Fine Focus 450

Instruction Manual
Plasma Cutting Machine
FineFocus 450
Article no.: .11.033.502
with swirl-gas torches type PB-S47 W

prepared for CNC controls
Table of contents page
1 Safety instructions 4
2 General information 8
2.1 The dry plasma cutting 8
2.2 Plasma cutting with swirl gas 8
2.3 Characteristic and advantages 9
2.4 Application 10
3 Technical data 11
3.1 Plasma rectifier FineFocus 450 11
3.2 Plasma torches 12
3.2.1 Plasma torches of the PB-S47 W line 12
3.2.2 Plasma torch PB-S47 W-x/O2 13
3.3 Components 14
3.3.1 Plasma gas controller PGE 1 14
3.3.2 Plasma gas controller PGE 2 14
3.3.3 Plasma ignition box PZ-S47 W 14
3.3.4 Plasmagas mixing unit PM-S47 W 14
3.3.5 Plasmatorch connection block PBA-S47 W 15
3.3.6 Plasma counter PZE 1 15
4 Technical description 16
4.1 Plasma rectifier FineFocus 450 16
4.2.1 Plasma machine torch PB-S47 W 16
4.2.2 Plasma machine torch PB-S47 W-x/O2 17
4.3 Accessories 18
4.3.1 Remote control FB 1 18
4.3.2 Plasma gas controller PGE 1 and PGE 2 18
4.3.3 Plasma torch connector PGA 1 und PGA 2 18
4.3.4 Cable set PZL-S47 W 19
4.3.5 Plasma ignition box PZ-S47 W 19
4.3.6 Plasmagas mixing unit PM-S47 W 19
4.3.7 Plasmatorch connection block PBA-S47 W 19
4.3.8 Cable set PBL-S47 W 19
4.3.9 Plasma counter PZE 1 20
5 Installation 21
5.1 Checkout, placement and installation 21
5.2 Mains connection 21
5.3 Workpiece cable connection 21
5.4 Filling up coolant 22
5.5 Terminal board FineFocus 450 22
5.6 Connection of plasma torches 23
5.6.1 Connection of plasma torches to the FineFocus 450 23
5.6.2 Connection of plasma torches to the PZ-S47 W 23
5.6.3 Connection of plasma torches to the PBA-S47 W 24
Fine Focus 450_BA_engl.doc 14/11/02

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page
5.7 Connection of the plasma gas controller PGE 1 24

5.8 Connection of the plasma gas controller PGE 2 24
5.9 Connection of the plasmagas ignition box PZ-S47 W 24
5.10 Connection of the plasmagas mixing unit PM-S47 W 25
5.11 Connection of the plasmatorch connection block PBA-S45 W 25
5.12 Plasma gas supply 26
5.12.1 Plasma gas 26
5.12.2 Swirl gas (air and oxygen) 27
5.13 Connection of the plasma counter PZE 1 27
5.14 Connection of the CNC controls 28
6 Operation 29
6.1 Front panel controls 29
6.2 Cutting 30
6.3 Protective circuits 32
6.4 Change of consumables 33
6.5 Trouble shooting 36
7 Maintenance 37
7.1 Intervals of maintenance 37
7.2 Cleaning 37
7.3 Gas pressure test 37
7.4 Cooling system 38
7.5 Electrical inspection 38
Enclosure Chart piercing during plasma cutting
Cutting data FineFocus 450 with PB-S47 W
Connection schemes FineFocus 450 with plasma torch PB-S47 W

(.11.033.502.K60b / .11.033.502.K70b / .11.823.310.AS1a)
Circuit diagrams FineFocus 450

(.11.033.502.SP1a / .11.033.502.SP2a / .11.033.502.SP60a / .11.033.502.SP70a / .11.033.502.SP90a)
Plasmatorch spare parts lists for PB-S47 W, PB-S47 W-1/O2 and PB-S47 W-2/O2

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1 Safety instructions
All endangerments through plasma cutting are related with process itself. Endangerments may occur
due to:
• High contact voltage

• High-voltage ignition
• Electromagnetic disturbance
• Heat and light radiation
• Gas and smoke
• Noise
• Hot metal and spatter
• handling of pressure cylinders
The plasma cutting machine has been developed in conformity with following standards:
• EN 60974-1 (VDE 0544 part 1) Safety requirements for installations for arc welding, welding
power sources and related methods
• EN 50078 (VDE 0544 part 203) Safety requirements for installations for arc welding
• Together with EN 50192 arc welding and plasma cutting systems
• EN 50199 (VDE 0544 Part 206) Elektromagnetic compatibility
• BGV D 1 Accident prevention rules
The rules of the BGV D 1 „Welding, cutting and related methods“ have to be followed strictly through
the user. Before starting the plasma cutting unit read this instruction manual carefully! Only advised
personnel is allowed to operate the plasma installation!
Endangerment due to high contact voltage
Attention!
Before opening the plasma rectifier generally the input power has to be disconnected visible
from the mains (unplug mains cable)!
Only advised personnel is allowed to carry out any repairs to the machine.
Connect the workpiece cable and earth the workpiece before starting the machine!
The power source is equipped with a cooling unit and there is an electric potential between housing
and workpiece in case the workpiece is not earthed and the machine is switched on. Because the
high resistance of more than 10 kOhm in the coolant the contact voltage is absolute not dangerous
but sensible.
In the FineFocus 450 the water cooling circuit is insulated from the housing . Therefore no contact
voltage! The pump is controlled by a fault-voltage switch.
Special hints:
• Connect power source only to correct earthed mains socket with proper connected safety
conductor.
• Wear insulating protective clothing (safety shoes, leather apron, gloves).
• Place torch on insulated holder.
• Don’t use damaged cables and torches.
• Keep cutting area and plasma machine components dry and clean.
• Arrange regular inspections.
• Never shorten safety circuits (door switch, protective cap, etc.).

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Working under elevated electrical endangerment
The plasma cutting unit in conformity with valid standards (EN 60974-1, BGV D 1) can be used for
operation under elevated electrical endangerment:
• The power source and the plasma torch are forming a safety-proofed installation which can be
separated only by using tools.
• The FineFocus 450 can’t be switched on when the door in the right cover plate is not closed
completely.
Therefore the FineFocus 450 is marked with the S-sign and operation under enhanced electrical
endangerment is allowed..
Attention!
Always follow the local safety rules (BGV D1 and EN 60974-1)!
Endangerment through high voltage ignition
A high-voltage ignitor starts the pilot arc. The Hv-supply is cut-off automatically after pilot arc has
struck.
Attention!
Never touch torch head when power source is switched on!
High-voltage ignition may establish electro-magnetic fields and can influence:
• pace makers
• electronic devices
Endangerment through electromagnetic interferences:
The plasma cutting unit is in conformity with the conditions of the EN 50199 (VDE 0544 part 206)
„Electromagnetic compatibility“. This standard is valid for arc welding and related processes (plasma
cutting) which comes in use in commercial and private fields.
WARNING!
Special precautions may be required if the plasma unit is used in private fields (for instance
screened cables, etc.)
The user takes the full risk when installing and using the machine. He has to follow strictly the
instructions of the supplier. If electromagnetic interferences are noticed the user has to contact the
producer to solve the problem.
Recommendations to classify the environment (EN 50199):
Before the installation takes place the user has to value the environment for electromagnetic
problems and to take into consideration:
• other mains supplies, control cables, signal and telecommunication lines along, above, below or
besides the installation
• broadcasting or television installations
• computer or other controls
• safety devices, protection circuits
• the health of people in the neighbourhood (heart pace makers, hearing aids, etc.)
• devices for measuring and calibrating
• the noise immunity of equipments around the installation are compatible to electromagnetic
interferences; that could require special protections
• the day time plasma cutting is performed

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Recommendations to minimise interferences:
If interferences take place following should be done:
• filter for mains connection

• screening of mains cable of the plasma installation (safe contact between screen and housing
required)
• regularly maintenance
• keep cover plates and doors of the plasma machine always closed
• avoid excessive welding or cutting cables
• earthing of the workpiece
• selective screening of other cables and installations
• arrange potential equalisation between metallic parts around the installation (the operator has to
be insulated from those parts)
Endangerment through heat and light radiation:
Ultraviolet and light radiation developed through the plasma arc can hurt eyes and skin. Following
precautions are required:
• wear of insulating and heavy to influence clothes (head shield, aprons, gloves, shoes)
• use of head shields with medium dark glasses
• arrange cutting area, so that no other persons are endangered directly or through reflections:
• install flexible walls
• use dark colours for walls
Endangerment through fumes and smoke
Due to the plasma process itself hazardous substances may be produced. To avoid risks on health
the following has to be done:
• keep cutting place well ventilated

• remove fumes and smoke by exhaustion devices
• remove 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 galvanised materials
• ensure that toxic limits are not exceeded
Attention!
The user of the plasma cutting machine has to proof by measurements the concentration of
hazardous substances the effectiveness of the ventilation!
Endangerment through noise
Be aware that during plasma cutting a high noise level arises.
Cutting current Material thickness Noise level in distance of

0.5m 1.0m
no load - - 56 dB(A)
50A 4mm 82 dB(A) 79 dB(A)
75A 16mm 86 dB(A) 83 dB(A)
130A 16mm 96 dB(A) 92 dB(A)
Chart 1: Noise level of FineFocus 450
Therefore wear correct ear protection.

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Endangerment through spatter:
During plasma cutting sparks, slag and hot metal are produced. The risk of burns and fire exists!
To avoid these endangerments the following has to be advised:
• Remove all potential flammable materials from cutting area, at least in a 10 m distance!
• Cool down freshly cut material before handling!
• Make fire extinguisher available in the cutting area!
Handling of pressure cylinders
For the plasma cutting process compressed gases are required. To avoid endangerments the
following has to be advised:
• Place cylinders upright in secured position.

• Don’t use damaged cylinders, pressure reducers and armatures.
• Use pressure reducers only for the gas it is determined.
• Never lubricate pressure reducers with grease or oil.
• All parts coming in touch with oxygen have to be prevented from oil and grease.
• When using oxygen the pressure reducer has to be equipped with an explosive-proofed device
(backfire-device).
• Perform gas test acc. to chapter 7.3

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2 General information
2.1 The dry plasma cutting

A plasma is defined as a gas having atoms and molecules which are partly split into ions and
electrons and having therefore a high electrical conductivity.
In the plasma torch this gas becomes heated up extremely and leaves it through the nozzle with 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 forming a very
small kerf in the material.
The plasma arc hereby is transferred from the cathode, installed in the plasma torch and connected
to the negative pole of the plasma power source to the workpiece, connected to the positive pole
(transferred arc).
Fig. 1:
Plasma cutting principle
1 pilot arc resistor

2 Hv-ignitor
3 Gas supply
4 cathode
5 nozzle
6 plasma arc
(main arc)
7 workpiece
The safe ignition of the (main) arc :
• High-voltage ignition of pilot arc

• Switching off ignitor after ignition of pilot arc
• Power increase automatically if pilot arc touches the workpiece
2.2 Plasma cutting with swirl gas

With conventional plasma torches there always the risk exists that during piercing or cutting
upcoming material and spatter will touch the torch tip and cause double arcing and nozzle defects.
The life time of the nozzle becomes reduced and the cutting quality influenced.
Plasma torches with swirl gas technology overcome those disadvantages. Here an additional gas
flow surrounds the plasma arc. Spatter and hot metal will be forced away through the gas swirl
especially during piercing.
The gas swirl has to be adjusted very carefully to match the requirement of each material and
thickness.
Figure 2 shows the principle of the swirl-gas technology.

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A A
C B C B Fig. 2:
D Plasma torch with swirl gas and
conventional plasma torch
a water inlet
b water return
c plasma gas
d swirl gas
E E
F F
without swirl-gas with swirl-gas
2.3 Characteristic and advantages

The FineFocus-plasma developed from Prof. Manfred von Ardenne is defined by an extreme high
density of energy offering various technological advantages:
• Double-Straight Effect (same cutting quality on both the cutting surfaces)

• narrow cutting kerfs
• low loss of material
• low heat input
• low distortion
• high cutting speed
• perfect cutting quality
Technological advantages for plasma cutting with oxygen result in the application of swirl-gas
technology and use of the XL-Life-Time system.
Further features and advantages are given:
• material depending cutting range of FineFocus 450 from 1 up to 35 mm (quality cut) respectively
45 mm (maximum cut) with a maximum cutting power of 20 kW
• stepless current setting from 40 A up to 130 A for optimised adaptation of the cutting power
• excellent cutting properties due to power source with twelve-pulse rectification
• microelectronic controls ensure highest constancy of the cutting outputs of the power source
• large CNC interface for connection to all available CNC and robot controls
• active power control through CNC controls possible
• adjustable “soft start” safes nozzles and cathodes
• internal cooling system for extended life time of nozzles and cathodes
• very easy to handle, safe operation start because of:
• Hv-ignition for pilot arc
• main arc starts if pilot arc touches workpiece
• safety circuits for perfect operation:
• pressure switch for gas flow control
• coolant flow switch ensures sufficient cooling
• time limitation for pilot arc
• automatic cut-off if nozzle touches workpiece
• comfortable access to torch terminal board through side wall door with safety switch
• easy operation, control board with symbols for service and control display
• high efficiency and low operation costs because of:
• internal fluid cooling system, therefore low consumption of gases
• use of inexpensive air for plasma gas possible
• up to date industrial design, easy to transport by crane or fork lift
• plasma cutting with gases air and oxygen as well as Ar/H2- respectively Ar/H2/N2-mixtures for
optimum cutting of all electrically conductive materials

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2.4 Application
The transferred arc principle allows cutting on all electrically conductive materials up to 45 mm
(depending on the material). Also gouging on these materials is possible.
It is possible to cut mild steels, high-alloyed steels, nonferrous metals (for example aluminium) and
special alloys. The following plasma gases we recommend:
• Mild steel
plasma gas Air / swirl gas Air
high productivity, nearly no dross, small content of nitrogen or oxygen in cutting surfaces
possible
plasma gas Oxygen / swirl gas Air:
high productivity, nearly no dross, cutting surface clean of nitrogen
• CrNi steels
plasma gas Air / swirl gas Air:
high productivity, nearly no dross, surface nitration and oxidation may occur, cutting surface
quality not so good as cutting with Ar/H2 respectively Ar/H2/N2-mixture
plasma gas Ar/H2- respectively Ar/H2/N2-mixture / swirl gas N2:
very clean surfaces, nearly no dross when using Ar/H2/N2-mixtures
• Aluminium
plasma gas Air / swirl gas Air:
high productivity, no or nearly no dross, agreeable cutting quality
plasma gas Ar/H2 / swirl gas Air:
perfect cutting quality
With the plasma torches PB-S47 W it is possible to start by piercing, either stationary or running.
The FineFocus 450 is suitable for straight line, profile and bevel cutting. Therefore semi finished
products as sheet steels, tubes, sections, forging and forming-parts sheet packs, scrap and gush
products can be separated or processed thermally.
The stepless control gives the possibility to adapt always the cutting power to the material thickness.
After changing consumables (see chapter 6.4) all plasma torches of the PB-S47 W line can be used
without swirl gas as well.

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3 Technical data
3.1 Plasma rectifier FineFocus 450
Primary side :
Input voltage U1 (+5%/-10%): Art. no. Fuse, slow: Mains cable,
Cu
3~ 400 V, 50 Hz .11.033.502 50 A 4 x 6 mm2
3~ 230/400 V, 50 Hz .11.033.503 80 A 4 x 10 mm2
3~ 500 V, 50 Hz .11.033.506 50 A 4 x 6 mm2
3~ 440 V, 60 Hz .11.033.508 50 A 4 x 6 mm2
3~ 480 V, 60 Hz .11.033.509 50 A 4 x 6 mm2
3~ 415 V (420) 50 Hz .11.033.5010 50 A 4 x 6 mm2
Power factor cos ϕ: 0.8 (100 A)
Efficiency: 0.77
Secondary side:
Cutting range 40-130 A
Open circuit voltage U0: 400 V
Cutting current IS: 40-130 A
Cutting voltage US: 160 V
Cutting power PS: 20 kW
Duty cycle X: 100 % (100 A)
75 % (130 A)
Sequence: 10 min
Material thickness ds :
Quality cut: 35 mm
Maximum cut: 45 mm
Pilot arc IPB: 15 A
Characteristic: drooping
Mode of ignition: • High-voltage ignition for pilot arc
• Main arc start through pilot arc
2
Workpiece cable: 35 mm
Weight m: 251 kg
Dimensions (l x w x h): 1025 x 711 x 970mm
(with undercarriage with castors and wheels)
protection class: IP22
Insulation class: F
Cooling: by fan
Torch cooling: integrated cooling circuit
Coolant: Coolant with integrated corrosion protection
„Kjellfrost“ (antifreeze up to -10 oC) respectively
„Kjellfrost-SUPER“ (antifreeze up to -25 oC)
0.45 MPa (4,5 bar) at 3.8 l/min
Pressure:
circa 11 l
Tank capacity:

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3.2 Plasma torch
3.2.1 Plasma torches of the PB-S47 W line
Machine torch: PB-S47 W/L PB-S47W/A

.11.834.211
Art. no. : .11.834.201
PB-S47 W-2/L PB-S47 W-2/A

.11.834.701 .11.834.711
Cutting thickness / -current: 45 mm (130 A)

Piercing 25 mm (130 A)
max. open circuit voltage UO: 400 V
max. pilot current IPb: 19 A
Duty cycle: 100 %
Ignition: High-voltage ignition (max.10kV) of pilot arc
Torch diameter: 42 mm (machine torch)
Weight m:
Type PB-S47 W/x: 6.0 kg (6 m hose parcel)
Type PB-S47 W-2/x 2.2 kg (1 m hose parcel)
Torch cooling: Coolant with integrated corrosion protection
circa 3.2 l/min
Flow rate:
Plasma gases Air Ar/H2/N2-mixture
(free of oil and moisture, (with PM-S47 W)
micro filter recommended)
0,5 - 0,6 MPa (5 - 6 bar)
Pressure: 1300 - 1600 l/h 0.5 - 0.6 MPa (5 - 6 bar)

Flow rate: (20 - 26 l/min) 1400 - 2300 l/h
(23 - 38 l/min)
Use as: ignition and cutting gas ignition and cutting gas
Swirl gas Air Nitrogen
Pressure: 0.5 - 0.6 MPa (5 - 6 bar) 0.5 - 0.6 MPa (5 - 6 bar)
Flow rate (start): 3700 - 5400 l/h 3700 - 5400 l/h
60 - 85 l/min 60 - 85 l/min
Flow rate (cutting): 1700 - 3200 l/h 1700 - 3200 l/h
26 - 49 l/min 26 - 49 l/min
Hose parcel Type PB-S47 W/x Type PB-S47 W-2/x

Length : 6 or 10 m 1 or 2 m
Connections
Water return / power: G 3/8"
Water supply: G 1/8"
Swirl gas: M12x1
Control gas: M8x1
1-pole plug
Pilot cable:
Plasma gas: G 1/4" (Air or Ar) G 1/4" (Air or Ar)

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G1/4”left (dummy)
Solenoid cable : 7-pole plug -
3.2.2 Plasma torch of type PB-S47 W-x/O2
Machine torch: PB-S47 W-1/O2 PB-S47 W-2/O2

Art. no.: .11.834.321 .11.834.721
Cutting thickness / -current: 45 mm (130 A)

Piercing 25 mm (130 A)
max. open circuit voltage UO: 400 V
max. pilot current IPb: 19 A
Duty cycle: 100 %
Ignition: High-voltage ignition (max.10kV) of pilot arc
Torch diameter: 42 mm
Weight m: 6,6 kg 2,2 kg
Type PB-S47 W/x: (6 m hose parcel) (1 m hose parcel)
Type PB-S47 W-2/x
Torch cooling: Coolant with integrated corrosion protection
circa 3.2 l/min
Flow rate:
Plasma gases Air Oxygen
(free of oil and moisture, (99,5 %, dry, clean, micro
micro filter recommended) filter recommended)
Flow rate: 1100 - 1700 l/h 900 - 1500 l/h

(18 - 28 l/min) (15 - 25 l/min)
Use as: Ignition gas Cutting gas
Swirl gas Air

Pressure: 0.5 - 0.6 MPa (5 - 6bar)
Flow rate (start): 3700 - 5400 l/h (60 - 85 l/min)
1700 - 3200 l/h (26 - 49 l/min)
Flow rate (cutting):
Hose parcel 6 or 10 m 1 or 2 m
Length :
Connections
Water return / power: G 3/8"
Water supply: G 1/8"
Swirl gas: M12x1
Control gas: M8x1
1-pole plug
Pilot cable:
Plasma gas: G 1/4" (Air) G 1/4" (Air)
G 1/4"lks. (O2) G 1/4"lks. (O2)
Solenoid cable : 7-pole plug -
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3.3 Components
3.3.1 Plasma gas controller PGE 1
Art. no.: .11.824.220

Control voltage: 24 V AC, 50 / 60 Hz
Dimensions (l x w x h): 310 x 185 x 340 mm
Weight : 7 kg
Plasma gases: Air Oxygen
(free of oil and moisture, (99,5%, dry, clean, micro
micro filter recommended) filter recommended)
Flow rate (with torch): 1100 - 1700 l/h 900 - 1500 l/h
18 - 28 l/min 15 - 25 l/min
Connector: G1/4” G1/4”
Swirl gas: Air Nitrogen
(min. 99.9 %)
Pressure: 0.5 - 0.6MPa (5 - 6bar) 0.5 - 0.6 MPa (5 - 6 bar)
max. flow rate (with torch): 3700 - 5400 l/h 3700 - 5400 l/h
60 - 85 l/min 60 - 85 l/min
Connector: G1/4" G1/4"
3.3.2 Plasma gas controller PGE 2
Art. no.: .11.824.225

Control voltage: 24 V AC, 50 / 60 Hz
Weight: 7 kg
Plasma gases: Argon Hydrogen Nitrogen
(99.996%) (99.95%) (99.999%)
Pressure: 0.5-0.6 MPa 0.5 - 0.6MPa 0.5 - 0.6 MPa
(5 - 6 bar) (5 - 6 bar) (5 - 6 bar)
Flow rate (with torch): 1100-1600 l/h 100-185 l/h 275-575 l/h
18 - 26 l/min 1.6 - 3 l/min 4.5 - 9.5 l/min
Connector: G1/4” G3/8” left G1/4”
Swirl gas: Nitrogen (see PGE 1)
3.3.3 Plasma ignition box PZ-S47 W
Art. no.: .11.821.925

Control voltage (solenoids): 24 V AC, 50 / 60 Hz
Weight: 11 kg
Plasma gases: Air, O2, (see chapter 3.3.1)
Connected to: FineFocus 450 with cable set PZL-S47 W

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3.3.4 Plasmagas mixing unit PM-S47 W
Art. no.: .11.824.217

Control voltage (solenoid): 24 V AC, 50 / 60 Hz
Dimensions ( l x w x h): 300 x 185 x 140 mm
Weight: 3,5 kg
Plasma gases (inlet): Ar, H2, N2 (see Pkt.3.3.2)
Plasma gases (outlet): Ar/H2/N2-Gemisch
Flow rate (with torch): 1400-2300 l/h (23 - 38 l/min)
Connection to: FineFocus 450 and PZ-S47 W
3.3.5 Plasma torch connection block PBA-S47 W
Art. no.: .11.820.216 (Air,O2)

.11.820.217 (Ar/H2/N2)
.11.820.218 (Air, O2, Ar/H2/N2)
Control voltage (solenoids): 24 V AC, 50 / 60 Hz
Dimensions (l x w x h): 170x237x280 mm
Weight: 4.9 kg
Plasma gases: Air, O2, Ar/H2/N2
3.3.6 Plasma counter PZE1
Art. no.: .11.824.250

Dimensions (lxwxh): 180 x 185 x 140
Weight: 2.0 kg
Connection to: FineFocus 450 with 3-pole control cable

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4 Technical description
4.1 Plasma rectifier FineFocus 450
The components of the power source are mounted into a movable housing. The front side contains
all the controls and displays, the workpiece cable connector, the entry for the torch hose parcel.
On the back side wall the plasma gas connector for air, the coolant filter neck, the mains cable entry
and the slots for the cooling air exit are located, also the fuses F1 - F12 and the connectors for the
plasma counter PZE 1, the flow controllers PGE 1 and PGE 2 and the CNC interface.
The connectors for the plasma torch respectively the hose parcel extensions and for the remote
control are accessible after opening the door in the right side cover plate.
The circulating cooling system consists of the pump, the tank, the heat exchanger and the flow
switch, which switches off the power source if the flow rate is low.
The plasma rectifier is provided with an air supply, consisting of an air filter, the solenoid valve and a
gas pressure switch, which switches off the power source if the gas pressure is below 0.3 MPa
(< 3 bar).
When using ArH2N2-mixtures for plasma gas the gas supply takes place through the plasmagas
mixing unit PM-S47 W or the plasma gas controllers PGE 1 and PGE 2 and when using oxygen or
air through the plasma ignition box PZ-S47 W-1. The power source of the FineFocus 450 itself
consists of the main transformer, the twelve-pulse rectifier set, the Hv ignitor and the pilot arc
resistors for striking the pilot arc.
4.2 Plasma torches

Attention!
Only plasma torches of the PB-S45 W / PB-S47 W line are allowed to be used in connection
with the plasma cutting unit FineFocus 450!
Before carrying out any maintenance or service on plasma torches disconnect input power
visible (unplug mains cable)!
The plasma torches are suitable for following plasma gases :

• PB-S47 W(-2)/x: Air or Ar/H2/N2-mixture, swirl gas
• PB-S47 W-1(-2)/O2: Oxygen (ignition with air), swirl gas
The plasma torches are based on similar design principles. A copper cable inserted in the water
return hose transfers the cutting current from the power source to the cathode.
The replaceable nozzle cap keeps the nozzle in a centred position in the nozzle holder. The coolant
circulates between nozzle and nozzle cap. A cooling tube directs the water flow into the cathode
assuring a very effective heat transfer. This cooling system grants a high life time of all torch parts.

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Attention!
Before using the plasma torch be sure that the torch head is equipped with parts suitable for
the job you are performing! After changing torch parts blow out coolant which occasionally
has collected in the nozzle by using the gas purge switch S5 in the front panel. Wet nozzles
and cathodes could be the reason for double arcing.
Attention!
The operator is allowed to change only above mentioned wearing parts! Torch repairs have
to be carried out only through advised personnel. Always use spare parts and consumables
of Kjellberg origin. Otherwise no guarantee for cutting performance and quality.
4.2.1 Plasma machine torch type PB-S47 W
The plasma machine torches of the PB-S47 W line are suitable for max. 130 A cutting current, that
means for thickness up to 45 mm. The torch consists of the torch head, the torch shank, the hose
parcel and the consumables.
Following torches of the PB-S47 W line are available:
• PB-S47 W/L / PB-S47 W-2/L

- for plasma gas air
• PB-S47 W/A, PB-S47 W-2/A

- for plasma gas Ar/H2/N2-mixture
The torches easily can be adapted to different plasma gases only by changing the consumables:
• .../L = torch is prepared for air
• .../A = torch is prepared for Ar/H2/N2-mixture
The following charts are showing the consumables for the different applications (see also fig. 7):
Application
Plasma cutting
Material thickness up to 16 mm up to 25 mm up to 45 mm
Cutting current up to 50 A up to 90 A up to 130 A
Cathode Kb (flat) Kb (flat) Kb (flat)
Nozzle Lle Lde Lee
Nozzle ∅ 1.0 mm 1.3 mm 1.4 mm
Chart 2: Consumables PB-S47 W(-2)/L for plasma gas air
Application
Plasmas cutting
Cathode Ka (sharp) Ka (sharp) Ka (sharp)
Nozzle Ade Aee Afe
Chart 3: Consumables PB-S47 W(-2)/A for plasma gas Ar/H2/N2-mixture
Consumables for cutting with swirl gas are: cathode, nozzles, nozzle cap with swirl-gas guide,
cooling tube, gas guide, swirl-gas nozzle, protective cap, swirl-gas cap and O-rings 6 x 2, 10 x 1,
12 x 1,5 , 20 x 2, 22 x 2 and 32 x 2.
Consumables for dry cutting without swirl gas are: cathode, nozzles, nozzle cap without swirl-gas
guide, cooling tube, gas guide, end cap, insulation ring for end cap and O-rings 6x2 ; 10x1 ; 12x1,5 ;
20x2 and 32x2.
For mounting cathode puller and spanner for nozzle cap have to be used.
For changing consumables see chapter 6.4.

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4.2.2 Plasma machine torch PB-S47 W-x/O2
Attention!
Keep all parts coming in touch with oxygen absolutely free of oil and grease (also
consumables)!
The plasma torch PB-S47 W-x/O2 is designed for 130 A cutting current and therefore applicable up
to 45 mm thickness.
The torch consists of the torch head , the torch body, the hose parcel and the consumables.
Because of the dual-gas ignition two gas supply hoses are provided. For the main consumables see
following chart (and fig. 7).
Application
Plasma cutting
Cathode Kb XL (flat) Kb XL (flat) Kb XL (flat)
Nozzle Lle XL Lde XL Lee XL
Chart 4: Consumables PB-S47 W-x/O2 for plasma gas oxygen
Consumables for cutting with swirl gas are: cathode, nozzles, nozzle cap with swirl-gas guide,
cooling tube, gas guide, swirl-gas nozzle, protective cap, swirl-gas cap and O-rings 6 x 2, 10 x 1,
12 x 1,5 , 20 x 2, 22 x 2 and 32 x 2.
Consumables for dry cutting without swirl gas are: cathode, nozzles, nozzle cap without swirl-gas
guide, cooling tube, gas guide, end cap, insulation ring for end cap and O-rings 6x2 ; 10x1 ; 12x1,5 ;
20x2 and 32x2.
For mounting cathode puller and spanner for nozzle cap have to be used.
For changing consumables see chapter 6.4.
Attention!
Keep all parts coming in touch with oxygen absolutely free of oil and grease (also
consumables)!
Use only XL nozzles und XL cathodes! Other types of nozzles and cathodes will damage the
plasma torch.
4.3 Accessories
4.3.1 Remote control FB1
With the remote control the cutting process with the machine torch becomes started and stopped. It
contents the green ON-button and the red OFF-button. The 10m long cable becomes connected to
the terminal board of the FineFocus 450.
4.3.2 Plasma gas controller PGE 1 and PGE 2
The plasma gas controller PGE 1 and PGA 2 are required for the precise adjustment of the flow rate
of the plasma gases and swirl gases.
The PGE 1 includes the gas connectors, pressure switches, solenoids and flow meters for the
plasma gases air and oxygen and for the swirl gas. A tumbler switch for the gas purge is provided.

- page 18 -
Through the 25-pole control cable the connection to the FineFocus 450 (back side, connector X110)
will be carried out.
The PGE 2 includes the gas connectors, pressure switches, solenoids and flow meters for the
plasma gases Ar H2 and N2. Tumbler switches allow to start or close the gas flow separately for each
plasma gas. Through a 4-pole control cable the connection to the FineFocus 450 (back side,
connector X120) will be carried out.
4.3.3 Plasma torch connector PGA 1 and PGA 2
For connection of the plasma machine torch PB-S47 W or the plasmatorch connection blockPBA-
S47 W with the cable set PBL-S47 W the plasma torch connectors PGA 1 and PGA 2 are required.
The PGA 1 contains the connectors for the plasma gases oxygen and air, the swirl gas and the
control gas. The PGA 2 contains the connectors for the plasma gases Ar / H2 / N2 and a dummy
connector G1/4” left.
The PGA 1 respectively PGA 2 are placed below the plasma flow controller. The combined units
PGA 1/PGE 1 and PGA 2/PGE 2will be placed on the top of the FineFocus 450 (holes provided).
4.3.4 Cable set PZL-S47 W
In many cases the hose parcel lengths of the plasma torches with 6 or 10 m are sufficient.
Extensions up to 40 m are possible by using the cable set PZL-S47 W and the plasma ignition box
PZ-S47 W.
The cable set PZL-S47 W consists of:
• water return hose with power cable

• water supply hose
• control cable, 17 poles
• supply cable, 2 poles
• pilot arc cable
• protective cable
4.3.5 Plasma ignition box PZ-S47 W
The plasma ignition box PZ-S47 W ensures a safe ignition of the plasma arc when using cable
extensions and acts as connection point between plasma torch hose parcel and extension cable.
Furthermore it contents the Hv-ignitor, solenoids for air and oxygen, the swirl gas and control gas
and the plasmagas mixing unit PM-S47 W.
4.3.6 Plasmagas mixing unit PM-S47 W
The plasmagas mixing unit PM-S47 W is required if a mixture of Ar and H2 or Ar, H2 and N2 is used
for the plasma torches PB-S47 W/A and PB-S47 W-2/A. The unit includes a solenoid valve for the
gas mixtures.
The control voltage is taken from the PZ-S47 W through as 8-pole cable (socket X105/PM-S47 W).
4.3.7 Plasmatorch connection block PBA-S47 W, PBA-S47 W/Robo
The PBA-S47 W enables the operator to change torches without time delay. It acts as a connection
point between the PB-S47 W-2 torches and The PZ-S47 W respectively the FineFocus 450. All “life”
connector parts are placed inside of a safety button protected compartment.
The plasma gas connectors are fitted outside the connection block.
In addition the PBA-S47 W/Robo is provided with a stress relief for the hose parcel.

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4.3.8 Cable set PBL-S47 W
The cable set connects the plasma torch connection block PBA-S47 W with the plasma ignition box
PZ-S47 W or with the power source FineFocus 450.
The cable set consists of
• water supply hose

• water return hose with cathode cable 6mm2
• swirl-gas hose
• control-gas hose
• pilot arc cable
For plasma gas supply the gas hoses for air and oxygen (from PGA 1 respectively PZ-S47 W) or for
Ar/H2/N2-mixture (from PGA 2 respectively PM-S47 W) have to be connected depending on
application mode.
4.3.9 Plasma counter PZE1
The plasma counter PZE 1 counts the number of ignitions and the effective cutting time.
It will be connected directly to the rear wall of the FineFocus 450 through a 3-pole control cable.

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5 Installation
Attention! Consider connection schemes!
All damages during transport or incomplete supplies should be claimed with the carrier or the
supplier just after receive of the unit.
5.1 Check out, placement and installation

The plasma cutting unit is designated for a service in non-explosion endangered rooms or outside
under a roof by following conditions:
• Ambient temperature: -10°C up to +40°C

• Relative moisture: max. 90%
Place the FineFocus 450 so, that the air flow is not blocked (intake through the front panel grating,
exhaust through rear panel)! Keep a 250 mm free distance around the machine.
The plasma cutting unit is designed acc. to protection class IP 22 (DIN 40050), that means:
• protection against penetration of solid parts above 12 mm

• protection against dripping water, vertical falling, with max. 15° inclination.
Avoid that dust, excessive moisture and corrosive substances will collect in the power source!
Transportation is possible manually, by crane or by forklift.
Attention!
For crane transport all the four lifting
hooks have to be used. The angle
between the ropes or chains should not
exceed 45°. When transporting by forklift
the FineFocus 450 should be lifted only
from the back side!
Fig. 3: Crane transport

- page 21 -
5.2 Mains connection
The plasma cutting machine is provided with a power supply cable (4 x 6 mm²), 5 m long. A wall-
mounted power switch has to be placed in line with the mains socket. Use fuses of proper size (see
3.1)!
5.3 Workpiece cable connection

For the workpiece cable connection a power supply socket is arranged in the front cover plate. The
work clamp must have a good contact to the workpiece or the cutting table.
Warning!
Never use conductive parts of the building, pipelines rails, etc. for the connection with the
workpiece!
Workpiece and cutting table have to be earthed properly!

5.4 Filling up coolant
The coolant has to be filled up before the torch is connected (elimination of air from the pump).
As coolant at temperatures below 0 °C the use of antifreezer “Kjellfrost” (resists freezing up to -10
°C) or “Kjellfrost-Super” (resists freezing up to -25 °C) is recommended. These coolants additionally
are protecting the pump, packings and cooling channels of the plasma torch.
Attention! It is not allowed to add water to the coolant (acid formation)!
The filler neck is placed on the back of the power source. The tank capacity amounts to
approximately 11 l. Excessive coolant leaves the tank through the overflow tube and is guided to the
floor. The filling level is indicated by a show glass (left side wall).
When using the plasma ignition box PZ-S47 W with a hose parcel extension PZL-S47 W 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 (filling
level on “max”).
After 12 months the complete coolant has to be replaced (with no regard to the working conditions).
5.5 Terminal board of the FineFocus 450

The terminal board of the FineFocus 450 become accessible by opening the door in the right side
cover plate with a screwdriver.
The terminal board contents the connection board and the stress relief for the hose parcels.
The following connections to the terminal board are possible:
• the plasma torches of the PB-S47 W line
• the PZL-S47 W , necessary for the connection of the PZ-S47 W-1 to extend the operational
area
• the cable set PBL-S47 W for the connection of the PBA-S47 W
• the plasmagas mixing unit PM-S47 W for plasma gas Ar/H2/N2 – mixtures
• the remote control FB1
Fig. 4: Terminal board FineFocus 450
1 Connection plasmagas mixing unit PM-S45 W-1 5 pin plug

2 Connection control cable PZL-S45 W-1 / 17 pin
PZL-S47 W socket

- page 22 -
3 Connection control cable PB-S47 W or cable set 7 pin socket
PZL-S47 W / PBL-S47 W
4 Connection pilot arc PZL-S45 W-1 and PZL-S47 W terminal M5
5 Connection remote control FB1 3 pin socket
6 Connection pilot cable plasma torch „X13/PB“ 1 pin socket
PB-S45 W(H)-1
7 Connection „water return“ G 3/8“
8 Connection „water supply“ G 1/8“
9 Connection „plasma gas air“ G 1/4"
5.6 Connection of plasma torches
Warning!
Never open the FineFocus 450 or the ignition box before the power source is switched off
and the power supply is visible disconnected from the mains (unplug power supply cable)!
The plasma torches of the PB-S47 W line either can be connected directly to the power source
FineFocus 450, or the plasma ignition box or the plasmagas connection block. For the use of an
Ar/H2/N2-mixture the plasmagas mixing unit M-S47 W generally is required.
The plasma torch PB-S47 W-2 requires in any case the plasmatorch connection block PBA-S47 W.
The machine torch has to be fixed to the guiding equipment. Use for that the torch fasting from
Kjellberg Finsterwalde.
5.6.1 Connection of the plasma torches to the FineFocus 450
• open the door in right side panel (use screw driver)
• open green stress relief clamp
• insert torch terminals through the entry in the front panel (chart 5)
• connect gas hoses to the PGA 1 or PGA 2 (see chart 5)
Hose parcel PB-S47 W(-1)/x Terminal board FineFocus 450 Fig.4

water return hose G3/8" "H2O return" 7
Water supply hose G1/8" "H2O inlet" 8
Control cable 7 pin plug "X104 / PZ" 3
Pilot cable 1 pin plug "X13 / PB / nozzle" 6
PGA 1 PGA 2
Swirl gas hose "M12x1" -
Control gas hose "M8x1" -
Plasma gas hose G1/4" "Air" "Ar/H2/N2"
Plasma gas hoses G1/4"/G1/4"left "Air"-/-"O2" "ArH2N2"-/-dummy
Chart 5: Connection PB-S47 W(-1)/x to FineFocus 450
After the torch connection is carried out the stress relief clamps has to be closed carefully and the
side wall door locked properly. The hose parcel has to be placed straight without sharp bends.
5.6.2 Connection of plasma torches to the plasma ignition box PZ-S47 W

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Suitable for the plasma ignition box PZ-S47 W are:
• Plasma machine torch PB-S47 W/x
• Plasma machine torch PB-S47 W-1/O2
• Take off cover from plasma ignition box

• Open green stress relief clamp
• Insert torch terminals through entry of the front side and place the parcel in on loop so that the
torch terminals can be fitted on the back side of the terminal plate (chart 6)
• Connect gas hoses PZ-S47 W respectively PM-S47 W (Chart 6):
Hose parcel PB-S47 W(-1) Terminal board PZ-S47 W

Water return hose G3/8" "H2O return"
Water inlet hose G1/8" "H2O inlet"
Control cable 7 pin plug "X104 B
Pilot arc cable 1 pin plug "nozzle +"
Swirl gas hose "M12x1"
Control gas hose "M8x1"
Front wall PZ PM-S47 W
Plasma gas hose G1/4" "Air" "Ar/H2/N2"
Plasma gas hose G1/4"/G1/4"lks. "Air"-/-"O2" "ArH2N2" / dummy
Chart 6: Connection PB-S47 W/x and PB-S47 W-1/O2 to PZ-S47 W/PM-S47 W
5.6.3 Connection of plasma torches to the plasma torch connector PBA-S47 W
The torches of the PB-S47 W-2 series generally have to be connected to the
PBA-S47 W.
The following has to be connected:
• water return hose G3/8" ("H2O return")

• water inlet G1/8" ("H2O inlet")
• swirl gas M12x1
• control gas M8x1
• pilot arc cable M4
the gas hose connections are outside of the PBA-s47 W.
5.7 Connection of the plasma flow controller PGE 1

The PGE 1 is provided with 25-pole control cable for the connection to the plug X110, placed on the
back side of the FineFocus 450.
The gas hose become connected to the back side of the PGE 1:
• input (oxygen, air, swirl gas): upper connectors
• outlet: lower connectors
By means of the swirl gas selectors WGU 1 (optional) two different gases can be connected to the
PGE 1 by manual selection.
When torches are direct connected to the power source the PGE 1 becomes connected with the
PGA 1, otherwise the PGE 1 has to be connected with the gas hoses to the PZ-S47 W.

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5.8 Connection of the Plasma flow controller PGE 2
The PGE 2 is provided with a pole control cable for the connection to the plug X120, placed in the
back side of the FineFocus 450. The gas hoses become connected to the back of the PGE 2:
• input (Ar, H2, N2): upper connectors

• outlet: lower connectors
When torches are direct connected to the power source the PGE 2 becomes connected with the
PGA 1, otherwise with the has hoses to the plasmagas mixing unit PM-S47 W.
5.9 Connection of plasma ignition box

see drawing no.: .11.820.310.AS2 a (connection PZ-S47 W to plasma power source with PZL-S47 W)
The cable set PZL-S47 W (max 40m) joints the power source with the plasma ignition box PZ-
S47 W.
Following connections have to be carried out:
FineFocus 450 Fig.4 Cable set PZL-S47 W PZ-S47 W terminal board

Terminal board
"H2O return / G3/8" 7 water return hose "H2O return / G3/8"
"H2O supply / G1/8" 8 water supply hose "H2O supply / G1/4"
"X103 / PZ" 2 control cable / 17 poles "X103A"
"X104 / PZ" 3 control cable / 7 poles X104 A
"X14 / PZ / nozzle / M5" 6 pilot arc cable / 1pole "X102A: nozzle +"
"X106: 1, 2" supply cable / 2 poles "X102A: 19, 20"
"Housing / M8" protective cable / 1 pole housing M8
Chart 7: Connection PZL-S47 W
Connections on the PZ-S47 W:

• Remove cover plate
• Insert cable set through entry of the back side and perform connections from the front of the
terminal plate
Connections on the FineFocus 450:

• Open door on right side with screw driver
• Insert cable set through the cable entry of the front side
• perform connection on the terminal plate (chart 7)
Close stress relief clamp carefully, avoid sharp bends when placing the cables and hoses.
Attention!
Close cover of the plasma cutting unit and plasma ignition box after all connections are
carried out.
Safety contacts are placed in both units to avoid operation with open covers.
5.10 Connection of the plasmagas mixing unit PM-S47 W
The plasmagas mixing unit can be placed either on the top of the plasma cutting machine or on the
top of the plasma ignition box. The connection cable will be inserted in the socket X105 / PM-S47 W.
For adjustment on the PZ-S47 W following steps have to be done:
• Removal of the handle on the top of the PZ-S47 W after the complete cover is taken off
• Fastening of the PM-S47 W
• Replacing of the cover
The plasmagas mixing unit can also set up beside the cutting machine respectively the ignition box.
- page 25 -
5.11 Connection of the plasmatorch connection block PBA-S47 W
The PBA-S47 W is prepared for the installation to the support of a profile cutting machine (two holes,
9mm diameter). After then the cable set PBL-S47 W will be connected to the PBA-S47 W. All gas
hose connections have to be gas tight.
Attention!
After the connections the safety switch in the PBA-S47 W has to be activated by removing
the link X102:21-X102:22 (terminal strip, 6 poles) placed on the terminal plate of the PZ-S47
W.
The effectiveness of the protective switch has to be proofed!
5.12 Plasma gas supply

5.12.1 Plasma gas
The connectors for the plasma gases air and oxygen are placed on the back side of the PGE 1.
The hoses for the plasma gases argon, hydrogen and nitrogen will be connected to the PGE 2.
The quality of the gases has an important influence on the life time of the consumables and the
cutting quality (see chapter 3.3.1 and 3.3.2).To avoid that the gas hoses become soiled small filters
are inserted in the gas connectors of the plasma torch gas hoses. For cleaning they can be screwed
out.
Following gas hoses have to be used:
Plasma gas Code colour Connector

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"
Chart 8 : Colour codes for gas hoses
Attention!
The input pressure never should exceed 1MPa (10 bar)! Attend rules for handling pressure
cylinders and pressure reducers! Watch to instructions of the manufacturers!
Plasma gas air
Gas supply from cylinder:

• Cylinder valves have to be clean and free of oil and grease. Clean if necessary!
• Open cylinder valve shortly to drain out dust and dirt
• Screw pressure reducer to cylinder
• Connect with gas hose G1/4"-G1/4" pressure reducer and PGE 1
• Open valve, adjust the pressure on the pressure reducer so that manometer on the PGE 1
indicates the required pressure acc. to chapter 3.3.1 (gas flow on)
Gas supply from shop line or compressor:

• Use oil and moisture separator placed between shop line and PGE 1
• Oil-free compressors do not need a separator
• Adjust pressure on the compressor so that under gas flow the manometer of the PGE 1
indicates the required pressure, see chapter 3.3.1
Plasma gas oxygen

- page 26 -
Attention!
All parts coming in touch with oxygen have to be absolutely free of oil and grease!
When using oxygen the pressure regulator has to be furnished with an explosion protection
device (back-fire valve! insert micro filter between gas supply and PZ-S47 W!
• Valves must be clean and free of oil and moisture, clean them if dirty
• Open cylinder valves shortly to remove dust
• Place back-fire valve to oxygen supply (pressure regulator, shop line)
• Connect pressure regulator with micro filter and micro filter with PGE 1 through gas hose G1/4"-
G1/4", blue
• Open valve, adjust the gas pressure so, that under gas flow the manometer on the PGE 1
indicates the requested pressure (see chapter 3.3.1)
Attention!
When a plasma ignition box PZ-S47 W is used a second explosion protection device should
be used (on the gas connector of the PZ-S47 W)!
(Can be supplied on request with the plasma cutting unit.)
Plasma gas Ar/H2/N2-mixture:
• Check cylinder valves, clean it if dirty

• Open cylinder valves shortly to remove dust
• Screw pressure reducers to the cylinders; use a pressure reducer only for that gas for which it is
intended
• Argon: gas hose black, G1/4"-G1/4"
Nitrogen: gas hose black/green, G1/4"-G1/4"
Hydrogen: gas hose red, G3/8"lks.-G3/8" left
to the marked connectors of the PGE 2
• Adjust the pressure on the pressure reducers so that under gas flow the manometers of the
PGE 2 indicated the recommended pressure (see chapter 3.3.2)
5.12.2 Swirl gas (air or nitrogen)
The connectors for the swirl gases are placed on the back side of the PGE 1.
• Clean cylinder valves if necessary

• Open cylinder valves shortly to drain out dust and dirt
• Connect suitable pressure reducers to the cylinders
• The gas hose black/grey, G1/4”-G1/4” (air) or the gas hose black/green, G1/4”-G1/4” (nitrogen)
has to be connected to the right connector on the PGE 1
• If alternately air or nitrogen is used for swirl-gas the swirl gas selector WGU 1 will be connected
to the swirl gas entry on the PGE 1; now the selected swirl gas can be fed to the PGE 1
5.13 Connection of plasma counter PZE 1

The plasma counter PZE 1 is furnished with a3-pole control cable for the connection to the socket
X130, placed on the rear wall of the FineFocus 450.

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5.14 Connection to CNC controls
(see circuit diagram .11.033.502 SP2)
The control cable for the combination of the FineFocus 450 with CNC controls of guiding systems or
robots has to be connected to 25-pole socket (system Wieland), placed in the back wall of the power
source. The respective cable the user has to prepare. The potential-free contacts are dimensioned
for a current load of max. 500 mA DC at 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 FineFocus 450 without the link or without emergency signal!
X102 Signal Remark

INPUT
B2-B3 "Torch on" from CNC potential free closing contact
A7 0...10V (= 20A...130A) ç Active- analogue input for active ç Remote-
B6 GND (workpiece potential) ç control control (potential free output ç control-
C7 +12V from CNC necessary) ç potentiometer
C3-C4 Emergency off from CNC potential free closing contact
Remove wire link fromX102
OUTPUT
A1-A2 "Main arc on" from power source (PA) potential free closing contact
A3-A4 "Pilot arc on" from PA potential free closing contact
A5-A6 "Transfer arc on“ from PA potential free closing contact
C1-C2 Emergency off from PA potential free closing contact
A9 Cathode potential (...-200V) ç Cutting-
B8 Nozzle potential (... –15V) ç Nozzle-
C9 Workpiece potential ( OV) ç voltage ç voltage
Chart 9: Signals between power source and interface
Attention!
If the remote control FB 1 is connected to the power source the plasma torch can’t be
started!

- page 28 -
6 Operation
Warning!
It is not allowed to operate the plasma cutting unit with removed cover plates!
Besides the electrical endangerment the cooling system is ineffective and damages will
follow!
Before opening the FineFocus 450 generally the power supply has to be disconnected
visible (unplug mains cable)!
6.1 Front panel controls
Fig 5: Control and signal elements

FineFocus 450

- page 29 -
1. LED H1 green „Stand-by“ 8. LED H7 red „thermal overload“
- LED H1 ON: Plasma machine ready for start - LED H7 ON: rectifier thermally overloaded
2. LED H3 yellow „Pilot arc“ 9. LED H9 green „coolant flow”

- LED H3 ON: Pilot arc on - LED H9 ON: coolant flow alright (flow controller
S10 activated)
3. LED H2 yellow „Main arc“
- LED H2 ON: Main arc on 10. Tumbler switch S5 “gas purge”
- upper position: gas purge on
4. LED H4 red „Pilot arc time“ - for gas pressure adjusting
- LED H4 ON: Pilot arc more than 15s activated, no - for gas flow measurement
reignition possible as long as LED H4 is on - to drain out water from torch head after
changing spare parts
5. LED H5 red „Nozzle contact“ - LED H6 is on „fault“
- LED H5 ON: Nozzle has touched workpiece during - power source can’t be switched
cutting
11. Selector switch S6 „gas selection“ „Air-O2-Ar/H2-
6. LED H8 green „Gas supply o.k.“ Ar/H2/N2“
- LED H8 ON: Gas pressure of all selected plasma gases “Air“ - Plasma gas air (connection to PGE1)
more than 0,3 MPa (3 bar) “O2“ - Plasmagas oxygen (connection to PGE1)
“Ar/H2“ - Plasma gas argon-hydrogen-mixture or
7. LED H6 red „Fault“ - Plasma gas argon-nitrogen-mixture
- LED H6 ON: Power source not activated (connection to PGE2)
- no coolant flow (LED H9) “Ar/H2/N2“ - Plasmagas argon-hydrogen-nitrogen-
- gas pressure < 0.3 MPa (3 bar) (LED H8) mixture (connection to PGE2)
- wrong plasma gas selection (selector switch S6, LED H8)
- tumbler switch S5 in position „gas purge“
- rectifier G1 thermally overloaded
- switch S7 „preset control“ activated
Attention!
The selector switch S6 does not switching over the solenoid valves „Ar/H2“ and „Ar/H2/N2“.
It only changes the value of the pilot resistors! In position „Ar/H2/N2“ the value is reduced to
ensure safe ignition. Using in this switch position Ar/H2- or Ar/N2-mixtures the higher pilot
arc current effects a faster consumption on nozzle and cathode.
The gas selection Ar, H2, N2 has to be done directly on the PGE 2 by the respective tumbler
switch.
12. Pressure gauge „Air“ 17. Voltmeter P1

- Display of cutting voltage
13. Switch S7 „preset control“
- cutting current (shown on ammeter 16) can be pre-set 18. Push button green S2 „stand-by“
with potentiometer 21 shown - Activated: - Plasma cutting machine ready to start
- LED H6 „fault“ ON - main transformer, pump, fan and control
- power source can’t be activated voltage activated
14. Selector switch S9 „Slope-up time main arc“ 19. Key switch S1 „mains on“
POSITION FUNCTION APPLICATION - position 0: - control transformer and fan for
heat exchanger OFF
left - fast current - max 25 mm plate thickn. - position 1: - control transformer and fan for
slope up - piercing up to 5 mm heat exchanger ON
centre - soft current - over 25 mm thickness 20. Red push button S3 “Emergency switch”
slope up - piercing up to 15 mm - pressed: - power source OFF, (not control
transformer and fan)
right - very soft - piercing up to 25 mm - release: - power source prepared to be
current switched ON
slope up (data depend on material)
21. Potentiometer R8 (cutting current)
15. Hose parcel entry for plasma torches and cable cutting current control 40 up to 130 A
extensions
22. Selector switch S8 „select control“
16. Ammeter P2 Chang-over switch from potentiometer control R8 to
- display of cutting current other controls:
- left „CNC“: - active control 0...10 V from CNC
controls or remote control with
potentiometer 1kΩ (see interface
chapter 5.14)
- right „PA“: - Build-in potentiometer
6.2 Cutting
Before cutting starts following inspections have to be done:
Inspection of plasma torch
• Plasma torch is in a correct and undamaged condition

- page 30 -
• The inserted consumables are matching with the used plasma gases and the intended working
method (cutting with or without swirl gas)
Inspection of the power source
• Mains fuses have recommended size (see chapter 3.1)

• The workpiece is properly fit (see chapter 5.3)
• The gas supply is in a safe and functional condition (see chapter 5.12)
Attention!
It is not allowed to direct the plasma torch towards eyes or any other parts of the body. The
high voltage ignition or the pilot arc can effect serious burns and injuries.
Switching on
1. Place selector switch “Gas” S6 (11) to the plasma gas which is selected
2. Place selector switch “select control” S8 (22) into desired position (CNC or PA)
3. Turn key switch S1 (1) to position “I” - fan of heat exchanger on
4. Press green push button S2 (19)

• Pump and fan on, cooling air leaves back side of power source
• Plasma gas flow activated for a short moment
• No water should appear on torch tip
• Green LED H1 (1) "stand-by", H8 (6) "gas supply o.k." and H9 (9) "coolant flow o.k." on
5. Keep tumbler switch S5 (10) at least 10 s in position "gas purge"

• to drain out water from torch head
• red LED H6 (7) "fault" on
6. Adjust gas pressure reducers or filter regulators depending on cutting task (see chapter 3.3) and
check on pressure gauges on PGE 1 or PGE 2. (See cutting diagrams for proper adjustment.)
7. Reset tumbler switch S5 (10) in off position, red LED "fault" off
8. The plasma installation is ready for start; if:

• Green LED H1 (1), H8 (6) and H9 (9) are on and
• Red LED H6 (7) "fault" is off
9. Turn switch S9 (14) into desired current slope up position
10. Adjust cutting current by using switch S7 (13) and potentiometer R7 (R8), the ammeter (16)
shows the adjusted value
Ignition of pilot arc
By pressing the ON button of the remote control FB 1 or through a signal of a guiding machine
(X102: B2, B3) the pilot arc ignites after the gas pre-flow time. The pilot arc time is limited to approx.
15 s.
If the nozzle is close enough to the workpiece the main arc strikes and the cutting process starts.
Pilot arc or main arc can be interrupted by pressing the OFF button of the remote control FB 1 or by
interrupting the ON signal of the guiding machine.
Running start
• Ignite pilot arc 10 up to 20 mm away from the workpiece

- page 31 -
• Move the plasma torch to the edge of the workpiece
• Main arc strikes automatically if pilot arc gets in contact to the workpiece
• Thinner plates require a reduced start speed compared with maximum speed
• Keep the distance between swirl-gas cap and workpiece in a range of 1.5 up to 4 mm (see
cutting table " FineFocus 450 with torch type PB-S47 W and swirl gas")
• When the plasma machine torch PB-S47 W is used without swirl gas see cutting table
" FineFocus 450 with torch type PB-S47 W without swirl gas"
Piercing (see chart „Piercing sequences during plasma cutting“)
Attention!
Spatter and sparks cause endangerment (burns and fire)!
• For materials up to 6 mm thickness the pilot arc should be ignited in a distance of 10 mm to the
plate. The main arc immediately strikes.
• To protect the torch head from coming up materials (sparks and spatter) the torch should be
moved in cutting direction just after the main arc has ignited.
• For materials up to max. 25 mm following method is recommended:
- Pilot arc ignition in a distance of at least 30 mm
- Ignition of pilot arc
- Lowering down the torch with pilot arc on (signal "pilot arc ON")
- During transition from pilot to main arc signal: “transition ON” and immediately after that “main
arc ON”
- start cutting movement and, if possible, short lift of plasma torch, to avoid damages of nozzle
by spatter
- after piercing set the torch in cutting height
Plasma gouging
Attention!
Spatter and sparks cause endangerment (burns and fire)!
feed protection
• Prepare the plasma machine torch for
gouging (without swirl gas, see chapter 6.4)
• Arrange torch position in desired direction,
inclination 25 up to 40°
• Strike arc though remote control FB 1
• Keep 2 mm distance between protective workpiece
cap and workpiece and arc length of 10 to

30 mm (see fig. 6)
Fig. 6: Plasma gouging
Switching off
When switching off the FineFocus 450 by using the key switch S1 (19) all components of the
machine are out of operation.
When using the red button S3 (20) "Emergency stop" all components except the control transformer
and the heat exchanger fan are switched off.
Please note,
that the switch S2 (18) remains in OFF position and has to be reset by a left hand rotation.
Disconnect the power source visible from the mains if it is not used for longer times.
6.3 Protective circuits

- page 32 -
The plasma cutting machine is ready for start (stand-by position) if after activating the key switch
(S1) and pushing the green button (S2 the green LED signal lamps
• H1 "stand by",
• H8 "gas supply." and
• H9 "water cooling" are on
and
• the red LED H6 "Error" is out.
Following protective circuits are indicating male functions so that the machine can’t be operated or
stops operation.
• Emergency stop, limit switch of side wall door, emergency-stop of CNC, fault-voltage
switch of pump:
If one of this circuits is activated no start by using the key switch (S1) and green push button
(S2) is possible (fan and pump do not run)
• Pilot arc limitation

(protects pilot resistor and reduces wear on nozzle and cathode)
- Switches off pilot arc after approximately 15 s to protect pilot resistors and to reduce
consumption on nozzle and cathode
- Red LED H4 is on for 5 s, reignition within this time is not possible
• Nozzle protection circuit

(protects nozzle when touching the workpiece; not activated, if cutting without swirl gas)
- Switches off main arc if nozzle contacts workpiece
- Red LED H5 indicates “nozzle contact” (function can be interrupted by placing the jumper
JP7 on pcb LP076458a)
The red LED „fault“ is on and the green LED „stand-by“ is off under following conditions:
• Coolant flow not sufficient

- Switches off if flow rate < 3,0 l/min
- Green LED H9 “flow control” off, but pump is running (Becomes activated max. 1 min later
after pump start, depending on the lengths of the water hoses!)
• Gas pressure to low

- Switches off if gas pressure is below 0.3 MPa (3 bar) or if swirl-gas cap is missing
- Green LED H8 "gas supply” is off
• Thermal overload
- Switches off if rectifier is overloaded
- Indicates by LED H7 “thermal overload”
6.4 Change of consumables

Attention!
Before carrying out any inspection or changing of torch parts the power source has to be
disconnected visible from the mains (unplug the power supply)!
When changing spare parts generally the plasma cutting machine has to be switched off, so
that an accidental start is not possible (VGB15 § 44). This condition is given, if after
switching off the key switch (fig. 5, item 19) is drawn out from the front plate.
Attention (when using oxygen for plasma gas)!

All parts coming in touch with oxygen have to be kept absolutely free of oil or grease! This
refers also torch parts and the consumables!
Change worn out or damaged parts in time.

- page 33 -
The life time of cathodes and nozzles widely depends on the cutting current, the plasma gas and the
number of ignitions. Continuous piercing and cutting with a too small distance to the material can
reduce the life time rapidly.
Always use the spare parts, suitable for the intended cutting process (fig. 9). Spare part change
should be done with special care and always by using suitable tools like cathode puller (A) and
nozzle cap puller (B) which are supplied with the machine.
During change of spare parts keep the torch tip upwards to avoid running out of coolant.
Taking out worn consumables
1. Turn torch tip in upper position

2. Unscrew protective cap (10) together with swirl-gas cap (9) by hand (press out swirl-gas cap
from protective cap)
3. Unscrew nozzle cap with swirl-gas guide (8), use socket spanner (B)
4. take out the nozzle (7)
5. Pull out cathode (4) together with gas guide ring (5) and O-ring 12 x 1,5 (6) by using the cathode
puller (A)
6. Change cooling tube (3) only if damaged
Inserting new consumables
1. Insert cooling tube (3) so that slots are directed to the cathode
2. Insert cathode (4) with O-ring6 x2 (4a) carefully, O-rings should not be damaged or twisted
3. Insert gas guide ring (5) with O-ring12x1,5 (6)
4. Insert nozzle (7)
5. Replace nozzle cap (8) by using the socket spanner (B), tighten it hand-tight
6. Place swirl-gas cap (9) into protective cap (10) and fasten it hand-tight
Converting of torch type PB-S47 W for dry cutting without swirl gas
1. Turn torch tip in upper position

2. Unscrew protective cap (10) together with swirl-gas cap (9) by hand
3. Unscrew nozzle cap with swirl-gas guide (8) by socket spanner (B)
4. Replace nozzle cap without swirl-gas guide (11) by using the socket spanner (B) tighten it hand-
tight
5. Replace insulation ring for dummy cap (12) and tighten with dummy cap (13) by hand
Change of O-rings only if deformed or damaged. Das Auswechseln der Rundringe muss nur bei
deren Deformierung oder Beschädigung erfolgen. For easier tightening it is recommended to use a
silicon spray (not at PB-S47 W-x/O2!).
Attention!
Be sure that all torch parts are properly replaced. Don’t use the torch without cooling tube!
The operator only is allowed to change consumables as described before. No other torch
parts can be removed from the torch head side!
Never apply silicon spray, oil or grease to torch parts if plasma gas oxygen is used!
warrenty is given only if origin parts are used.
When starting the plasma machine after a change of spare parts the following has to be
obtained (see also chapter 6.2):
1. After pressing the green button S2:

- automatic gas purge activated
- no water leakage on the torch tip is allowed
2. Activate switch S5 “gas purge” for at least 20 sec.:

- to drain out all the water which has collected in the torch head
- the smallest leakage in the torch can leads to damages in the torch

- page 34 -
O2 7.1
Air 10 9 (9a) 8 7.2 6 5
Ar/H2 /(N2 ) 9.3 (9a) 7.3
O ,Air,
Fig. 7: Consumables for plasma machine torch Type PB-S47 W

- page 35 -
Part Name Application for plasma gas
no. O2 air Ar/H2/(N2)
1 O-ring 32x2 x x x
2 O-ring 20x2 x x x
3 Cooling tube (stuck) x x x
4.1 Cathode(flat) with O-ring 6x2 Kb XL
4.2 Cathode(flat) with O-ring 6x2 Kb
4.3 Cathode(sharp) with O-ring 6x2 Ka
4a O-ring 6x2 x x x
5 Gas guide with O-ring 10x1 x x x
5a O-ring 10x1 x x x
6 O-ring 12x1,5 x x x
7.1 Nozzle O2 / pasma cutting Lle XL, Lde XL,
Lee XL
Nozzle air / plasma cutting Lle, Lde, Lee
7.2
Nozzle air / plasma gouging Lk, Ln
Nozzle Ar/H2 / plasma cutting Ade, Aee, Afe
7.3
Nozzle Ar/H2 / plasma gouging Ak, An
8 Nozzle cap with swirl-gas cap x x x
9 Swirl-gas cap 4 with O-ring 22x1,5 x x
9.3 Swirl-gas cap 3 with O-ring 22x1,5 x
9a O-ring 22x1,5 x x x
10 Protective cap x x x
11 Nozzle cap without swirl-gas guide x x x
12 Insulation ring for dummy cap x x x
13 Dummy cap x x x
Tools
A Cathode puller x x x
B Spanner nozzle cap x x x
6.5 Hints for troubleshooting
If any irregularity during operation on the machine is noticed the machine has to be stopped.
Attention!
Before carrying out any test or repairs on the plasma unit the power source has to be
switched off and disconnected visible from the mains (unplug mains cable)!
Only advised personnel are allowed to open the machine (see VDE 0105).
1. Fan and pump does not start when activating the key switch S1 (19) and the green push button
S2 (18):
- emergency switch S3 (20) not in reset position
- wire link X102:C3, C4 (emergency stop from CNC) not removed
- door in right side wall open
or
side walls of PZ-S47 W removed
or
door of PBA-S47 W opened
2. Fan and pump rotate, green signal lamp H1 (1) "stand-by" off, red LED H6 (7) "fault" is on and
green LED H8 (6) "gas supply" does not light:
- gas pressure < 0.3 MPa (3 bar)
- gas selection switch not in conformity with the connected plasma gas
3. Not ready for operation, red LED H6 (7) "fault" is on and green LED H9 (9) "water cooling" is off:
- flow rate < 3,0 l/min
- to low coolant level in the tank
4. Not ready for operation, red LED H6 (7) "fault" is on and yellow LED H7 (8) "thermal overload" is
on:
- rectifier overloaded, cool down with running fan

- page 36 -
5. Fan and pump rotate,
green LED H1 (1) "stand-by" and red LED H6 (7) "fault" is on:
- tumbler switch S5 (10) in "gas purge" position
6. Insufficient cutting power, automatic switch-off after approximately 15 s:

- workpiece cable not connected
7. Cutting current only 40A

- Selector switch "select control" in position "CNC"
7 Maintenance
Attention!
Before carrying out any test or repairs on the plasma unit the power source has to be
switched off and disconnected visible from the mains (unplug mains cable).
Only advised personnel is allowed to open the machine (see VDE 0105).
7.1 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 filling level of the coolant (if necessary filling up)
2. monthly: Gas pressure test (chapter 7.3)
3. after 4 up to 6 months: Cleaning the power source and all components
4. after 6 months: electrical revision
5. yearly: Change of coolant (Kjellfrost)
7.2 Cleaning
From the power source all dust and dirt which has collected inside the fan have to be removed in
intervals of 4 up to 6 months. Blowing out should be done carefully with dry compressed air, but
better is to use a vacuum cleaner.
In the same way all components of the system have to be cleaned.
Filter regulators and micro filters have to be cleaned weekly. Condensed water has to be drained,
filter inserts have to be replaced in time.

- page 37 -
The small filter screws of the gas connectors of the plasmagas control units have to be inspected
every 4 up to 6 months, and cleaned if necessary. For that reason the pressure reducers of the gas
cylinders have to be close and the respective gas hose remove from the control unit. The filter
screws only can be taken out by a small screw driver.
7.3 Gas pressure test

The complete check of the entire gas supply system is very important. Unnoticed escape of oxygen
or hydrogen can cause serious endangerments. Therefore the following gas pressure test hast to be
carried out monthly!.
1. Disconnect the supply lines from the coil of the plasma torch PB-S47 W respectively
plasmatorch connection unit PBA-S47 W to avoid activation.
2. Start plasma cutting unit and activate purge switch to fill up the gas hoses.
3. Close outlet valves on the pressure reducers, gas purge switch remains open!
4. Observe the pressure on the pressure gauges on the plasmagas control units. The adjusted
value must be kept constant for at least 10 min!
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.
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 the gas pressure tests have to be carried
out carefully and must be recorded!
7.4 Cooling system
the coolant has to be changed yearly.
Losses of coolant during the change of consumables have to be replaced. Therefore weekly the
filling level has to be checked on the show glass, placed in the left side wall of the power source. The
level of coolant should reach the mark “max.”.
For replacing the complete coolant the following steps have to be taken:
• Remove right side wall of the power source.

• Unscrew water inlet hose of the plasma torch.
• Open connection between tank and pump (G3/8”). Drain the old coolant into a container.
• Close the connection carefully.
• Fill up fresh coolant mixture “Kjellfrost” respectively “Kjellfrost-Super”.
• Screw water inlet hose back to the connector of the terminal board.
• Check connections of tightness.
7.5 Electrical revision

According to legal standards the FineFocus 450 has to be inspected:
• every six months, when machine often changes the cutting place
• once a year, if the machine is used stationary
a) Visual inspection,
- check the condition of the complete unit
- test insulation of all alive parts against accidental contact
- inspect fuses, protective devices and cables for proper sizes
- inspect condition of cables and wirings, tighten screwed contact points
- replace broken cables or wirings, never use cables with damaged insulation

- page 38 -
b) by measurement has to be proofed that the protection against excessive touch potentials of
parts functionally not activated is granted (test of protective conductor):
- Measurement of the transition resistance between marked protective conductor connection of
the plasma cutting unit and all touchable metallic parts not functionally activated: <0.1 Ohm
c) The insulating capacity of winding and line insulation has to be proofed:

- If mechanical, thermal or chemical damages on the insulation are noticed
- If the plasma cutting unit is more than 15 years old or an aggressive environment untimely
disturbances will cause
- 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 > 2,5 MOhm (dry
and cold condition)
Noticed faults have to be eliminated by an expert immediately.
7.6 Plasma torches
The plasma torches have to be handled with care. Powerful handling and stress load have to be
avoided. All spare parts must be in clean condition and carefully changed in time (see chapter 6.6).
Damages of parts inside the torch, as nozzle holder and cathode tube have to be avoided. Besides
the change of consumable parts under 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 PB-S47W(-1) type the filter screws have to be
cleaned from time to time after unscrewing from the gas connector.
Attention!
Plasma torches have to be water tight at any time! Defective torches generally will be
repaired by the Kjellberg service centre or licensed repair shops!
Attention!
All components and parts coming in touch with oxygen have to be free of oil and grease!
This refers especially to the torch head and the consumables!

- page 39 -
C:\GASTZUGANG\033_502_BA_engl.doc JM: 26.07.2002

- page 40 -
- page 41 -
ENCLOSURE 1
Cutting data
of
Plasma Cutting Unit FineFocus 450
and
Plasma Machine Torches
PB-S47 W
PB-S47 W-1/O2
PB-S47 W-2/O2
( 6 pages incl. cover sheet )

- page 42 -
Cutting data FineFocus 450
torch: PB-S47 W mild steel (2 up to 30 mm)
material: St37b-2 (mild steel) plasma gas Air with swirl gas Air
Thick- Current Nozzle WGK Cutting gas Swirl gas Piercing Torch Ignition Arc Cutting
ness Diam. Air Air delay distance height voltage speed
[mm] [A] [mm] [bar]/[scale div.] [bar]/[scale div.] [s] [mm] [mm] [V] [m/min]
2 80 Lde 4 0,6 / 50 0,6 / 40 0,1 2,0 4 120 3,00
4 80 Lde 4 0,6 / 50 0,6 / 40 0,1 2,0 4 120 2,10
6 130 Lee 4 0,6 / 50 0,6 / 40 0,2 2,0 4 120 3,00
10 130 Lee 4 0,6 / 50 0,6 / 40 0,3 2,0 5 125 1,70
16 130 Lee 4 0,6 / 50 0,6 / 50 0,4 2,0 5 130 1,10
20 130 Lee 4 0,6 / 50 0,6 / 50 0,6 3,0 6 135 0,90
25 130 Lee 4 0,6 / 50 0,6 / 50 0,7 3,0 6 155 0,25
30 130 Lee 4 0,6 / 50 0,6 / 50 0,8 3,0 6 160 0.20
Torch parts: 4 6 4 4 6 4 6 4 4
6 6 6
2 8 2 8 2 8 2 8 2 8 2 8
Position selector switch at
1.01 Cathode Kb
0 10 0 10 0 10 0 10 0 10 0 10
front panel FineFocus 450
1.02 Gas guide Z111
1.03 Nozzles Ar/H2
Lde O2 90A 1,3 mm
Lee O2 130A 1,4 mm Air
100 100 100 100 100 100
1.04 Nozzle cap PB46/47 vollst.
1.05 WGK - Swirl-gas cap
W 4140 - 4,0 mm orifice
50 50 50 50 50 50
1.06 Protective cap PB46/47
Remarks: 10 10 10 10 10 10
-Piercing delay to be adjusted Cutting parameters and results may differ because
of material composition, material surface and shape
on profile cutting machine of workpiece.
- Scale adjustment = ball centre
• For setting of gas flow use switch “gas test”
- Flowmeter activ, balls black • Change of gas flow during cutting possible,
readjusting not necessary
• Piercing up to 25 mm possible (pay attention to
PGE 1 PGE 2 piercing sequences)

- page 43 -
torch: PB-S47 W mild steel (2 up to 30 mm)
material: St37 (mild steel) plasma gas O2 with swirl gas Air
Thick- Current Nozzle WGK Ignition gas Cutting gas Swirl gas Piercing Torch Ignition Arc Cutting
ness Diam. Air O2 Air delay distance height voltage speed
[mm] [A] [mm] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [bar]/[scale div.] [s] [mm] [mm] [V] [m/min]
2 45 Lle-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,1 2,0 4 110 3,0
4 45 Lle-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,1 2,0 4 110 1,20
2 70 Lde-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,1 3,0 4 110 3,00
4 90 Lde-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,1 3,0 4 110 3,00
4 130 Lee-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,1 3,0 4 110 3,00
8 130 Lee-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,2 3,0 5 120 2,65
10 130 Lee-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,3 3,0 5 130 1,90
15 130 Lee-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,4 3,0 5 130 1,20
20 130 Lee-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,6 3,0 6 135 0,90
25 130 Lee-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,7 3,0 6 150 0,30
30 130 Lee-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,7 3,0 6 155 0,20
40 130 Lee-XL 4 0,6 / 30 0,6 / 40 0,6 / 50 0,7 3,0 6
Torch parts: 4 6 4 6 4 6 4 6 4 6 4 6
2.01 Cathode Kb-XL O2

2 8 2 8 2 8 2 8 2 8 2 8
0 10 10 0 10 0 10 10 10
2.02 Gasf guide Z111
0 0 0
2.03 Nozzles
Lle - XL O2 45A 1,0 mm
Lde - XL O2 90A 1,3 mm
Lee - XL O2 130A 1,4 mm 100 100 100 100 100 100
2.04 Nozzle cap PB46/47 compl..

2.05 WGK - swirl-gas cap
W 4140 - 4,0 mm orifice 50 50 50 50 50 50

10 10 10 10 10 10
Remarks: Cutting parameters and results may differ because
-Piercing delay to be adjusted of material composition, material surface and shape
on profile cutting machine of workpiece.
- Flowmeter activ, balls black • Change of gas flow during cutting possible,
P G E 1 • Piercing up to 25 mm possible (pay attention to
P G E 2 piercing sequences)
- page 44 -
torch: PB-S47 W aluminium (1 up to 50 mm)
material: AlMg3 plasma gas Ar/H2 with swirl gas N2
Thick- Current Nozzle WGK Swirl gas Plasma gas Plasma gas Plasma gas Piercing Torch Ignition Arc Cutting
ness Diam. N2 Ar H2 N2 delay distance height voltage speed
1 45 Ale 3 0,6 / 0 0,6 / 20 0,6 / 50 0,1 2,0 4 125 3,50
3 130 Afe 3 0,6 / 30 0,6 / 30 0,6 / 70 0,1 2,0 4 135 3,50
6 130 Afe 3 0,6 / 30 0,6 / 30 0,6 / 70 0,2 2,0 4 140 2,50
10 130 Afe 3 0,6 / 50 0,6 / 30 0,6 / 70 0,3 2,0 5 145 1,40
16 130 Afe 3 0,6 / 50 0,6 / 30 0,6 / 70 0,3 2,0 5 147 1,20
20 130 Afe 3 0,6 / 50 0,6 / 30 0,6 / 70 0,4 2,0 6 150 0,80
25 130 Afe 3 0,6 / 50 0,6 / 30 0,6 / 70 0,5 2,0 6 152 0,65
30 130 Afe 3 0,6 / 50 0,6 / 30 0,6 / 70 0,6 3,0 6 158 0,45
40 130 Afe 3 0,6 / 50 0,6 / 30 0,6 / 70 0,7 3,0 6 163 0,25
50 130 Afe 3 0,6 / 30 0,6 / 30 0,6 / 70 0,8 3,0 6 175 0,20
Torch parts: 4 6 4 6 4 6 4 6 4 6 4 6
2 8 2 8 2 8 2 8 2 8 2 8
10
3.01 Cathode Ka 0 10 0 10 0 10 0 0 10 0 10
3.02 Gas guide Z111

3.03 Düsen
Ale 45A 1,0 mm
Afe 130A 1,6 mm 100 100 100 100 100 100
3.04 Nozzle cap PB46/47 compl.

3.05 WGK - Swirl-gas cap
50 50 50 50 50 50
10 10 10 10 10 10
Cutting parameters and results may differ because

Remarks: of material composition, material surface and shape
-Piercing delay to be adjusted of workpiece.
on profile cutting machine • For setting of gas flow use switch “gas test”
- Scale adjustment = ball centre • Change of gas flow during cutting possible,
- Flowmeter activ, balls black
P G E 1 P G E 2 piercing sequences)
- page 45 -
torch: PB-S47 W high-alloyed steel (6 up to 40 mm)
material: 1.4571 plasma gas Ar/H2 with swirl gas N2
Thick- Current Nozzle WGK Swirl gas Plasma gas Plasma gas Plasma gas Piercing Torch Ignition Arc Cutting
6 130 Afe 3 0,6 / 80 0,6 / 40 0,6 / 25 0,2 2,0 4 115 1,70
8 130 Afe 3 0,6 / 80 0,6 / 40 0,6 / 25 0,2 2,0 5 120 1,30
10 130 Afe 3 0,6 / 80 0,6 / 40 0,6 / 25 0,3 2,0 5 125 1,10
15 130 Afe 3 0,6 / 40 0,6 / 40 0,6 / 25 0,4 3,0 5 135 0,70
20 130 Afe 3 0,5 / 20 0,6 / 30 0,6 / 60 0,5 3,5 6 150 0,55
30 130 Afe 3 0,5 / 20 0,6 / 30 0,6 / 60 0,6 4,0 6 160 0,30
40 130 Afe 3 0,5 / 20 0,6 / 30 0,6 / 60 0,6 5,0 6 170 0,20
Torch parts: 4 6 4 6 4 6 4 6 4 6 4 6
2 8 2 8 2 8 2 8 2 8 2 8
3.01 Cathode Ka 0 10 0 10 0 10 0 10 0 10 0 10
3.02 Gas guide Z111
3.03 Nozzles
Ale 45A 1,0 mm
100 100 100 100 100
Afe 130A 1,6 mm 100
3.04 Nozzle cap PB46/47 compl.

3.05 WGK - Swirl gas cap
50 50 50 50 50 50
10 10 10 10 10 10
Cutting parameters and results may differ because

Remarks: of material composition, material surface and shape
-Piercing delay to be adjusted of workpiece.
on profile cutting machine • For setting of gas flow use switch “gas test”
• Change of gas flow during cutting possible,
- Flowmeter activ, balls black • Piercing up to 25 mm possible (pay attention to

- page 46 -
torch: PB-S47 W high-alloyed steel (2 up to 30 mm)
material: 1.4301 plasma gas Ar/H2/N2 with swirl gas N2
Thick Current Nozzle WGK Swirl gas Plasma gas Plasma gas Plasma gas Piercing Torch Ignition Arc Cutting
2 100 Afe 3 0,6 / 100 0,6 / 18 0,6 / 5 0,6 / 20 0,1 3,0 4 100 4,00
3 120 Afe 3 0,6 / 100 0,6 / 25 0,6 / 5 0,6 / 10 0,1 3,0 4 118 3,60
4 130 Afe 3 0,6 / 100 0,6 / 30 0,6 / 13 0,1 3,0 4 120 2,90
6 130 Afe 3 0,6 / 80 0,6 / 40 0,6 / 20 0,2 3,0 4 108 1,90
8 130 Afe 3 0,6 / 80 0,6 / 40 0,6 / 20 0,2 3,0 4 110 1,40
10 130 Afe 3 0,6 / 80 0,6 / 40 0,6 / 20 0,3 3,0 4 120 1,10
16 130 Afe 3 0,5 / 20 0,6 / 30 0,6 / 38 0,4 3,0 5 140 0,65
20 130 Afe 3 0,5 / 20 0,6 / 30 0,6 / 38 0,5 3,5 5 140 0,50
30 130 Afe 3 0,6 / 35 0,6 / 70 0,6 5,0 6 155 0,43
4 6 4 6 4 6 4 6 4 6 4 6
Torch parts
2 8 2 8 2 8 2 8 2 8 2 8
10 10 0 10
0 0 10 0 0 10 0 10
3.01 Cathode Ka front panel FineFocus 450
3.02 Gas guide Z111
3.03 Nozzles
Afe 130A 1,6 mm
100 100 100 100 100 100
3.04 Nozzle cap PB46/47compl.

3.05 WGK - swirl-gas cap
W 4130 - 3,0 mm orifice 50 50 50 50 50 50
*
10 10 10 10 10 10
Remarks: Cutting parameters and results may differ because

-Piercing delay to be adjusted of material composition, material surface and shape
of workpiece.
on profile cutting machine
- Scale adjustment = ball centre • Change of gas flow during cutting possible,
- Flowmeter activ, balls black * readjusting not necessary
- page 47 -
ENCLOSURE 2
Connection schemes
of
and
PB-S47 W
PB-S47 W-1/O2
PB-S47 W-2/O2
( 5 pages including cover sheet )

- page 48 -
- page 49 -
- page 50 -
- page 51 -
- page 52 -
ENCLOSURE 3
Circuit diagrams
for
( 6 pages including cover sheet )

- page 53 -
- page 54 -
- page 55 -
- page 56 -
- page 57 -
- page 58 -
ENCLOSURE 4
Spare parts lists for
PB-S47 W PB-S47 W-1/O2 PB-S47 W-2/O2

Art. no.: .11.834.201.000E Art. no.: .11.834.321.000E Art. no.: .11.834.721.000E
Dear customer,
with the plasma cutting torches you have purchased a quality product from
Kjellberg Finsterwalde Elektroden und Maschinen GmbH.
When using 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 lists. For more information we are
always at your disposal.

- page 59 -
Spare Parts List
PB-S47 W/L (130 A, 1MV) July 2002

.11.834.201.000E
Pos. Article-No. Designation pcs.
00.00.01 .11.834.201.006 PB-S47 W/L 6m/130A 1SV 1.00

00.00.02 .11.834.201.106 PB-S47 W/L 6m/130A/C 1 SOLENOID V. 1.00
00.00.03 .11.834.201.010 PB-S47 W/L 10m/130A 1SV 1.00
00.00.04 .11.834.201.110 PB-S47 W/L 10m/130A 1MV SHIELDED 1.00
00.00.05 .11.834.201.015 PB-S47 W/L 15m/130A 1MV 1.00
00.00.06 .11.834.201.115 PB-S47 W/L 15m/130A 1MV GESCHIRMT 1.00
01.01.00 .11.834.201.900 PB-S47 W/L WITHOUT HOSE PARCEL 1.00

01.01.01 .11.832.201.100 TORCH HEAD PB-S46/47/L 1.00
01.01.02 .10.505.948 O-RING 32x2 1.00
01.01.03 .10.505.915 O-RING 24X2 1.00
01.01.04 .11.832.201.152 COOLING TUBE PB-S46/47 1.00
01.01.05 .11.828.001.3001 CATHODE Kb AIR, COMPLETE WITH O-RING 1.00
01.01.06 .10.505.827 O-RING 6x2 1.00
01.01.07 .11.834.321.153 GAS GUIDING CAP PB-S4x/Z111 1.00
01.01.09 .10.575.036 O-RING 12x1,5 1.00
01.01.10 .11.828.203.410 NOZZLE Lle AIR 45A 1,0mm 1.00
01.01.10 .11.828.203.413 NOZZLE Lde AIR 90A 1,3mm 1.00
01.01.10 .11.828.203.414 NOZZLE Lee AIR 130A 1,4mm 1.00
01.01.11 .11.832.201.160 NOZZLE CAP PB-S46/47 1.00
01.01.12 .11.832.201.1561 SWIRL GAS CAP 3 WITH O-RING 1.00
01.01.12 .11.832.201.1571 SWIRL GAS CAP 4 WITH 0-RING 22x1,5 1.00
01.01.13 .10.505.911 O-RING 22x1.5 1.00
01.01.14 .11.832.201.081 PROTECTION CAP PB-S46/47 1.00
01.02.00 .10.501.059 HOSE CLIP 1.00
01.03.00 .10.902.105 INSULATION 0.25x160x270 1.00
01.04.00 .11.834.321.250 TUBE PB-S47 W-1 1.00
01.05.00 .12.59840 ORIFICE 0,75 1.00
01.06.00 .11.832.201.077 BUSHING 1.00
01.07.00 .11.832.201.076 OUTER BUSHING 1.00
01.08.00 .10.505.915 O-RING 24X2 1.00
03.01.00 .11.834.211.900 PB-S47 W/A WITHOUT HOSE PARCEL 1.00

03.01.01 .11.832.211.100 TORCH HEAD PB-S46/47/A 1.00
03.01.02 .10.505.948 O-RING 32x2 1.00
03.01.03 .10.505.915 O-RING 24X2 1.00
03.01.04 .11.832.201.152 COOLING TUBE PB-S46/47 1.00
03.01.05 .11.828.211.5001 CATHODE Ka ArH2 WITH O-RING 1.00
03.01.06 .10.505.827 O-RING 6x2 1.00
03.01.09 .10.575.036 O-RING 12x1,5 1.00
03.01.10 .11.828.213.610 NOZZLE Ale ArH2 45A 1,0mm 1.00
03.01.10 .11.828.213.613 NOZZLE Ade ArH2 80A 1,3mm 1.00
03.01.10 .11.828.213.614 NOZZLE Aee ArH2 100A 1,4mm 1.00
03.01.10 .11.828.213.616 NOZZLE Afe ArH2 130A 1,6mm 1.00
03.01.11 .11.832.201.160 NOZZLE CAP PB-S46/47 1.00
03.01.13 .10.505.911 O-RING 22x1.5 1.00

- page 60 -
PB-S47 W/L (130 A, 1MV) July 2002
.11.834.201.000E
04.01.00 .16.500.308 PARTS FOR CUTTING WITHOUT SWIRL GAS 1.00

04.01.11 .11.830.301.151 NOZZLE CAP Dm 9,6 1.00
04.01.12 .11.832.201.086 INSULATING CAP PB-S46/47 1.00
04.01.14 .11.832.201.085 END CAP PB-S46/47 1.00
05.00.00 .11.834.201.700 HOSE PARCEL PB-S47 W 6m 1.00

05.01.00 .10.575.037 HOSE 40 X 1,5 1.00
05.02.00 .11.834.201.710 PLASMA GAS HOSE 5.82m 1.00
05.02.01 .12.29270 FILTER, M5 X 22 1.00
05.04.00 .11.832.201.720 WATER INLET HOSE 6,32m 1.00
05.05.00 .11.832.201.730 WATER RETURN HOSE 6,29m 1.00
05.06.00 .11.834.201.740 CONTROL CABLE 6.0m 1.00
05.07.00 .11.834.301.745 PILOT CABLE 6,42m 1.00
05.08.00 .11.834.301.707 SWIRL GAS HOSE 6,34m 1.00
05.09.00 .11.834.301.718 CONTROL GAS HOSE 6,36m 1.00
05.10.00 .11.834.201.280 SOLENOID VALVE, COMPLETE 1.00
05.10.01 .10.639.732 PLUG FOR SOLENOID VALVE 1.00
05.10.02 .12.61170 SOLENOID VALVE 24V 50/60Hz 1.00
06.00.00 .11.834.201.701 HOSE PARCEL PB-S47 W 10m 1.00

06.01.00 .10.575.037 HOSE 40 X 1,5 1.00
06.02.00 .11.834.201.750 PLASMA GAS HOSE 9.82m 1.00
06.02.01 .12.29270 FILTER, M5 X 22 1.00
06.06.00 .11.834.201.780 CONTROL CABLE 10.0m 1.00
06.07.00 .11.834.301.785 PILOT CABLE 10,42m 1.00
06.08.00 .11.834.301.790 SWIRL GAS HOSE 10,34m 1.00
07.00.00 .11.834.201.701A HOSE PARCEL PB-S47 W 15m 1.00

07.01.00 .10.575.037 HOSE 40 X 1,5 1.00
07.02.00 .11.834.201.750A PLASMA GAS HOSE 14.82m 1.00
07.02.01 .12.29270 FILTER, M5 X 22 1.00
07.04.00 .11.832.201.760A WATER INLET HOSE 15,32m 1.00
07.05.00 .11.832.201.770A WATER RETURN HOSE 15,29m 1.00
07.06.00 .11.834.201.780A CONTROL CABLE 15.0m 1.00
07.07.00 .11.834.301.785A PILOT CABLE 15,42m 1.00
07.08.00 .11.834.301.790A SWIRL GAS HOSE 15,34m 1.00
07.09.00 .11.834.301.758A CONTROL GAS HOSE 15,36m 1.00
20.00.00 .16.500.006 TORCH TOOLS: 1.00

20.01.00 .11.828.001.820 CATHODE PULLER 1.00
20.02.00 .11.828.001.810 SOCKET SPANNER (NOZZLE CAP) 1.00

- page 61 -
- page 62 -
Spare Parts List
PB-S47 W-1/O2 (130 A, 2MV + SST) July 2002

.11.834.321.000E
00.00.01 .11.834.321.006 PB-S47 W-1/O2 6m/130A 2SV+CP 1.00

00.00.02 .11.834.321.010 PB-S47 W-1/O2 10m/130A 2SV+CP 1.00
00.00.03 .11.834.321.015 PB-S47 W-1/O2 15m/130A 2SV+CT 1.00
01.01.00 .11.834.321.900 PB-S47 W-1/O2 SWIRL GAS,WITHOUT HOSES 1.00

01.01.01 .11.832.221.100 TORCH HEAD PB-S46/47/O2 1.00
01.01.02 .10.505.948 O-RING 32x2 1.00
01.01.03 .10.575.052 O-RING 20x2 1.00
01.01.04 .11.832.201.152 COOLING TUBE PB-S46/47 1.00
01.01.05 .11.834.321.3001 CATHODE Kb-XL O2 WITH O-RING 6x2 1.00
01.01.06 .10.505.827 O-RING 6x2 1.00
01.01.09 .10.575.036 O-RING 12x1,5 1.00
01.01.10 .11.834.321.410 NOZZLE Lle-XL O2 45A 1,0mm 1.00
01.01.10 .11.834.321.413 NOZZLE Lde-XL O2 90A 1,3mm 1.00
01.01.10 .11.834.321.414 NOZZLE Lee-XL O2 130A 1,4mm 1.00
01.01.11 .11.832.201.160 NOZZLE CAP PB-S46/47 1.00
01.01.13 .10.505.911 O-RING 22x1.5 1.00
01.02.00 .10.501.059 HOSE CLIP 1.00
01.03.00 .10.902.105 INSULATION 0.25x160x270 1.00
01.04.00 .11.834.321.250 TUBE PB-S47 W-1 1.00
01.05.00 .12.59840 ORIFICE 0,75 1.00
01.06.00 .11.832.201.077 BUSHING 1.00
01.07.00 .11.832.201.076 OUTER BUSHING 1.00
01.08.00 .10.505.915 O-RING 24X2 1.00
02.01.00 .11.834.301.900 PB-S47 W-1/L SWIRL GAS, WITHOUT HOSES 1.00

02.01.01 .11.832.201.100 TORCH HEAD PB-S46/47/L 1.00
02.01.02 .10.505.948 O-RING 32x2 1.00
02.01.03 .10.575.052 O-RING 20x2 1.00
02.01.04 .11.832.201.152 COOLING TUBE PB-S46/47 1.00
02.01.06 .10.505.827 O-RING 6x2 1.00
02.01.09 .10.575.036 O-RING 12x1,5 1.00
02.01.11 .11.832.201.160 NOZZLE CAP PB-S46/47 1.00
02.01.13 .10.505.911 O-RING 22x1.5 1.00

- page 63 -
PB-S47 W-1/O2 (130 A, 2MV + SST) July 2002
.11.834.321.000E
03.01.00 .11.834.311.900 PB-S47 W-1/A SWIRL GAS, WITHOUT HOSES 1.00

03.01.01 .11.832.211.100 TORCH HEAD PB-S46/47/A 1.00
03.01.02 .10.505.948 O-RING 32x2 1.00
03.01.03 .10.575.052 O-RING 20x2 1.00
03.01.04 .11.832.201.152 COOLING TUBE PB-S46/47 1.00
03.01.06 .10.505.827 O-RING 6x2 1.00
03.01.09 .10.575.036 O-RING 12x1,5 1.00
03.01.11 .11.832.201.160 NOZZLE CAP PB-S46/47 1.00
03.01.13 .10.505.911 O-RING 22x1.5 1.00

04.01.11 .11.830.301.151 NOZZLE CAP Dm 9,6 1.00
04.01.13 .11.832.201.085 END CAP PB-S46/47 1.00
05.00.00 .11.834.321.700 HOSE PARCEL PB-S47 W-1/O2 6m 1.00

05.01.00 .10.575.037 HOSE 40 X 1,5 1.00
05.02.00 .11.834.321.710 PLASMA GAS HOSE O2 5,77m 1.00
05.02.01 .12.29270 FILTER, M5 X 22 1.00
05.03.00 .11.834.321.715 PLASMA GAS HOSE AIR 5,76m 1.00
05.03.01 .12.29270 FILTER, M5 X 22 1.00
05.06.00 .11.834.321.740 CONTROL CABLE 5,9m 1.00
05.07.00 .11.834.301.745 PILOT CABLE 6,42m 1.00
05.08.00 .11.834.301.707 SWIRL GAS HOSE 6,34m 1.00
05.10.00 .11.834.321.280 SOLENOID VALVE UNIT COMPLETE (2SV/CP) 1.00
05.10.03 .11.834.321.281 COLLECTOR 1.00
06.00.00 .11.834.321.701 HOSE PARCEL PB-S47 W-1/O2 10m 1.00
06.01.00 .10.575.037 HOSE 40 X 1,5 1.00
06.02.00 .11.834.321.750 PLASMA GAS HOSE O2 9,77m 1.00
06.03.00 .11.834.321.755 PLASMA GAS HOSE AIR 9,76m 1.00
06.06.00 .11.834.321.780 CONTROL CABLE 9,9m 1.00
06.07.00 .11.834.301.785 PILOT CABLE 10,42m 1.00
06.08.00 .11.834.301.790 SWIRL GAS HOSE 10,34m 1.00
07.00.00 .11.834.321.701A HOSE PARCEL PB-S47 W-1/O2 15m 1.00

07.01.00 .10.575.037 HOSE 40 X 1,5 1.00
07.02.00 .11.834.321.750A PLASMA GAS HOSE O2 14.76m 1.00
07.03.00 .11.834.321.755A PLASMA GAS HOSE AIR 14,76m 1.00
07.04.00 .11.832.201.760A WATER INLET HOSE 15,32m 1.00
07.05.00 .11.832.201.770A WATER RETURN HOSE 15,29m 1.00
07.06.00 .11.834.321.780A CONTROL CABLE 14,9m 1.00
07.07.00 .11.834.301.785A PILOT CABLE 15,42m 1.00
07.08.00 .11.834.301.790A SWIRL GAS HOSE 15,34m 1.00
07.09.00 .11.834.301.758A CONTROL GAS HOSE 15,36m 1.00
20.00.00 .16.500.006 TORCH TOOLS: 1.00

20.01.00 .11.828.001.820 CATHODE PULLER 1.00
30.01.00 .16.500.100 SV= SOLENOID VALVE 0.00

30.02.00 .16.500.102 CP= CONNECTING PIECE 0.00

- page 64 -
- page 65 -
Spare Parts List
PB-S47 W-2/O2 (130 A, without MV + SST) July 2002

.11.834.721.000E
00.00.01 .11.834.721.101 PB-S47 W-2/O2 1m/130A SHELT. 1.00

00.00.02 .11.834.721.1015 PB-S47 W-27O2 1.5m/130A SHELT. 1.00
01.01.00 .11.834.721.900 PB-S47 W-2/O2 (SWIRL G.) WITHOUT HOSE 1.00

01.01.01 .11.832.221.100 TORCH HEAD PB-S46/47/O2 1.00
01.01.02 .10.505.948 O-RING 32x2 1.00
01.01.03 .10.575.052 O-RING 20x2 1.00
01.01.04 .11.832.201.152 COOLING TUBE PB-S46/47 1.00
01.01.05 .11.834.321.3001 CATHODE Kb-XL O2 WITH O-RING 6x2 1.00
01.01.06 .10.505.827 O-RING 6x2 1.00
01.01.09 .10.575.036 O-RING 12x1,5 1.00
01.01.10 .11.834.321.410 NOZZLE Lle-XL O2 45A 1,0mm 1.00
01.01.10 .11.834.321.413 NOZZLE Lde-XL O2 90A 1,3mm 1.00
01.01.10 .11.834.321.414 NOZZLE Lee-XL O2 130A 1,4mm 1.00
01.01.11 .11.832.201.160 NOZZLE CAP PB-S46/47 1.00
01.01.13 .10.505.911 O-RING 22x1.5 1.00
01.02.00 .10.501.059 HOSE CLIP 1.00
01.03.00 .10.902.105 INSULATION 0.25x160x270 1.00
01.04.00 .11.834.321.250 TUBE PB-S47 W-1 1.00
01.05.00 .12.59840 ORIFICE 0,75 1.00
01.06.00 .11.832.201.077 BUSHING 1.00
01.07.00 .11.832.201.076 OUTER BUSHING 1.00
01.08.00 .10.505.915 O-RING 24X2 1.00
02.01.00 .11.834.701.900 PB-S47 W-2/L (SWIRL GAS) WITHOUT HOSE 1.00

02.01.01 .11.832.201.100 TORCH HEAD PB-S46/47/L 1.00
02.01.02 .10.505.948 O-RING 32x2 1.00
02.01.03 .10.575.052 O-RING 20x2 1.00
02.01.04 .11.832.201.152 COOLING TUBE PB-S46/47 1.00
02.01.06 .10.505.827 O-RING 6x2 1.00
02.01.09 .10.575.036 O-RING 12x1,5 1.00
02.01.11 .11.832.201.160 NOZZLE CAP PB-S46/47 1.00
02.01.13 .10.505.911 O-RING 22x1.5 1.00

- page 66 -
PB-S47 W-2/O2 (130 A, without MV + SST) July 2002
.11.834.721.000E
03.01.00 .11.834.711.900 PB-S47 W-2/A (SWIRL GAS) WITHOUT HOSE 1.00

03.01.01 .11.832.211.100 TORCH HEAD PB-S46/47/A 1.00
03.01.02 .10.505.948 O-RING 32x2 1.00
03.01.03 .10.575.052 O-RING 20x2 1.00
03.01.04 .11.832.201.152 COOLING TUBE PB-S46/47 1.00
03.01.06 .10.505.827 O-RING 6x2 1.00
03.01.09 .10.575.036 O-RING 12x1,5 1.00
03.01.11 .11.832.201.160 NOZZLE CAP PB-S46/47 1.00
03.01.13 .10.505.911 O-RING 22x1.5 1.00

04.01.11 .11.830.301.151 NOZZLE CAP Dm 9,6 1.00
04.01.14 .11.832.201.085 END CAP PB-S46/47 1.00
05.00.00 .11.834.721.700 HOSE PARCEL PB-S47 W-2 1m 1.00

05.01.00 .10.575.037 HOSE 40 X 1,5 1.00
05.02.00 .11.834.721.710 PLASMA GAS HOSE O2 0.67m 1.00
05.02.01 .12.29270 FILTER, M5 X 22 1.00
05.03.00 .11.834.721.715 PLASMA GAS HOSE 0.67m 1.00
05.03.01 .12.29270 FILTER, M5 X 22 1.00
05.04.00 .11.834.701.720 WATER SUPPLY HOSE 1.315m 1.00
05.05.00 .11.834.701.730 WATER RETURN HOSE 1.285m 1.00
05.06.00 .11.834.701.745 PILOT ARC CABLE 1.415m 1.00
05.07.00 .11.834.721.705 COLLECTING-HOSE O2 0.7m 1.00
05.08.00 .11.834.701.707 SWIRL-GAS HOSE 1.29m 1.00
05.09.00 .11.834.701.718 CONTROL GAS HOSE 1.315m 1.00
05.10.03 .12.60840 COLLECTING-PIECE 1.00
06.00.00 .11.834.721.700B HOSE PARCEL PB-S47 W-2 1.5m 1.00

06.01.00 .10.575.037 HOSE 40 X 1,5 1.00
06.02.00 .11.834.721.710B PLASMA GAS HOSE O2 1.17m 1.00
06.02.01 .12.29270 FILTER, M5 X 22 1.00
06.03.00 .11.834.721.715B PLASMAGASSCHLAUCH 1.17m 1.00
06.03.01 .12.29270 FILTER, M5 X 22 1.00
06.04.00 .11.834.701.720B WATER SUPPLY HOSE 1.815m 1.00
06.05.00 .11.834.701.730B WATER RETURN HOSE 1.785m 1.00
06.06.00 .11.834.701.745B PILOT ARC CABLE 1.915m 1.00
06.07.00 .11.834.721.705 COLLECTING-HOSE O2 0.7m 1.00
06.08.00 .11.834.701.707B WIRBELGASSCHLAUCH 1,79m 1.00
06.09.00 .11.834.701.718B CONTROL GAS HOSE 1.815m 1.00
06.10.00 .12.60840 COLLECTING-PIECE 1.00
20.00.00 .16.500.006 TORCH TOOLS: 1.00

20.01.00 .11.828.001.820 CATHODE PULLER 1.00
30.01.00 .16.500.100 SV= SOLENOID VALVE 0.00

30.02.00 .16.500.102 CP= CONNECTING PIECE 0.00

- page 67 -
- page 68 -
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 alternations to the product in order to follow the latest technical
development. Therefore, claims whatever kind can't be derived from this operating manual.
For any request you are kindly asked to quote Model Name and Model Number
n Please keep this Instruction Manual always ready for use. Read carefully all chapters
before starting the unit!
n The operating personnel must have through knowledge of the Instruction Manual.
n The Instruction Manual always must accompany the machine.
For damages due to misuse or wrong service we will not take any responsibility.
Kjellberg Finsterwalde Elektroden und Maschinen GmbH

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

- page 69 -
Änderungsnummer Änderungsdatum ab BON Geschrieben / geändert von ...
.11.033.502 BA dt a 20.06.2002 123442 Peter Jagieniak / Corinna Kloas
.11.033.502 BA engl a 26.07.2002 123442 Peter Jagieniak / Corinna Kloas

- page 70 -

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Instruction Manual

Plasma Cutting Machine

with swirl-gas torches type PB-S47 W

Fine Focus 450_BA_engl.doc 14/11/02

5.7 Connection of the plasma gas controller PGE 1 24

Enclosure Chart piercing during plasma cutting

Cutting data FineFocus 450 with PB-S47 W

Connection schemes FineFocus 450 with plasma torch PB-S47 W

Circuit diagrams FineFocus 450

Fine Focus 450_BA_engl.doc 14/11/02

• High contact voltage

Endangerment due to high contact voltage

Fine Focus 450_BA_engl.doc 14/11/02

Endangerment through high voltage ignition

High-voltage ignition may establish electro-magnetic fields and can influence:

Endangerment through electromagnetic interferences:

Recommendations to classify the environment (EN 50199):

Fine Focus 450_BA_engl.doc 14/11/02

If interferences take place following should be done:

• filter for mains connection

Endangerment through heat and light radiation:

Endangerment through fumes and smoke

• keep cutting place well ventilated

Endangerment through noise

Be aware that during plasma cutting a high noise level arises.

Cutting current Material thickness Noise level in distance of

Chart 1: Noise level of FineFocus 450

Therefore wear correct ear protection.

Fine Focus 450_BA_engl.doc 14/11/02

To avoid these endangerments the following has to be advised:

Handling of pressure cylinders

• Place cylinders upright in secured position.

Fine Focus 450_BA_engl.doc 14/11/02

2.1 The dry plasma cutting

1 pilot arc resistor

The safe ignition of the (main) arc :

• High-voltage ignition of pilot arc

2.2 Plasma cutting with swirl gas

Figure 2 shows the principle of the swirl-gas technology.

Fine Focus 450_BA_engl.doc 14/11/02

without swirl-gas with swirl-gas

2.3 Characteristic and advantages

• Double-Straight Effect (same cutting quality on both the cutting surfaces)

Further features and advantages are given:

Fine Focus 450_BA_engl.doc 14/11/02

Fine Focus 450_BA_engl.doc 14/11/02

3.1 Plasma rectifier FineFocus 450

Fine Focus 450_BA_engl.doc 14/11/02

3.2.1 Plasma torches of the PB-S47 W line

Machine torch: PB-S47 W/L PB-S47W/A

PB-S47 W-2/L PB-S47 W-2/A

Cutting thickness / -current: 45 mm (130 A)

Pressure: 1300 - 1600 l/h 0.5 - 0.6 MPa (5 - 6 bar)

Hose parcel Type PB-S47 W/x Type PB-S47 W-2/x

Fine Focus 450_BA_engl.doc 14/11/02

3.2.2 Plasma torch of type PB-S47 W-x/O2

Machine torch: PB-S47 W-1/O2 PB-S47 W-2/O2

Cutting thickness / -current: 45 mm (130 A)

Flow rate: 1100 - 1700 l/h 900 - 1500 l/h