 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

420 6 115 - R052 Z111 R2514 R3008 - R4530 Z501 - 2 70 0 30 99 70 5,5 4 2,5 4 0,1 138 2400 * 2,5 464 200 4

421 6 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 70 0 30 99 75 5,5 4 2,5 4 0,1 140 3200 * 2,7 465 200 4

422 8 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 75 0 35 99 75 5,5 4 2,5 4 0,2 138 2200 * 2,9 465 200 4

423 10 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 75 0 35 99 75 5,5 4 2,5 4 0,3 140 1600 * 3 465 200 4

424 12 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 75 0 35 99 80 5,5 4 2,5 5 0,4 140 1400 * 3,1 465 200 4

425 16 130 - R052 Z111 R2516 R3008 - R4530 Z501 - 2 75 0 35 99 80 5,5 4 3 6 0,5 142 1000 * 3,3 465 200 4

426 20 130 - R052 Z111 R2516 R3008 - R4540 Z501 - 2 80 0 35 99 80 5,5 5 3,5 8 0,6 146 800 * 3,5 465 200 4

427 25 130 - R052 Z111 R2516 R3008 - R4540 Z501 - 2 80 0 35 99 80 5,5 6 3,5 9 0,9 155 600 * 3,8 465 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

464 0 10 - R052 Z111 R2514 R3008 - R4530 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 56 3000 * 0 0 200 4

465 0 12 - R052 Z111 R2516 R3008 - R4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

420
6.0
3.3536
mm
AlMg3
nozzle : R2514
HiFocusF
more : F1
115A
PG1 PG2 PG3 WG1 WG2

Ar H2 N2 N2 /H2
70 30 99 70
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.5 p2 5.5 bar v : 2400 mm/min

Pos: 1.100 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.101 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD23 HiFo 160i FC PerCut 160/170 - Alu 8-10 mm @ 0\mod_1216628256899_19.doc @ 4928
cutting tables
HiFocus 160i #23
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F+ - 3.3536 AlMg3 ( 8 - 10 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

440 8 130 - R052 Z111 R2516 R3018 - R4530 Z501 - 2 90 0 45 99 75 7 4 3 4 0,4 126 1850 * 2,9 465 200 4

441 10 130 - R052 Z111 R2516 R3018 - R4530 Z501 - 2 98 0 50 99 75 7 4 3 4 0,5 128 1600 * 3 465 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

465 0 12 - R052 Z111 R2516 R3008 - R4535 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 54 3000 * 0 0 200 4

440
8.0 mm
3.3536 AlMg3
nozzle : R2516
HiFocusF+
more : F1
130A
PG1 PG2 PG3 WG1 WG2

Ar H2 N2 N2 /H2
90 45 99 75
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 7.0 p2 7.0 bar v : 1850 mm/min

Pos: 1.102 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.103 /Anlagen/Schneidtabellen/HiFocus160i/3D-SD/SD24 HiFo 160i FC PerCut 160/170 - Alu 10-25mm @ 0\mod_1216628420458_19.doc @ 4932
 cutting tables
HiFocus 160i #24
FlowControl 1 - PerCut 160/170 3D
data version: 4 - valid from: 19.04.2007 HiFocus F - 3.3536 AlMg3 ( 10 - 25 mm )

cutting records ZG [ignition gas] Ar - PG [cutting gas] Ar, H2 - WG [swirl gas] N2, N2/H2 (5% H2)

technology range / switch position

PG1 [plasma gas 1] [scale values]
PG2 [plasma gas 2] [scale values]
PG3 [plasma gas 3] [scale values]

cutting speed [quality] [mm/min]

WG1 [swirl gas 1] [scale values]
WG2 [swirl gas 2] [scale values]

cutting speed [max] [mm/min]

cutting pressure [bar]

ignition height [mm]

cutting height [mm]

pierce height [mm]

cutting voltage [V]

cutting current [A]

kerf [quality] [mm]

down slope [ms]

swirl gas nozzle
thickness [mm]

marking record
record number

protection cap

pierce time [s]

up slope [ms]
swirl gas cap
cooling tube

special part
nozzle cap
gas guide
cathode

nozzle

428 10 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 80 0 35 99 85 5,6 4 3 4 0,2 140 1800 * 2,5 466 200 4

429 12 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 80 0 40 99 85 5,6 4 3 4 0,3 142 1650 * 2,7 466 200 4

430 15 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 80 0 40 99 90 5,6 4 3 5 0,3 145 1250 * 2,9 466 200 4

431 20 160 - R052 Z111 R2518 R3008 - R4530 Z501 - 2 80 0 40 99 95 5,6 4 3,5 6 0,5 148 1000 * 3 466 200 4

432 25 160 - R052 Z111 R2518 R3008 - R4540 Z501 - 2 80 0 40 99 99 5,6 5 3,5 8 0,6 150 800 * 3,1 466 200 4

marking records ZG [ignition gas] Ar - PG [marking gas] Ar

466 0 14 - R052 Z111 R2518 R3008 - R4540 Z501 - 2 0 0 30 0 0 5,5 4 2,5 4 0 52 3000 * 0 0 200 4

428
10 mm
3.3536 AlMg3
nozzle : R2518
HiFocusF
more : F1
160A
PG1 PG2 PG3 WG1 WG2

Ar H2 N2 N2 /H2
80 35 99 85
New Data: < COPY >
Select Record: < ENTER >
OK or Error
Pressure :p1 5.6 p2 5.6 bar v : 1800 mm/min

Pos: 1.104 /Anlagen/Schneidtabellen/Text unter Schneidtabellen mit Lochstechzeit @ 0\mod_1198070320294_19.doc @ 2160

Information
− pierce delay is adjusted at profile-cutting-machine
− cutting parameters and results may differ because of material composition, material surface and
shape of workpiece.
− the compliance of the determined cutting distance is very important.
− the set cutting voltages are approximate values only, because they depend on other conditions
too, for example contact between workpiece and cutting table or length of the hose parcel

Pos: 1.105 /Plasmabrenner/PerCut 160/170/VT-Übersicht-PerCut160/170-3D @ 0\mod_1217416686182_19.doc @ 5004

cutting tables

===== Ende der Stückliste =====

 FINE FOCUS

ENCLOSURE 2

wiring diagrams

of the

plasma cutting machine HiFocus 160i (SP 0001)

.11.033.702.SP1 l
.11.033.702.SP2 h
.11.412.002.SP b

with

FlowControl (SP 0002, SP 0005)

.11.033.702.SP82 a
.11.033.702.SP92 a
.11.420.001.SP d
.11.825.150.SP k
.11.825.150.GP d

or

PGE-HM (SP 0003)

.11.033.702.SP81 a
.11.033.702.SP91 a

or

PGE1-HM (SP 0004)

.11.033.702.SP80 a
.11.033.702.SP90 a
SP 0001 - 01.01.2007 Kjellberg Finsterwalde
- page A2-2 -
SP 0001 - 01.01.2007 Kjellberg Finsterwalde
- page A2-3 -
SP 0001 - 01.01.2007 Kjellberg Finsterwalde
- page A2-4 -
SP 0002 - 19.04.2004 Kjellberg Finsterwalde
- page A2-5 -
SP 0002 - 19.04.2004 Kjellberg Finsterwalde
- page A2-6 -
SP 0005 - 01.01.2007 Kjellberg Finsterwalde
- page A2-7 -
SP 0005 - 01.01.2007 Kjellberg Finsterwalde
- page A2-8 -
SP 0005 - 01.01.2007 Kjellberg Finsterwalde
- page A2-9 -
 ENCLOSURE 3

order information and connection diagrams

for

plasma cutting machine HiFocus 160 i

and

plasma machine torches

PerCut 160-2
PerCut 170-2

.11.033.702.K80 .11.033.702.S83
.11.033.702.S85A-PGE
.11.033.702.S85B-PGC

.11.032.702.K90 .11.033.702.S93
.11.033.702.S95A-PGE
.11.033.702.S95B-PGC

(11 pages including cover sheet)

BHA 0001 - 21.01.2008 - page A3-1 - Kjellberg Finsterwalde

 order information September 2007

.11.033.702.K80 HiFocus 160i 400 V catalogue

connection of torch: torch connection with plasma-torch connection unit
plasma gases: oxygen; argon/hydrogen/nitrogen
swirl gases: oxygen; oxygen/nitrogen; nitrogen; nitrogen/hydrogen
torch: plasma machine torch PerCut 160-2/170-2 with swirl gas

pos. article no. designation pcs.

1.11 .11.033.702 HiFocus 160i 400V/50Hz 1,00

1.18 .16.500.447 With undercarriage, primary cable 5m
1.19 .16.500.223 With 63 A CEE-plug
1.90 .12.53620 Workpiece Cable 35 qmm, 5 m 1,00

2.00 .16.500.380 Control cables power source - PGE

2.00 .16.500.455 Gas supply - gas control
2.02 .11.500.700.413 Control cable 25 pol. 1,5m 1,00
2.03 .11.570.003.0018 Control cable/RS485 PA -PGC 1,8m 1,00
2.04 .11.501.500.059 Gas hose Air G1/4" 6m 1,00
2.05 .11.501.500.060 Gas hose O2 G1/4" 6m 1,00
2.06 .11.501.500.058 Gas hose Ar G1/4" 6m 1,00
2.07 .11.501.500.057 Gas hose H2 G3/8" Left, 6m 1,00
2.08 .11.501.500.094 Gas hose N2 G1/4" 6m 1,00
2.09 .11.501.500.267 Gas hose N2/H2 G3/8" LEFT 6m 1,00
2.14 .11.501.500.065 Gas hose AIR G1/4" 10m 1,00
2.15 .11.501.500.061 Gas hose O2 G1/4" 10m 1,00
2.16 .11.501.500.069 Gas hose Ar G1/4" 10m 1,00
2.17 .11.501.500.073 Gas hose H2 G3/8" Left 10m 1,00
2.18 .11.501.500.095 Gas hose N2 G1/4" 10 m 1,00
2.19 .11.501.500.268 Gas hose N2/H2 G3/8" Left 10m 1,00
2.24 .11.501.500.066 Gas hose Air G1/4" 20 m 1,00
2.25 .11.501.500.062 Gas hose O2 G1/4" 20m 1,00
2.26 .11.501.500.070 Gas hose Ar G1/4" 20m 1,00
2.26 .11.501.500.071 Gas hose Ar G1/4" 30m 1,00
2.27 .11.501.500.074 Gas hose H2 G3/8" Left 20m 1,00
2.28 .11.501.500.096 Gas hose N2 G1/4" 20m 1,00
2.29 .11.501.500.269 Gas hose N2/H2 G3/8" LEFT 20m 1,00
2.34 .11.501.500.067 Gas hose Air G1/4" 30m 1,00
2.35 .11.501.500.063 Gas hose O2 G1/4" 30m 1,00
2.36 .11.501.500.071 Gas hose Ar G1/4" 30m 1,00
2.37 .11.501.500.075 Gas hose H2 3/8" Left 30m 1,00
2.38 .11.501.500.097 Gas hose N2 G1/4" 30m 1,00
2.39 .11.501.500.270 Gas hose N2/H2 G3/8" LEFT 30m 1,00
2.44 .11.501.500.068 Gas hose Air G1/4" 40m 1,00
2.45 .11.501.500.064 Gas hose O2 G1/4" 40m 1,00
2.46 .11.501.500.072 Gas hose Ar G1/4" 40m 1,00
2.47 .11.501.500.076 Gas hose H2 G3/8" Left 40m 1,00
2.48 .11.501.500.098 Gas hose N2 G1/4" 40m 1,00
2.49 .11.501.500.271 Gas hose N2/H2 G3/8" LEFT 40m 1,00

BHA 0001 - 01.09.2007 - page A3-2 - Kjellberg Finsterwalde

 order information September 2007

.11.033.702.K80 HiFocus 160i 400 V catalogue

pos. article no. designation pcs.

3.00 .16.500.456 Gas supply - manual

3.10 .11.825.101 PGE1-HM Gas Controller Man. L/O2 1,00
3.20 .11.825.110 PGE-HM PG Control Unit (All Gases) 1,00
3.30 .16.500.457 Gas control automatic - flowcontrol
3.31 .11.420.001 PGC 1 Control Unit for PGV 1 1,00
3.31 .11.420.001.900 Power Supply PGC 1 1.5m 1,00
3.32 .11.825.150 PGV 1 Plasma Gas Controller 1,00
3.40 .11.570.001.0018 Control cable/CAN1 PGV-PGC 1,8m 1,00
3.41 .11.570.001.005 Control cable/CAN1 PGV/PGC 5m 1,00
3.50 .11.570.002.0018 Control cable/24VAC PGV-PGC 1,8m 1,00
3.51 .11.570.002.005 Control cable/24VAC PGV-PGC 5m 1,00

6.00 .11.820.243 PBA-H160 1,00

6.01 .16.500.385 hose parcel extension PA/PZ - PBA
6.10 .11.825.704.1 PBL-H160 Hoses/Cables PA/PZ-PBA 4m/C 1,00
6.11 .11.501.500.280 Gas hose PG1 air/N2 G1/4"-G1/8" 4m 1,00
6.12 .11.501.500.285 Gas hose PG2 O2/N2 G1/4"L-G1/8" 4m 1,00
6.13 .11.501.500.290 Gas hose PG3 H2 G3/8"L-G1/8" 4m 1,00
6.18 .11.501.500.295 Gas hose SG M12x1-G1/8" 4m 1,00
6.20 .11.825.706.1 PBL-H160 Hoses/Cables PA/PZ-PBA 6m/C 1,00
6.21 .11.501.500.281 Gas hose PG1 air/N2 G1/4"-G1/8" 6m 1,00
6.22 .11.501.500.286 Gas hose PG2 O2/N2 G1/4"L-G1/8" 6m 1,00
6.23 .11.501.500.291 Gas hose PG3 H2 G3/8"L-G1/8" 6m 1,00
6.28 .11.501.500.296 Gas hose SG M12-G1/8" 6m 1,00
6.30 .11.825.710.1 PBL-H160 Hoses/Cables PA/PZ-PBA 10m/C 1,00
6.31 .11.501.500.282 Gas hose PG1 air/N2 G1/4"-G1/8" 10m 1,00
6.32 .11.501.500.287 Gas hose PG2 O2/N2 G1/4"L-G1/8" 10m 1,00
6.33 .11.501.500.292 Gas hose PG3 H2 G3/8"L-G1/8" 10m 1,00
6.38 .11.501.500.297 Gas hose SG M12x1-G1/8" 10m 1,00
6.40 .11.825.715.1 PBL-H160 Hoses/Cables PA/PZ-PBA 15m/C 1,00
6.41 .11.501.500.283 Gas hose PG1 air/N2 G1/4"-G1/8" 15m 1,00
6.42 .11.501.500.288 Gas hose PG2 O2/N2 G1/4"L-G1/8" 15m 1,00
6.43 .11.501.500.293 Gas hose PG3 H2 G3/8"L-G1/8" 15m 1,00
6.48 .11.501.500.298 Gas hose SG M12x1-G1/8" 15m 1,00

7.00 .16.500.242 Optional peripher units

7.01 .11.824.800.010 FB - Remote Control 10m 1,00
7.10 .11.824.250 PZE-1 Plasma Timer 1,00
7.11 .11.500.700.387 Control cbale PZE1 4pole 10m 1,00

8.00 .16.500.233 Plasma machine torches:

8.46 .11.842.421.101 PerCut 160-2 1m/160A/C 1,00
8.47 .11.842.421.1015 PerCut 160-2 1,5m/160A/C 1,00
8.50 .11.822.577 Torch Holder, Compl. PerCut 100 1,00
8.51 .11.843.021.901 Shaft Percut 170-2 1,0m/C 1,00
8.52 .11.843.021.9015 Shaft PerCut 170-2 1,5m/C 1,00
8.53 .11.843.021.100 Quick-change head PerCut 170 1,00
8.58 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1,00
8.60 .11.822.583 Torch Holder, Compl. PerCut 110/170 1,00

BHA 0001 - 01.09.2007 - page A3-3 - Kjellberg Finsterwalde

 order information September 2007

.11.033.702.K80 HiFocus 160i 400 V catalogue

pos. article no. designation pcs.

9.00 .16.500.006 Torch tools

9.01 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1,00
9.02 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1,00
9.03 .11.842.401.810 Socket Spanner (Nozzle Cap) 1,00
9.05 .11.843.021.830 Station for Head PerCut 170 Double 1,00
9.06 .11.839.021.840 Tool for Quick-Change Head PerCut 110/170 1,00
9.07 .36.000.015 Cathode dial indicator 1,00
9.20 .16.500.257 Options gas / water supply:
9.21 .12.62320 Coolant Kjellfrost -15° C / 10l 1,00
9.22 .12.62330 Coolant Kjellfrost -15°C / 20l 1,00
9.23 .12.62340 Coolant Kjellfrost -25°C / 10l 1,00
9.24 .12.62350 Coolant Kjellfrost -25°C/ 20l 1,00

10.00 .16.500.004 Consumables:

12.00 .11.843.011.880 Consumables KIT PerCut 160/170 CrNi 1,00

12.00 .16.500.465 Consumables HiFocus CrNi-steel
12.10 .16.500.254 Consumables category A
12.11 .11.842.411.510 Cathode A S042 HiFinox 1,00
12.11 .11.842.511.510 Cathode A S052 FineFocus 1,00
12.13 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
12.13 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
12.13 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1,00
12.13 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1,00
12.13 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1,00
12.15 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
12.15 .11.835.411.1580 Swirl Gas Cap 3,5 Z4535 1,00
12.15 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1,00
12.15 .11.835.411.1590 Swirl Gas Cap 4,5 Z4545 1,00
12.15 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1,00
12.20 .16.500.255 Consumables category B
12.22 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
12.22 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
12.24 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
12.24 .11.842.401.1621 Nozzle cap complete 0,8 S3018 1,00
12.26 .11.835.201.081 Protection Cap Z501 1,00

14.00 .11.843.021.880 Consum. KIT PerCut 160/170 Mild Steel 1,00

14.00 .16.500.464 Consumables HiFocus mild steel
14.10 .16.500.254 Consumables category A
14.11 .11.843.021.320 Cathode O2 XL S002Y 1,00
14.11 .11.843.121.310 Cathode 02 XL S012X 1,00
14.13 .11.843.021.406 Nozzle 0,6 S2006X 25A 1,00
14.13 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
14.13 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
14.13 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1,00
14.13 .11.843.021.410 Nozzle 1,0 S2010X 80/90A 1,00
14.13 .11.843.021.411 Nozzle 1,1 S2011X 90/100A 1,00
14.13 .11.843.021.412 Nozzle 1,2 S2012X 100/130A 1,00
14.13 .11.843.021.414 Nozzle 1,4 S2014X 130/160A 1,00

BHA 0001 - 01.09.2007 - page A3-4 - Kjellberg Finsterwalde

 order information September 2007

.11.033.702.K80 HiFocus 160i 400 V catalogue

pos. article no. designation pcs.

14.13 .11.843.021.416 Nozzle 1,6 S2016X 160A 1,00

14.13 .11.843.121.412 Nozzle 1,2 S2112X 100A 1,00
14.13 .11.843.121.414 Nozzle 1,4 S2114X 130A 1,00
14.13 .11.843.121.416 Nozzle 1,6 S2116X 160A 1,00
14.15 .11.835.201.1551 Swirl Gas Cap 2,2 Z4022 1,00
14.15 .11.835.201.1561 Swirl Gas Cap 1,5 Z4015 1,00
14.15 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
14.15 .11.835.201.1581 Swirl Gas Cap 2,5 Z4025 1,00
14.15 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1,00
14.15 .11.835.401.1571 Swirl Gas Cap 4,0 Z4140 1,00
14.20 .16.500.255 Consumables category B
14.22 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
14.22 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
14.22 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1,00
14.23 .11.835.421.303 Spacer Z111A 1,00
14.24 .11.842.401.160 Nozzle cap compete 0,4 S3004 1,00
14.24 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
14.24 .11.842.401.1622 Nozzle cap complete 0,8 S3028 1,00
14.26 .11.835.201.081 Protection Cap Z501 1,00

25.00 .16.500.257 Options gas / water supply:

25.00 .16.500.400 Safety instructions!
25.00 .16.500.426 Gas from cylinders
25.10 .10.500.205 Explosion Protection 1,00
25.11 .11.822.618 Micro filter O2 25/0,01ym 1,00
25.12 .11.822.621 Micro filter O2 0,01ym 1,00
25.15 .11.822.619 Micro filter air 5/0,01ym 14bar 1,00
25.16 .11.822.623 Micro filter air 5/0,1ym 1,00
25.21 .10.639.312 Pressure reducer air 20 bar 1,00
25.21 .10.639.322 Pressure reducer air 10 bar 1,00
25.22 .10.639.309 Pressure reducer Ar/Co2 20 bar 1,00
25.22 .10.639.319 Pressure reducer Ar 10 bar 1,00
25.23 .10.639.310 Pressure reducer H2 20 bar 1,00
25.23 .10.639.320 Pressure reducer H2 10 bar 1,00
25.24 .10.639.311 Pressure reducer N2 20 bar 1,00
25.24 .10.639.321 Pressure reducer N2 10 bar 1,00
25.25 .10.639.313 Pressure reducer O2 20 bar 1,00
25.25 .10.639.323 Pressure reducer O2 10 bar 1,00

30.00 .16.500.438 Plug X102 for interface

30.00 .16.500.439 Plasma cutting unit - CNC
30.11 .11.822.200 Interface 25 pol Plug 1,00
30.20 .16.500.439 Plasma cutting unit - CNC
30.20 .16.500.481 Plug X104 for interface
30.21 .11.822.203 Interface 4pol. plug 1,00

BHA 0001 - 01.09.2007 - page A3-5 - Kjellberg Finsterwalde

 2.x8
Wirbelgase N2
Bezeichnungsnummern im Anschluss-Schema sind identisch mit
Swirl gases O2 25.12 2.x5 den Positionsnummern in den Bestellhinweisen.
Das “x” steht für eine Variante oder Länge.

Numbers in the diagram a re indentically with the item numbers in

the order information. “X” means version or length.
25.11 2.x5
Plasmagase O2
Plasma gases Air 25.16 2.x4

6.xx max. 15 m
3.10
6.x0 max. 15 m

PBA-H PBA-H
PGV 1
PGC 1 PGE1-HM 6.00
7.01 CNC
FB
2.x2

8.x0
1.11 8.xx

HiFocus 160i

11.033.702.S83
1.90

N2 H2 2.x9
Wirbelgase 2.x8
N2
Swirl gases
O2 25.12 2.x5 Bezeichnungsnummern im Anschluss-Schema sind identisch mit
den Positionsnummern in den Bestellhinweisen.
N2 2.x8 Das “x” steht für eine Variante oder Länge.

H2 2.x7
Numbers in the diagram are indentically with the item numbers in
Ar 2.x6
Plasmagase the order information. “X” means version or length.

Plasma gases O2 25.11 2.x5

25.16 2.x4
Air

6.xx max. 15 m
3.20
6.x0 max. 15 m PBA-H

PGE-HM
6.00
7.01 CNC
FB
2.x2

8.x0
1.11 8.xx

HiFocus 160i

11.033.702.S85A
1.90

N2H2 2.x9
Wirbelgase N2 2.x8
Swirl gases
O2 25.11 2.x5
Bezeichnungsnummern im Anschluss-Schem a sind identisch mit
den Positionsnum mern in den Bestellhinweisen.
N2 2.x8 Das “x” steht für eine Variante oder Länge.
H2 2.x7
Plasmagase Ar 2.x6 Numbers in the diagram are indentically with the item numbers in
the order information. “X” m eans version or length.
Plasma gases O2 25.11 2.x5
25.15 2.x4
Air

3.32 6.xx max. 15 m

3.4x
3.31 3.5x
6.x0 max. 15 m
PBA-H PBA-H

PGC 1 PGV 1
2.x2
2.x3 6.00
7.01 CNC
FB

8.x0
1.11 8.xx

HiFocus 160i

11.033.702.S85B
1.90

BHA 0001 - 01.09.2007 - page A3-6 - Kjellberg Finsterwalde

 order information September 2007

.11.033.702.K90 HiFocus 160i 400 V catalogue

connection of torch: with plasma ignition box, hose parcel and plasma-torch connection unit
plasma gases: oxygen; argon/hydrogen/nitrogen
swirl gases: oxygen; oxygen/nitrogen; nitrogen; nitrogen/hydrogen
torch: plasma machine torch PerCut 160-2/170-2 with swirl gas

pos. article no. designation pcs.

1.11 .11.033.702 HiFocus 160i 400V/50Hz 1,00

1.18 .16.500.447 With undercarriage, primary cable 5m
1.19 .16.500.223 With 63 A CEE-plug
1.90 .12.53620 Workpiece Cable 35 qmm, 5 m 1,00

2.00 .16.500.454 Cables and hoses PA-PZ

2.00 .16.500.455 Gas supply - gas control
2.10 .11.821.710 PZL-H101 Hose and Cables Set 10m 1,00
2.11 .11.500.700.470 Control cable 2pol. 2x0,75 10,5m 1,00
2.12 .11.500.700.394 Control cable PA-PGE/PGV 25 pole, 10m 1,00
2.13 .11.570.003.010 Control cable/RS485 PA -PGC 10m 1,00
2.14 .11.501.500.065 Gas hose AIR G1/4" 10m 1,00
2.15 .11.501.500.061 Gas hose O2 G1/4" 10m 1,00
2.16 .11.501.500.069 Gas hose Ar G1/4" 10m 1,00
2.17 .11.501.500.073 Gas hose H2 G3/8" Left 10m 1,00
2.18 .11.501.500.095 Gas hose N2 G1/4" 10 m 1,00
2.19 .11.501.500.268 Gas hose N2/H2 G3/8" Left 10m 1,00
2.20 .11.821.720 PZL-H101 Hose and Cables Set 20m 1,00
2.21 .11.500.700.471 Control cable 2pol. 2x0,75 20,5m 1,00
2.22 .11.500.700.396 Control cable PA-PGE/PGV 25 pol. 20m 1,00
2.23 .11.570.003.020 Control cable/RS485 PA -PGC 20m 1,00
2.24 .11.501.500.066 Gas hose Air G1/4" 20 m 1,00
2.25 .11.501.500.062 Gas hose O2 G1/4" 20m 1,00
2.26 .11.501.500.070 Gas hose Ar G1/4" 20m 1,00
2.27 .11.501.500.074 Gas hose H2 G3/8" Left 20m 1,00
2.28 .11.501.500.096 Gas hose N2 G1/4" 20m 1,00
2.29 .11.501.500.269 Gas hose N2/H2 G3/8" LEFT 20m 1,00
2.30 .11.821.730 PZL-H101 Hose and Cables Set 30m 1,00
2.31 .11.500.700.472 Control Cable 2pol. 30m 1,00
2.32 .11.500.700.398 Control cable PA-PGE/PGV 25 pole, 30m 1,00
2.33 .11.570.003.030 Control cable/RS485 PA -PGC 30m 1,00
2.34 .11.501.500.067 Gas hose Air G1/4" 30m 1,00
2.35 .11.501.500.063 Gas hose O2 G1/4" 30m 1,00
2.36 .11.501.500.071 Gas hose Ar G1/4" 30m 1,00
2.37 .11.501.500.075 Gas hose H2 3/8" Left 30m 1,00
2.38 .11.501.500.097 Gas hose N2 G1/4" 30m 1,00
2.39 .11.501.500.270 Gas hose N2/H2 G3/8" LEFT 30m 1,00
2.40 .11.821.740 PZL-H101 Hose and Cables Set 40m 1,00
2.41 .11.500.700.473 Control cable 2pol. 2x0,75 40m 1,00
2.42 .11.500.700.400 Control cable PA-PGE/PGV 25 pole, 40m 1,00
2.43 .11.570.003.040 Control cable/RS485 PA -PGC 40m 1,00
2.44 .11.501.500.068 Gas hose Air G1/4" 40m 1,00

BHA 0001 - 01.09.2007 - page A3-7 - Kjellberg Finsterwalde

 order information September 2007

.11.033.702.K90 HiFocus 160i 400 V catalogue

pos. article no. designation pcs.

2.45 .11.501.500.064 Gas hose O2 G1/4" 40m 1,00

2.46 .11.501.500.072 Gas hose Ar G1/4" 40m 1,00
2.47 .11.501.500.076 Gas hose H2 G3/8" Left 40m 1,00
2.48 .11.501.500.098 Gas hose N2 G1/4" 40m 1,00
2.49 .11.501.500.271 Gas hose N2/H2 G3/8" LEFT 40m 1,00

3.00 .16.500.456 Gas supply - manual

3.10 .11.825.101 PGE1-HM Gas Controller Man. L/O2 1,00
3.20 .11.825.110 PGE-HM PG Control Unit (All Gases) 1,00
3.30 .16.500.457 Gas control automatic - flowcontrol
3.31 .11.420.001 PGC 1 Control Unit for PGV 1 1,00
3.31 .11.420.001.900 Power Supply PGC 1 1.5m 1,00
3.32 .11.825.150 PGV 1 Plasma Gas Controller 1,00
3.42 .11.570.001.010 Control cable/CAN1 PGV-PGC 10m 1,00
3.43 .11.570.001.020 Control cable /CAN1 PGV-PGC 20m 1,00
3.44 .11.570.001.030 Control cable /CAN1 PGV-PGC 30m 1,00
3.45 .11.570.001.040 Control cable /CAN1 PGV-PGC 40m 1,00
3.52 .11.570.002.010 Control cable/24VAC PGV-PGC 10m 1,00
3.53 .11.570.002.020 Control cable/24VAC PGV-PGC 20m 1,00
3.54 .11.570.002.030 Control cable /24VDC PGV-PGC 30m 1,00
3.55 .11.570.002.040 Control cable/24VAC PGV-PGC 40m 1,00

4.00 .16.500.382 Gas hoses PGE/PGV - PGA

4.10 .16.500.263 Hoses 3m
4.11 .11.501.500.255 Gas Hose Air, G1/4"-4x3,5 3m 1,00
4.12 .11.501.500.245 Gas hose PG2 O2/N2 G1/4"left 3m 1,00
4.13 .11.501.500.275 Gas hose PG3 H2 G3/8"Left 3m 1,00
4.18 .11.501.500.157 Gas hose WG M12x1-4x3,5 3m 1,00
4.19 .11.501.500.230 Gas hose KG G1/8"-4x3,5 3m 1,00
4.20 .16.500.264 Hoses 6m
4.21 .11.501.500.251 Gas hose PG1 Air/N2 G1/4" 6m 1,00
4.22 .11.501.500.241 Gas hose PG2 O2/N2 G1/4"left 6m 1,00
4.23 .11.501.500.273 Gas hose PG3 H2 G3/8"Left 6m 1,00
4.28 .11.501.500.132 Gas hose WG M12x1-4x3,5 6m 1,00
4.29 .11.501.500.231 Gas hose KG G1/8"-4x3,5 6m 1,00
4.30 .16.500.265 Hoses 10m
4.31 .11.501.500.253 Gas Hose Air, G1/4"-4x3,5 10m 1,00
4.32 .11.501.500.243 Gas hose PG2 O2/N2 G1/4"left -10m 1,00
4.33 .11.501.500.274 Gas hose PG3 H2 G3/8"Left 10m 1,00
4.38 .11.501.500.134 Gas hose WG M12x1-4x3,5 10m 1,00
4.39 .11.501.500.233 Gas hose KG G1/8"-4x3,5 10m 1,00
4.41 .11.501.500.257 Gas hose PG1 Air/N2 G1/4"-15m 1,00
4.42 .11.501.500.247 Gas hose PG2 O2/N2 G1/4"left 15m 1,00
4.43 .11.580.006.015 Gas hose PG3 H2 G3/8"Left 15m 1,00
4.48 .11.501.500.260 Gas hose WG M12x1-4x3,5 15m 1,00
4.49 .11.501.500.261 Gas hose KG G1/8"-4x3,5 15m 1,00

5.10 .11.825.106 PGA-HM Plasma Gas Connection Unit Man. 1,00

5.20 .11.821.931 PZ-H Plasma Ignition Box for HiFocus 1,00

BHA 0001 - 01.09.2007 - page A3-8 - Kjellberg Finsterwalde

 order information September 2007

.11.033.702.K90 HiFocus 160i 400 V catalogue

pos. article no. designation pcs.

6.00 .11.820.243 PBA-H160 1,00

6.01 .16.500.385 hose parcel extension PA/PZ - PBA
6.10 .11.825.704.1 PBL-H160 Hoses/Cables PA/PZ-PBA 4m/C 1,00
6.11 .11.501.500.280 Gas hose PG1 air/N2 G1/4"-G1/8" 4m 1,00
6.12 .11.501.500.285 Gas hose PG2 O2/N2 G1/4"L-G1/8" 4m 1,00
6.13 .11.501.500.290 Gas hose PG3 H2 G3/8"L-G1/8" 4m 1,00
6.18 .11.501.500.295 Gas hose SG M12x1-G1/8" 4m 1,00
6.20 .11.825.706.1 PBL-H160 Hoses/Cables PA/PZ-PBA 6m/C 1,00
6.21 .11.501.500.281 Gas hose PG1 air/N2 G1/4"-G1/8" 6m 1,00
6.22 .11.501.500.286 Gas hose PG2 O2/N2 G1/4"L-G1/8" 6m 1,00
6.23 .11.501.500.291 Gas hose PG3 H2 G3/8"L-G1/8" 6m 1,00
6.28 .11.501.500.296 Gas hose SG M12-G1/8" 6m 1,00
6.30 .11.825.710.1 PBL-H160 Hoses/Cables PA/PZ-PBA 10m/C 1,00
6.31 .11.501.500.282 Gas hose PG1 air/N2 G1/4"-G1/8" 10m 1,00
6.32 .11.501.500.287 Gas hose PG2 O2/N2 G1/4"L-G1/8" 10m 1,00
6.33 .11.501.500.292 Gas hose PG3 H2 G3/8"L-G1/8" 10m 1,00
6.38 .11.501.500.297 Gas hose SG M12x1-G1/8" 10m 1,00
6.40 .11.825.715.1 PBL-H160 Hoses/Cables PA/PZ-PBA 15m/C 1,00
6.41 .11.501.500.283 Gas hose PG1 air/N2 G1/4"-G1/8" 15m 1,00
6.42 .11.501.500.288 Gas hose PG2 O2/N2 G1/4"L-G1/8" 15m 1,00
6.43 .11.501.500.293 Gas hose PG3 H2 G3/8"L-G1/8" 15m 1,00
6.48 .11.501.500.298 Gas hose SG M12x1-G1/8" 15m 1,00

7.00 .16.500.242 Optional peripher units

7.01 .11.824.800.010 FB - Remote Control 10m 1,00
7.10 .11.824.250 PZE-1 Plasma Timer 1,00
7.11 .11.500.700.387 Control cbale PZE1 4pole 10m 1,00

8.00 .16.500.233 Plasma machine torches:

8.46 .11.842.421.101 PerCut 160-2 1m/160A/C 1,00
8.47 .11.842.421.1015 PerCut 160-2 1,5m/160A/C 1,00
8.50 .11.822.577 Torch Holder, Compl. PerCut 100 1,00
8.51 .11.843.021.901 Shaft Percut 170-2 1,0m/C 1,00
8.52 .11.843.021.9015 Shaft PerCut 170-2 1,5m/C 1,00
8.53 .11.843.021.100 Quick-change head PerCut 170 1,00
8.58 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1,00
8.60 .11.822.583 Torch Holder, Compl. PerCut 110/170 1,00

9.00 .16.500.006 Torch tools

9.01 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1,00
9.02 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1,00
9.05 .11.843.021.830 Station for Head PerCut 170 Double 1,00
9.06 .11.839.021.840 Tool for Quick-Change Head PerCut 110/170 1,00
9.07 .36.000.015 Cathode dial indicator 1,00
9.20 .16.500.257 Options gas / water supply:
9.21 .12.62320 Coolant Kjellfrost -15° C / 10l 1,00
9.22 .12.62330 Coolant Kjellfrost -15°C / 20l 1,00
9.23 .12.62340 Coolant Kjellfrost -25°C / 10l 1,00
9.24 .12.62350 Coolant Kjellfrost -25°C/ 20l 1,00

BHA 0001 - 01.09.2007 - page A3-9 - Kjellberg Finsterwalde

 order information September 2007

.11.033.702.K90 HiFocus 160i 400 V catalogue

pos. article no. designation pcs.

10.00 .16.500.004 Consumables:

12.00 .11.843.011.880 Consumables KIT PerCut 160/170 CrNi 1,00

12.00 .16.500.465 Consumables HiFocus CrNi-steel
12.10 .16.500.254 Consumables category A
12.11 .11.842.411.510 Cathode A S042 HiFinox 1,00
12.11 .11.842.511.510 Cathode A S052 FineFocus 1,00
12.13 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
12.13 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
12.13 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1,00
12.13 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1,00
12.13 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1,00
12.15 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
12.15 .11.835.411.1580 Swirl Gas Cap 3,5 Z4535 1,00
12.15 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1,00
12.15 .11.835.411.1590 Swirl Gas Cap 4,5 Z4545 1,00
12.15 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1,00
12.20 .16.500.255 Consumables category B
12.22 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
12.22 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
12.24 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
12.24 .11.842.401.1621 Nozzle cap complete 0,8 S3018 1,00
12.26 .11.835.201.081 Protection Cap Z501 1,00

14.00 .11.843.021.880 Consum. KIT PerCut 160/170 Mild Steel 1,00

14.00 .16.500.464 Consumables HiFocus mild steel
14.10 .16.500.254 Consumables category A
14.11 .11.843.021.320 Cathode O2 XL S002Y 1,00
14.11 .11.843.121.310 Cathode O2 XL S012X 1,00
14.13 .11.843.021.406 Nozzle 0,6 S2006X 25A 1,00
14.13 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
14.13 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
14.13 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1,00
14.13 .11.843.021.410 Nozzle 1,0 S2010X 80/90A 1,00
14.13 .11.843.021.411 Nozzle 1,1 S2011X 90/100A 1,00
14.13 .11.843.021.412 Nozzle 1,2 S2012X 100/130A 1,00
14.13 .11.843.021.414 Nozzle 1,4 S2014X 130/160A 1,00
14.13 .11.843.021.416 Nozzle 1,6 S2016X 160A 1,00
14.13 .11.843.121.412 Nozzle 1,2 S2112X 100A 1,00
14.13 .11.843.121.414 Nozzle 1,4 S2114X 130A 1,00
14.13 .11.843.121.416 Nozzle 1,6 S2116X 160A 1,00
14.15 .11.835.201.1551 Swirl Gas Cap 2,2 Z4022 1,00
14.15 .11.835.201.1561 Swirl Gas Cap 1,5 Z4015 1,00
14.15 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
14.15 .11.835.201.1581 Swirl Gas Cap 2,5 Z4025 1,00
14.15 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1,00
14.15 .11.835.401.1571 Swirl Gas Cap 4,0 Z4140 1,00
14.20 .16.500.255 Consumables category B
14.22 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
14.22 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00

BHA 0001 - 01.09.2007 - page A3-10 - Kjellberg Finsterwalde

 order information September 2007

.11.033.702.K90 HiFocus 160i 400 V catalogue

pos. article no. designation pcs.

14.22 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1,00

14.23 .11.835.421.303 Spacer Z111A 1,00
14.24 .11.842.401.160 Nozzle cap compete 0,4 S3004 1,00
14.24 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
14.24 .11.842.401.1622 Nozzle cap complete 0,8 S3028 1,00
14.26 .11.835.201.081 Protection Cap Z501 1,00

25.00 .16.500.257 Options gas / water supply:

25.00 .16.500.400 Safety instructions!
25.00 .16.500.426 Gas from cylinders
25.10 .10.500.205 Explosion Protection 1,00
25.11 .11.822.618 Micro filter O2 25/0,01ym 1,00
25.12 .11.822.621 Micro filter O2 0,01ym 1,00
25.15 .11.822.619 Micro filter air 5/0,01ym 14bar 1,00
25.16 .11.822.623 Micro filter air 5/0,1ym 1,00
25.21 .10.639.312 Pressure reducer air 20 bar 1,00
25.21 .10.639.322 Pressure reducer air 10 bar 1,00
25.22 .10.639.309 Pressure reducer Ar/Co2 20 bar 1,00
25.22 .10.639.319 Pressure reducer Ar 10 bar 1,00
25.23 .10.639.310 Pressure reducer H2 20 bar 1,00
25.23 .10.639.320 Pressure reducer H2 10 bar 1,00
25.24 .10.639.311 Pressure reducer N2 20 bar 1,00
25.24 .10.639.321 Pressure reducer N2 10 bar 1,00
25.25 .10.639.313 Pressure reducer O2 20 bar 1,00
25.25 .10.639.323 Pressure reducer O2 10 bar 1,00

30.00 .16.500.438 Plug X102 for interface

30.00 .16.500.439 Plasma cutting unit - CNC
30.11 .11.822.200 Interface 25 pol Plug 1,00
30.20 .16.500.439 Plasma cutting unit - CNC
30.20 .16.500.481 Plug X104 for interface
30.21 .11.822.203 Interface 4pol. plug 1,00

BHA 0001 - 01.09.2007 - page A3-11 - Kjellberg Finsterwalde

 N2 2.x8
Wirbelgase Bezeichnungsnummern im Anschluss-Schema sind identisch mit
Swirl gases O2 25.12 2.x5 den Positionsnummern in den Bestellhinweisen.
Das “x” steht für eine Variante oder Länge.

Numbers in the diagram are indentically with the item numbers in

O2 25.11 2.x5
the order information. “X” means version or length.

Plasmagase
Plasma gases Air 25.16 2.x4

3.10 5.10 6.xx max. 15 m

4.xx
6.x0 max. 15 m
PGV 1

PBA-H
PGE1-HM 5.20
2.x0 2.x1
6.00
7.01 CNC
FB
2.x2

8.x0
1.11 8.xx

HiFocus 160i

11.033.702.S93
1.90

N2 H2 2.x9
Wirbelgase 2.x8
N2
Swirl gases 25.12 2.x5
O2 Bezeichnungsnummern im Anschluss-Schema sind identisch mit
den Positionsnummern in den Bestellhinweisen.
N2 2.x8 Das “x” steht für eine Variante oder Länge.
2.x7
H2 Numbers in the diagram are indentically with the item numbers in
2.x6
Plasmagase Ar the order information. “X” means version or length.

Plasma gases 25.11 2.x5

O2
Air 25.16 2.x4

3.20 5.10 6.xx max. 15 m

4.xx
PGE-HM 6.x0 max. 15 m
PGV 1 5.20 PBA-H
2.x0 2.x1
6.00
7.01 CNC
FB
2.x2

8.x0
1.11 8.xx

HiFocus 160i

11.033.702.S95A
1.90

N2 H2 2.x9
Wirbelgase N2 2.x8 Bezeichnungsnummern im Anschluss-Schema sind identisch mit
Swirl gases 25.11 2.x5 den Positionsnummern in den Bestellhinweisen.
O2 Das “x” steht für eine Variante oder Länge.

N2 2.x8 Numbers in the diagram are indentically with the item numbers in
the order information. “X” means version or length.
H2 2.x7
Plasmagase Ar 2.x6
Plasma gases O2 25.11 2.x5

Air 25.15 2.x4

3.32
5.10 6.xx max. 15 m
3.4x
3.31 3.5x 4.xx
6.x0 max. 15 m
PGV 1
PBA-H

PGC 1 5.20
2.x2 2.x0 2.x1
6.00
7.01 CNC
FB
2.x3

8.x0
1.11 8.xx

HiFocus 160i

11.033.702.S95B
1.90

BHA 0001 - 01.09.2007 - page A3-12 - Kjellberg Finsterwalde

 ENCLOSURE 4
spare parts lists

for

plasma cutting machine HiFocus 160i

and for

plasma machine torches

PerCut 160-2 and PerCut 170-2

article no. .11..033.702.E

Dear customer,

with the plasma cutting system you have purchased a quality product from

Kjellberg Finsterwalde Plasma und Maschinen GmbH.

When ordering spare parts, please mention the complete article no. of the torch and also the
complete

designation with article no. of the spare parts

We need these data to complete the delivery. Please direct your order straight to us or to your
contractor. Claims of whatever kind can’t be derived from this spare parts list. For more information
we are always at your disposal.

ETL 0001 - 14.11.2007 - page A4-1 - Kjellberg Finsterwalde

 spare parts list

HiFocus 160i (400 V/50 Hz) August 2007

.11.033.702.E

Pos. article no. designation code of pcs.

wiring diagram

01.00 .16.500.368 Front wall

01.01 .10.108.408 BUTTOM "EMERGENCY OFF" S3 1,00
01.02 .10.108.409 Contact part (S2,S3) 2,00
01.03 .10.108.412 Contact, opener (S3) 2,00
01.04 .10.145.011 Cam switch with key S1 1,00
01.05 .10.108.406 ILLUMINATED BUTTON, GN, WITHOUT CONT. S2 1,00
01.06 .10.108.411 Contact, closer (S2) 2,00
01.07 .10.184.055 LAMP MSKD 24V 2W-BA9s TGL 10449 H1 1,00
01.08 130.676.004 STEP SWITCH S5 1,00
01.09 .10.187.180 Knob 28mm Grey (S5,P5) 2,00
01.10 .10.187.182 COVER PLATE 28mm GREY (S5) 1,00
01.11 .10.187.186 RING 28mm GREY (S5,P5) 2,00
01.12 .10.187.184 COVER PLATE 28mm RED (P5) 1,00
01.13 .10.105.671 Frame for LCD display (A3) 2,00
01.14 .10.187.160 KNOB, GREY 15mm (A3) 3,00
01.15 .10.187.162 COVER PLATE, 15mm (A3) 3,00
01.16 .10.187.166 ARROW RING 15mm GREY (A3) 3,00
01.17 .12.LP066501 PCB 066501A FRONT WALL A3 1,00
01.18 .10.504.555 HANDLE PART, RIGHT SIDE 1,00
01.19 .11.934.303.736 HANDLE BAR 1,00
01.20 .10.504.557 HANDLE PART, LEFT SIDE 1,00
01.21 .10.124.056 POTENTIOMETER 1k P5,2 1,00
01.22 .11.032.702.313 PLASTIC TUBE 12x8x198mm 1,00
01.23 .10.502.848 CONNECTOR G3/8" A12 2,00

02.00 .16.500.369 Rear wall

02.01 .10.615.612 Cover For Filler Neck 1,00
02.02 .12.59550 Filler Neck 1,00
02.03 .10.189.300 Fuseholder 6,3X32 mm 15,00
02.04 .10.189.302 Fuse cap 6,3 x 32 mm 15,00
02.05 .10.189.308 Fuse T 4A 1,00
02.06 .10.189.309 Fuse 6,25A 6,3x32mm 2,00
02.07 .10.189.305 Fuse T 2A, 6,3X32 mm 6,00
02.08 .10.189.311 Fuse T 500 mA 6,00
02.09 .10.164.174 Plug Insert, Female 7 Poles X121 1,00
02.10 .10.164.200 Body Part 3,00
02.11 .10.164.201 Crimp Contact, Female 0,75-1,5 qmm 41,00
02.11 (X102,X110,X121,X132,X122) 0,00
02.12 .10.603.006R CABLE ENTRY M40x1.5 20-26mm RED. 1,00
02.13 .10.603.015 NUT M 40x1,5 BLACK 1,00
02.14 023.763.000 DIX TBE 35-70 Mounting jack 1,00
02.15 .10.164.065 Socket insert 4 poles + PE X104 1,00
02.17 .10.164.197 Plug Insert, Female 8 Poles X132 1,00
02.18 .10.164.110 Plug Insert, Female, 25-Pol. X102,X110 2,00
02.19 .10.164.113 Plug Base (X102,X110) 2,00
02.20 .10.164.176 Plug Insert, Female 10 Poles X114 1,00

ETL 0001 - 14.11.2007 - page A4-2 - Kjellberg Finsterwalde

 spare parts list

HiFocus 160i (400 V/50 Hz) August 2007

.11.033.702.E

Pos. article no. designation code of pcs.

wiring diagram

02.21 .10.164.179 Plug Base (X114) 1,00

02.22 .10.164.702 SUB-D socket 9pol/insert/soldered conn. X4.2 1,00
02.23 .10.164.701 SUB-D plug 9pol./insert/soldered connect. X4.1 1,00
02.24 .10.164.704.1 SUB-D clamping bolt short 8 mm 4,00
02.25 .10.164.714 SUB-D cover plate for socket red 1,00
02.26 .10.164.715 SUB-D Cover plate for plug blue 1,00
02.27 .10.164.170 Plug Insert, Female 3 Poles X122 1,00
02.28 .10.580.139 Clamp 1,00
02.29 .10.274.024 Knurled nut M6 2,00
02.30 .10.148.303 SAFETY SWITCH 3A TYP2-5700-IG2-P10 Q2F 1,00

03.00 .16.500.504 Power source, right side

03.01 .10.269.566 Lifting eye M 10 4,00
03.02 .10.535.611 FAN 7855S 230V/39W M3 1,00
03.03 .12.57690 Water Flow Switch S10 1,00
03.04 .10.615.110 Heat Exchanger 1,00
03.05 .10.129.104 Resistor 6 OHM 5A 400W 29x300 R2 1,00
03.06 .11.033.702.310 TANK COMPLETE 1,00
03.07 .11.573.001.005 AINS CABLE 4x10qmm, 5m, WITHOUT PLUG 1,00
03.08 .10.580.572 Wheel B-VPP 160 G 2,00
03.09 .10.640.166 Cooling Pump LNY-2841 M1/M2 2,00
03.10 .10.535.603 Fan Boxer 119x119x25 2,00
03.11 .10.140.724 Filter Medium125 x 125 x 8 mm F100S 2,00
03.12 .10.580.564 CASTOR L-VPP 160 G 2,00
03.13 .10.184.763 Spring catch 4,00
03.14 .10.190.031 Filter 3x470n/10n 1,00
03.15 671.100.012 Capacitor B - 12 MFD - VIS M8 C4 1,00
03.16 .10.129.107 Fixed resistor 12 OHM 5A 400W 29x300 R1 1,00
03.17 .11.412.002B1 Invertermodul 3 Plasma 80A (uni) with box 2,00

04.00 .16.500.371 Control Unit

04.01 .10.190.376 ISOLATION TRAFO EI60/31 200V/30VA T3 1,00
04.02 .10.190.230 TRANSFORMER 230/400 T2 1,00
04.03 .10.161.703 Contact G481 02 for Type CF/BF (K4) 2,00
04.04 .10.101.603 Operating hours counter 24V AC 50/60Hz P1 1,00
04.05 .10.161.712.24 CONTACTOR BG0601A024 50 K9 1,00
04.06 .10.161.710.24 Contactor BG0040A024 50/60 Hz K6 1,00
04.07 .10.161.722.24 Contactor BF25 00 24V 50/60Hz K4 1,00
04.08 .10.190.364 Transformer T1 1,00
04.08 .12.LP070321 PCB 070321 current supply 24 V DC A7 1,00
04.09 .10.190.029 Suppressor choke L3 1,00
04.10 .101.20.031 Resistor 100K 4,50 W 5% TK 200 R7 1,00
04.11 671.100.025 Capacitor B - 25 MFD - VIS M8 C3 1,00
04.12 .101.30.056 Resistor 47R 7,00 W 5% TK 200 R6 1,00
04.13 .10.109.519 Micro switch A1 S4 1,00
04.14 .101.30.029 RESISTOR 4K7 4.00W 5% TK 200 R8 1,00
04.15 .11.035.002.070 HF-Transformer T3 1,00
04.16 .12.58800 PCB 078300 Ignition Box A4 1,00
04.17 .11.033.702.470 Current relais K2 1,00
04.18 .10.161.701 CONTACT FOR G481 20 FOR TYPE CF/BF (Q1,K4) 1,00
04.19 .10.164.170 Plug Insert, Female 3 Poles X103 1,00
04.20 .10.164.200.1 Case Base Plastic (X103) 1,00
04.21 .10.161.726.230 Contactor BF65 00 223-230V 50/60Hz Q1 1,00
04.22 .12.LP066455 PCB 066455A A1 1,00
04.23 .10.164.283 Distribution Strip X50 1,00
04.24 .12.LP066611 PCB 066611E A2 1,00
04.25 .16.003.945 Converter RS-232 to RS-485 A8 1,00

ETL 0001 - 14.11.2007 - page A4-3 - Kjellberg Finsterwalde

 spare parts list

HiFocus 160i (400 V/50 Hz) August 2007

.11.033.702.E

Pos. article no. designation code of pcs.

wiring diagram

04.26 .10.110.461 RELAY, 24VDC COIL K8,12,13,15 5,00

04.27 .10.110.467 Socket for relay (K12,K13) 2,00
04.28 .10.110.469 Frame for relay (K12,K13) 2,00
04.29 .109.1N4007 diode 1N4007 V1,V2 2,00
04.30 .10.110.480 Relay 24 VAC SPU.2 5A 250 VA K5,K11 2,00
04.31 .10.110.975 Relay K10 1,00
04.32 .10.110.977 Socket (K10) 1,00
04.33 .10.161.725.002 Auxiliary Contact f. BF50-BF95 (Q1) 2,00
04.34 .11.033.702.460 Current relais K1,K3,K7.1,K7.2 4,00

05.00 .16.500.506 Power module

05.01 .10.535.601 Fan Type W2S130-AA03-44 Dm.150 M1,M2 2,00
05.02 .10.100.042 IGBT Module FF100R12KS4 Tr1-Tr4 2,00
05.03 .10.105.846 Module DSEP 2X91-06 A FRED Miniblock V1-V4 4,00
05.04 .10.105.868 Module SKD 62/16 B1 1,00
05.05 .10.123.261 PTC Resistor 60°C PTC 3,00
05.06 .11.412.002.450 Choke module 80 A L4 2,00
05.07 .10.535.605 Fan Boxer 135x135x38 230VAC 50/60Hz M3 1,00
05.08 .11.412.002.490 Choke L3 Module L3 1,00
05.09 .11.412.002.100 Transformer module plasma 80 A T1 1,00
05.10 .11.412.002.480 Choke L2 Module L2 1,00
05.11 .11.412.002.470 Choke L1 Module L1 1,00
05.12 .10.132.937 Capacitor 9uF 10% 700 VDC, STYLE SP C1 2,00
05.13 .10.164.097 Terminal strip 2.5qmm/8pole X3 1,00
05.14 .12.LP068311 PCB 068311C E-INLE A2 1,00
05.15 .10.164.189 Terminal strip 9700A/8 S35 3,00
05.16 .10.164.190 Protective terminal 10qmm 9700 A 2,00
05.17 .10.190.032 Toroidal choke R63 3x3mH/40A/6qmm L6 1,00
05.18 .10.190.031 Filter 3x470n/10n A1 1,00
05.19 .10.190.021 Mains transformer 400V/42V 0,8A, 50/60 Hz T2 1,00
05.20 .12.LP068320 PCB 068320 a A-INLE A4 1,00
05.21 .12.LP067000 PCB 067000 t INST2 A5 1,00
05.21 .12.LP067001 PCB 67000_r Inst2 / 80i-320i, modul 2,5 Hz 1,00
05.22 .12.LP068210 PCB 068210 c IGBT-INLE A3 1,00

ETL 0001 - 14.11.2007 - page A4-4 - Kjellberg Finsterwalde

 fig. 1
Front view of HiFocus 160i

ETL 0001 - 14.11.2007 - page A4-5 - Kjellberg Finsterwalde

 fig. 2
Back view of HiFocus 160i

ETL 0001 - 14.11.2007 - page A4-6 - Kjellberg Finsterwalde

 fig. 3
Side view of HiFocus 160i

ETL 0001 - 14.11.2007 - page A4-7 - Kjellberg Finsterwalde

 fig. 4
Control unit of HiFocus 160i

ETL 0001 - 14.11.2007 - page A4-8 - Kjellberg Finsterwalde

 fig. 5
Power module of HiFocus 160i

ETL 0001 - 14.11.2007 - page A4-9 - Kjellberg Finsterwalde

 spare parts list

PerCut 160-2 (160 A) September 07

.11.842.421.E0

Pos. article no. designation pcs.

0.1 .11.842.421.101 PerCut 160-2 1m/160A/C 1,00

0.2 .11.842.421.1015 PerCut 160-2 1,5m/160A/C 1,00

00.03 .10.505.946 O-ring 36x2 VMQ ISO 1692 70 shore 1,00

00.04 .10.505.916 O-ring 26x2 VMQ ISO 1629 70 shore 1,00
00.05 .11.842.401.152 Cooling Tube PerCut 160 1,00

01.01 .11.843.021.320 Cathode O2 S002Y complete 1,00

01.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
01.03 .11.843.021.406 Nozzle 0,6 S2006X 25A 1,00
01.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
01.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
01.04 .11.842.401.160 Nozzle cap compete 0,4 S3004 1,00
01.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
01.05 .11.835.201.1561 Swirl Gas Cap 1,5 Z4015 1,00
01.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
01.06 .11.835.201.081 Protection Cap Z501 1,00

02.01 .11.843.021.320 Cathode O2 S002Y complete 1,00

02.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
02.02 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1,00
02.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
02.03 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1,00
02.03 .11.843.021.410 Nozzle 1,1 S2011X 90/100A 1,00
02.03 .11.843.021.411 Nozzle 1,0 S2010X 80/90A 1,00
02.03 .11.843.021.412 Nozzle 1,2 S2012X 100/130A 1,00
02.03 .11.843.021.414 Nozzle 1,6 S2016X 160A 1,00
02.03 .11.843.021.416 Nozzle 1,4 S2014X 130/160A 1,00
02.04 .11.842.401.1622 Nozzle cap complete 0,8 S3028 1,00
02.04 .11.842.401.1624 Nozzle cap complete 0,8 S3048 1,00
02.05 .11.835.201.1551 Swirl Gas Cap 2,2 Z4022 1,00
02.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
02.05 .11.835.201.1581 Swirl Gas Cap 2,5 Z4025 1,00
02.05 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1,00
02.06 .11.835.201.081 Protection Cap Z501 1,00

03.01 .11.843.121.310 Cathode 02 XL S012X 1,00

03.02 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
03.03 .11.843.121.412 Nozzle 1,2 S2112X 100A 1,00
03.03 .11.843.121.414 Nozzle 1,4 S2114X 130A 1,00
03.03 .11.843.121.416 Nozzle 1,6 S2116X 160A 1,00
03.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
03.05 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1,00
03.05 .11.835.401.1571 Swirl Gas Cap 4,0 Z4140 1,00
03.06 .11.835.201.081 Protection Cap Z501 1,00
03.07 .11.835.421.303 Spacer Z111A 1,00

ETL 0002 - 01.09.2007 - page A4-10 - Kjellberg Finsterwalde

 spare parts list

PerCut 160-2 (160 A) September 07

.11.842.421.E0

Pos. article no. designation pcs.

04.01 .11.842.411.510 Cathode A S042 HiFinox 1,00

04.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
04.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
04.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
04.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
04.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
04.06 .11.835.201.081 Protection Cap Z501 1,00

05.01 .11.842.511.510 Cathode A S052 FineFocus 1,00

05.02 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
05.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1,00
05.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1,00
05.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1,00
05.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
05.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1,00
05.05 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1,00
05.06 .11.835.201.081 Protection Cap Z501 1,00

06.01 .11.842.511.510 Cathode A S052 FineFocus 1,00

06.02 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
06.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1,00
06.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1,00
06.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1,00
06.04 .11.842.401.1621 Nozzle cap complete 0,8 S3018 1,00
06.05 .11.835.411.1580 Swirl Gas Cap 3,5 Z4535 1,00
06.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1,00
06.05 .11.835.411.1590 Swirl Gas Cap 4.0 with O-ring Z4540 1,00
06.05 .11.835.411.1591 Swirl Gas Cap 4,5 Z4545 1,00
06.06 .11.835.201.081 Protection Cap Z501 1,00

10.00 .16.500.006 Torch tools

10.01 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1,00
10.03 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1,00

ETL 0002 - 01.09.2007 - page A4-11 - Kjellberg Finsterwalde

ETL 0002 - 01.09.2007 - page A4-12 - Kjellberg Finsterwalde
ETL 0002 - 01.09.2007 - page A4-13 - Kjellberg Finsterwalde
 spare parts list

PerCut 160-2 Robo (160 A) September 07

.11.842.621.E0

Pos. article no. designation pcs.

0.1 .11.842.621.1015 PerCut 160-2 Robo 1,5m/160A/C 1,00

00.03 .10.505.946 O-ring 36x2 VMQ ISO 1692 70 shore 1,00

00.04 .10.505.916 O-ring 26x2 VMQ ISO 1629 70 shore 1,00
00.05 .11.842.401.152 Cooling Tube PerCut 160 1,00

01.01 .11.843.021.320 Cathode O2 S002Y complete 1,00

01.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
01.03 .11.843.021.406 Nozzle 0,6 S2006X 25A 1,00
01.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
01.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
01.04 .11.842.401.160 Nozzle cap compete 0,4 S3004 1,00
01.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
01.05 .11.835.201.1561 Swirl Gas Cap 1,5 Z4015 1,00
01.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
01.06 .11.835.201.081 Protection Cap Z501 1,00

02.01 .11.843.021.320 Cathode O2 S002Y complete 1,00

02.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
02.02 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1,00
02.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
02.03 .11.843.021.416 Nozzle 1,6 S2016X 160A 1,00
02.03 .11.843.021.414 Nozzle 1,4 S2014X 130/160A 1,00
02.03 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1,00
02.03 .11.843.021.410 Nozzle 1,0 S2010X 80/90A 1,00
02.03 .11.843.021.412 Nozzle 1,2 S2012X 100/130A 1,00
02.03 .11.843.021.411 Nozzle 1,1 S2011X 90/100A 1,00
02.04 .11.842.401.1622 Nozzle cap complete 0,8 S3028 1,00
02.04 .11.842.401.1624 Nozzle cap complete 0,8 S3048 1,00
02.05 .11.835.201.1551 Swirl Gas Cap 2,2 Z4022 1,00
02.05 .11.835.201.1581 Swirl Gas Cap 2,5 Z4025 1,00
02.05 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1,00
02.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
02.06 .11.835.201.081 Protection Cap Z501 1,00

03.01 .11.843.121.310 Cathode 02 XL S012X 1,00

03.02 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
03.03 .11.843.121.412 Nozzle 1,2 S2112X 100A 1,00
03.03 .11.843.121.416 Nozzle 1,6 S2116X 160A 1,00
03.03 .11.843.121.414 Nozzle 1,4 S2114X 130A 1,00
03.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
03.05 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1,00
03.05 .11.835.401.1571 Swirl Gas Cap 4,0 Z4140 1,00
03.06 .11.835.201.081 Protection Cap Z501 1,00
03.07 .11.835.421.303 Spacer Z111A 1,00

ETL 0003 - 01.09.2007 - page A4-14 - Kjellberg Finsterwalde

 spare parts list

PerCut 160-2 Robo (160 A) September 07

.11.842.621.E0

Pos. article no. designation pcs.

04.01 .11.842.411.510 Cathode A S042 HiFinox 1,00

04.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
04.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
04.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
04.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
04.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
04.06 .11.835.201.081 Protection Cap Z501 1,00

05.01 .11.842.511.510 Cathode A S052 FineFocus 1,00

05.02 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
05.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1,00
05.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1,00
05.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1,00
05.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
05.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1,00
05.05 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1,00
05.06 .11.835.201.081 Protection Cap Z501 1,00

06.01 .11.842.511.510 Cathode A S052 FineFocus 1,00

06.02 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
06.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1,00
06.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1,00
06.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1,00
06.04 .11.842.401.1621 Nozzle cap complete 0,8 S3018 1,00
06.05 .11.835.411.1580 Swirl Gas Cap 3,5 Z4535 1,00
06.05 .11.835.411.1590 Swirl Gas Cap 4,5 Z4545 1,00
06.05 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1,00
06.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1,00
06.06 .11.835.201.081 Protection Cap Z501 1,00

10.00 .16.500.006 Torch tools

10.01 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1,00
10.03 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1,00

ETL 0003 - 01.09.2007 - page A4-15 - Kjellberg Finsterwalde

ETL 0003 - 01.09.2007 - page A4-16 - Kjellberg Finsterwalde
ETL 0003 - 01.09.2007 - page A4-17 - Kjellberg Finsterwalde
 spare parts list

PerCut 170-2 (160 A) September 07

.11.843.021.E0

Pos. article no. designation pcs.

0.1 .11.843.021.1007 PerCut 170-2 0,7m/160A/C 1,00

0.2 .11.843.021.101 PerCut 170-2 1m/160A/C 1,00

00.01 .11.843.021.9007 Shaft PerCut 170-2 0,7m/C 1,00

00.01 .11.843.021.901 Shaft Percut 170-2 1,0m/C 1,00
00.02 .11.843.021.100 Quick-change head PerCut 170 1,00
00.03 .10.505.946 O-ring 36x2 VMQ ISO 1692 70 shore 1,00
00.04 .10.505.916 O-ring 26x2 VMQ ISO 1629 70 shore 1,00
00.05 .11.842.401.152 Cooling Tube PerCut 160 1,00

00.11 .10.251.324 INTERNAL WRENCHING BOLT M 3x5 DIN 912 3,00

00.13 .11.839.001.179 NIPPLE WG/PG 30mm PERCUT 110 2,00
00.14 .11.839.001.181 NIPPLE WV/KG 28mm PERCUT 110 2,00
00.15 .10.505.799 O-ring 3.5x1.5 VMQ ISO 1629 70 shore 1,00

01.01 .11.843.021.320 Cathode O2 S002Y complete 1,00

01.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
01.03 .11.843.021.406 Nozzle 0,6 S2006X 25A 1,00
01.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
01.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
01.04 .11.842.401.160 Nozzle cap compete 0,4 S3004 1,00
01.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
01.05 .11.835.201.1561 Swirl Gas Cap 1,5 Z4015 1,00
01.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
01.06 .11.835.201.081 Protection Cap Z501 1,00

02.01 .11.843.021.320 Cathode O2 S002Y complete 1,00

02.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
02.02 .11.835.221.154 Gas guide 0,4(2x cw) Z102 1,00
02.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
02.03 .11.843.021.410 Nozzle 1,0 S2010X 80/90A 1,00
02.03 .11.843.021.412 Nozzle 1,2 S2012X 100/130A 1,00
02.03 .11.843.021.416 Nozzle 1,6 S2016X 160A 1,00
02.03 .11.843.021.414 Nozzle 1,4 S2014X 130/160A 1,00
02.03 .11.843.021.411 Nozzle 1,1 S2011X 90/100A 1,00
02.03 .11.843.021.409 Nozzle 0,9 S2009X 70/80A 1,00
02.04 .11.842.401.1622 Nozzle cap complete 0,8 S3028 1,00
02.04 .11.842.401.1624 Nozzle cap complete 0,8 S3048 1,00
02.05 .11.835.201.1551 Swirl Gas Cap 2,2 Z4022 1,00
02.05 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1,00
02.05 .11.835.201.1581 Swirl Gas Cap 2,5 Z4025 1,00
02.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
02.06 .11.835.201.081 Protection Cap Z501 1,00

ETL 0004 - 01.09.2007 - page A4-18 - Kjellberg Finsterwalde

 spare parts list

PerCut 170-2 (160 A) September 07

.11.843.021.E0

Pos. article no. designation pcs.

03.01 .11.843.121.310 Cathode 02 XL S012X 1,00

03.02 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
03.03 .11.843.121.412 Nozzle 1,2 S2112X 100A 1,00
03.03 .11.843.121.416 Nozzle 1,6 S2116X 160A 1,00
03.03 .11.843.121.414 Nozzle 1,4 S2114X 130A 1,00
03.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
03.05 .11.835.201.1591 Swirl Gas Cap 3,0 Z4030 1,00
03.05 .11.835.401.1571 Swirl Gas Cap 4,0 Z4140 1,00
03.06 .11.835.201.081 Protection Cap Z501 1,00
03.07 .11.835.421.303 Spacer Z111A 1,00

04.01 .11.842.411.510 Cathode A S042 HiFinox 1,00

04.02 .11.835.221.153 Gas guide 0,4(3x cw) Z101 1,00
04.03 .11.843.021.407 Nozzle 0,7 S2007X 35A 1,00
04.03 .11.843.021.408 Nozzle 0,8 S2008X 50/60A 1,00
04.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
04.05 .11.835.201.1571 Swirl Gas Cap 2,0 Z4020 1,00
04.06 .11.835.201.081 Protection Cap Z501 1,00

05.01 .11.842.511.510 Cathode A S052 FineFocus 1,00

05.02 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
05.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1,00
05.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1,00
05.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1,00
05.04 .11.842.401.162 Nozzle cap complete 0,8 S3008 1,00
05.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1,00
05.05 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1,00
05.06 .11.835.201.081 Protection Cap Z501 1,00

06.01 .11.842.511.510 Cathode A S052 FineFocus 1,00

06.02 .11.834.321.153 Gas guide PB-S4x/Z111 1,00
06.03 .11.843.111.614 Nozzle 1,4 A S2514X 120A 1,00
06.03 .11.843.111.616 Nozzle 1,6 A S2516X 140A 1,00
06.03 .11.843.111.618 Nozzle 1,8 A S2518X 160A 1,00
06.04 .11.842.401.1621 Nozzle cap complete 0,8 S3018 1,00
06.05 .11.835.411.1580 Swirl Gas Cap 3,5 Z4535 1,00
06.05 .11.835.411.1590 Swirl Gas Cap 4,5 Z4545 1,00
06.05 .11.835.411.1591 Swirl Gas Cap 4.0 with O-ring Z4540 1,00
06.05 .11.835.411.1581 Swirl Gas Cap 3.0 with O-ring Z4530 1,00
06.06 .11.835.201.081 Protection Cap Z501 1,00

10.00 .16.500.006 Torch tools

10.01 .11.835.221.820 Cathode-/Gasguidepuller PerCut 100 1,00
10.03 .11.843.001.810 Socket Spanner (Nozzle Cap/Nozzle) 1,00
10.04 .11.839.021.845 SOCKET WRENCH FOR NIPPLE PERCUT 110 1,00

11.00 .16.500.129 Accessories:

11.01 .10.616.104 Lubricant for O2 LC 40 Fluid 25 ml 1,00

ETL 0004 - 01.09.2007 - page A4-19 - Kjellberg Finsterwalde

ETL 0004 - 01.09.2007 - page A4-20 - Kjellberg Finsterwalde
ETL 0004 - 01.09.2007 - page A4-21 - Kjellberg Finsterwalde
 Enclosure 5

Protocol

for the

monthly gas pressure test

(3pages incl. coversheet)

- 24.10.2006 - page A5-1 - Kjellberg Finsterwalde

Protocol for the monthly gas pressure test

Attention!
Due to the existing risk of fire and explosion by using of oxygen, hydrogen and in-
flammable gas mixtures, the monthly spot check of the gas supply system has to be
carried out carefully and proofed by protocol. The spot check occurs according to the
section "gas pressure test" at the instruction manual separatly for oxygen, hydrogen
and all inflammable gas mixtures.

Year Month carried out gas pressure test for : Date Name Signature

Oxygen Hydrogen

Jan.
Feb
Mar
Apr
Mai
Jun
Jul
Aug
Sep
Oct
Nov
Dec

Jan.
Feb
Mar
Apr
Mai
Jun
Jul
Aug
Sep
Oct
Nov
Dec

- 24.10.2006 - page A5-2 - Kjellberg Finsterwalde

 Year Month carried out gas pressure test for : Date Name Signature

forming gas

Jan.
Feb
Mar
Apr
Mai
Jun
Jul
Aug
Sep
Oct
Nov
Dec

Jan.
Feb
Mar
Apr
Mai
Jun
Jul
Aug
Sep
Oct
Nov
Dec

- 24.10.2006 - page A5-3 - Kjellberg Finsterwalde