Kjellberg Product Brochure En

Welding Technique and Wear Protection Systems

www.kjellberg.de

Product Catalogue

Torch technology InFocus for laser-like joining results; more on page 22

A determined person will find better use for a single screwdriver than the waverer

for a whole shop of tools.

(Emil Oesch, Swiss writer and publisher, 1894 – 1974)

Kjellberg Finsterwalde Plasma cutting techniqueWelding electrodesWelding technique

Submerged-arc weldingTechnologyStandard automatsPower sourcesManual SA welding

MIG weldingTechnologyMachines

Electrode welding

Special welding processes

Industrial system supplier

PTA and keyhole weldingTechnologyPower sources

Plasma cutting technique

Welding periphery

System solutions

Options

Rental service

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Contents

PTA welding sample

InFocus welding sample

Submerged-arc welding sample

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Kjellberg Group

The Foundation and its Ambitions

Our long history started when Oscar Kjellberg invented the coated welding electrode. This innovation represented a breakthrough in the metal-working industry at that time and from our present point of view we can say: we have always maintained our high aspirations for innovation and have been able to implement them in our products.

Today, we enjoy an international reputation as manufacturer of highest-quality welding and plasma cutting technique, welding electrodes and excellent welding systems of every discription.

Furthermore, the Kjellberg Group, run by the Kjellberg Foundation, fulfils a number of ethical requirements, i.e. the exclusively peaceful use of our know-how, the support of diverse cultural events or the awarding of scholarships. In this way, we secure high-level sustainability of our production and systematic promotion of junior

personnel and we also help preserve a unique handicraft culture. In addition, we strengthen the site and the attribute „Made in Germany“. Our production includes all parts of our plants, from planning to manufacture and programming. Only in this way can we offer the quality which our customers expect from us and which we gladly provide. The Kjellberg Foundation is the sole shareholder of all Kjellberg companies:

Kjellberg Finsterwalde Plasma und Maschinen GmbH

Kjellberg Finsterwalde Elektroden und Zusatzwerkstoffe GmbH

Kjellberg Finsterwalde Schweißtechnik und Verschleißschutzsysteme GmbH

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Organizational Structure

Kjellberg Foundation100% shareholder

PLASMA TECHNIQUE WELDING TECHNIQUEWELDING ELECTRODES

Product Groups

Kjellberg Group

Business Divisions

Plasma Technique

Product Portfolio

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CNC and Mechanized Technique

HiFocus seriesparticularly high cut quality with high-precision HiFocus systems (now with integrated Contour Cut technology)

FineFocus series

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robust units for reliable cut quality – even under the most severe conditions and under water

! PA-S seriescost-efficient units for simple applications

! CutFire seriespowerful, technically simple plasma cutting inverters with low investment costs

Manual Plasma Cutting Units

CUTi seriessmall mobile units for the best possible cuts, on construction sites or for confined production space

CutLine series

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technically simple and cost-efficient plasma cutting systems for versatile use, also for gouging

Accessories and Consumables

accessories for marking, height control, tractor guiding and torch changingnozzle caps, cathodes, etc.

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Please find a selection of plasma products on pages 28, 29 and 43.

For more than 50 years we have worked with plasma cutting technique. This makes our Plasma und Maschinen GmbH the most experienced manufacturer in this sector. The first patent in 1965 and continuous further developments have paid off: With more than 250 employees we are the biggest business division of the Kjellberg Group.

„Made in Germany“ is one of our quality attributes which is no empty promise but holds true for every tiny part of our machines and consumables. We develop and produce our machines through our own efforts. The latest

high-tech processes have been developed out of the beginnings of the plasma fusion cutting process and the fine-focus plasma cutting technology. Today, our technique can be used for cutting everywhere, also underwater. Up to now, our international success has also been based on the steadily increasing flexibility, the ever new possibilities of processing and the increasing cutting speeds of our systems. And the rising trend continues.

The newly developed Contour Cut technology convinces with precise cut results when cutting small holes and contours.

Business Divisions

Welding Electrodes

A sense of research, flexibility and ambitiousness is also a key element of our electrodes and filler materials division Elektroden und Zusatzwerkstoffe GmbH: Our product portfolio includes more than 60 standard electrodes and numerous special electrodes for diverse applications, all of them quality-tested and most of them certified. Are

you looking not only for heat-resistant, high-alloyed and unalloyed electrodes but also for nickel-based electrodes for cast iron machining or even your own mixture in the constantly diversifying market? Here you can quickly find what you need. On request, we develop your special electrode, no matter how complex – and on this point we won't change.

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Product Portfolio

Alloyed and Unalloyed Welding Electrodes

Unalloyed electrodes

Heat-resistant electrodes

High-alloyed electrodes

Nickel-based electrodes

Cast iron electrodes

Electrodes for surface welding

Cutting electrodes

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Filler MaterialsFor companies that have their own productionwe produce and supply mixtures for electrode coating.

Special ElectrodesOn customer request, we develop and/or produce welding electrodes for special requirements as regards the use or colour.

You will find welding electrodes on pages 20 and 21.

Quality electrodes with different features have been developed and produced since 1922.

Business Divisions

Welding Technique

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The knowledge of several generations of Kjellberg Finsterwalde's experts, continuous research and a team of highly specialised skilled employees have made the Kjellberg Finsterwalde Schweißtechnik und Verschleiß-schutzsysteme GmbH what it is: your partner for welding equipment. Being pioneers in automated welding technique, we do not rely on one single method only. Our portfolio includes among others the submerged-arc welding technology and system solutions on the basis of gas-shielded arc welding and plasma-transferred arc welding. Our quality-tested and further developed welding units are designed for the worldwide use under nearly all working

conditions. No matter whether you are looking for special welding systems for large production processes, compact units for manual use or whether you need thermal tools for your art and hobby: Kjellberg offers the optimum solution from the welding unit itself to spare parts and consumables. We consider it as a matter of course that we support you from the initial idea through to the approval, if you wish so.

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Product PortfolioSubmerged-arc Welding Technique

SAW automatsflexible modular concept for individual system solutions with a wide range of technological applications

Manual SA welding

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!for welding of large seam geometries on which mechanization is impossible

! Power sourcesmake it possible to weld with a current of up to 1.400 A

GMA Welding

flexible use for mechanised, partly and fully mechanised welding processes with high seam quality

! Power sources

PTA Welding

predefined welding programmes facilitate the industrial use for producing high-quality protective layers

! Power sources

Welding Periphery

column and booms, gantries and rotating devices produced and installed according to customer requirements

!

For more information about the welding technique product portfolio please see the following pages.

Complex Plants

! with different components from our portfolio

The submerged-arc welding method ensures a clean welding process due to the flux-covered arc.

Automated Submerged-Arc Welding

Submerged-arc welding (SAW) is an arc welding process where the arc burns between an endless wire electrode and the work-piece. A flux layer covers the arc and, thus, ensures an almost emission-free process. The usual sight protection measures are not necessary. This high-performance process achieves a high degree of thermal efficiency, further, the slag is a protective shield against the atmosphere.

On request, we install the Kjellberg SA welding technique on gantries, column and booms, motor-driven axle systems or carriages. Its modular design and diverse support systems allow the welding of numerous different work-pieces and seam geometries, e.g. in shipbuilding, bridge and steel construction or in container production. SA welding can be used efficiently for material thicknesses from 6 mm.

It is also suited for joint welding or for applying wear and corrosion protection layers – steels as well as chromium-nickel steels can be welded. The process can be used as fully automated, mechanised or manual solution with hand torches and achieves uninterrupted, long welds at high speeds and low costs.

Process Principle

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Technology

Quelle: DVS

Type/Art. no. Picture MethodMax.

welding currentWire

diameter (mm)Recommended power sources

KA 1-UP

3mm: .11.300.103

5mm: .11.300.105

Single-wire SA welding tractor for different wire diameters

500/800 A

1.400 A

1,6–3,0or

2,5–5,0

GTH 522GTH 802

GTH 1002GTH 1402

KA 1-UPas steerable version

.11.303.105Single-wire SA welding tractor for container and inner tube welding (e. g. windmill towers)

1.400 A 2,5–5,0GTH 1002GTH 1402

KA 2-UP/UPP

3mm: .11.300.203

5mm: .11.300.205

2x3mm: .11.300.270

Single-wire welding head (also available as parallel-wire SA welding head for installation on column and booms, gantries etc. in this or other assembled forms, also without carriage) for different wire diameters

800 A

1.400 A

1.400 A

1,6–3,0or

2,5–5,0

2x 2,0 – 2x 3,0

GTH 802

GTH 1002GTH 1402

GTH 1002GTH 1402

KA 4-UPDG

.11.300.400 SA welding tractor with two articulated arms (welding of two fillet or butt welds simultaneously)

600 A(on each

welding head)

1,6–2,5 (on each

welding head)

2 x GTH 5222 x GTH 802

KA 7-UPP

.11.300.700 Parallel-wire SA welding tractor (also available with automatic steering system)

1.400 A 2x 2,0 – 2x 3,0GTH 1002GTH 1402

UPK

.11.300.104

SA fillet welding 800 A 1,6–4,0 GTH 802

Standard Automats of the KA Series


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Kjellberg! More on page 46.

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Variable Automats for Applications

Advantages of Application Solutions


The flexible modular concept of the KA series is the basis for different technological system solutions in the area of welding automation technology.

In combination with the welding power sources made by Kjellberg, there are numerous possibilities for customized solutions which guarantee an effective use in the industry, like welding gantries and equipment for column and booms. Please see pages 36 to 41 for some application examples.

Welding Tasks

Container, longitudinal weld

CladdingContainer, circular weld

(inside and outside)

T-Beam Double T-Beam Box girder Butt weld joint

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High welding quality due to stable speedometer-controlled wire feeding! with four-wheel drive for wires up to diameter 3 mm (SAW and GMAW)! for wires from diameter 2,5 - 5 mm for single-wire SA welding (KA 1-UP), for parallel wire (KA 7-UPP)

diameter 2 x 2.0 up to 2 x 3.0! as double drive for welding with two articulated arms KA 4-UPDG up to 2 x 2.5 mm wire diameter

Flexible, technological use due to! Fixed welding head, pivoting to the side and for piercing and dragging fillet welding (KA 1-UP)

long lifetime at welding currents of up to 1,400 A (KA 1-UP, KA 7-UPP)convertible for narrow-gap welding with screwing nozzles (KA 1-UP)convertible to KA 7-UPP (parallel wire)

! Welding head as drag arm (KA 4-UPDG)reliable, mechanical seam tracking; cost-efficient compared to complex electronic sensorsUP diameter 2 x 1.6 up to 2 x 2.5

Visual seam tracking with laser cross

Quick positioning of the welding head due to manual linear axes (effective adjustment track per 100 mm)

Further increase of the stability possible with optional axle extensions

Minimisation of auxiliary times due to optional accessories: pneumatic flux recovery unit(low-wear injection principle)

High transportation safety due to protected eye hooks

Easy to handle, comfortable control unit with! pre-selection of parameters for welding current, arc voltage and welding speed! pre-selectable procedure for start mode and crater filling

Support of wire coil up to max. 30 kg (ISO K 435)

Flexible installation of strain relief for hose parcels (can be screw-connected to the side or front)

Safe guidance of the carriageAlong profiles, webs, flanges and, on request, suitable for rails due to stepless adjustable supporting rolls

Safe drive of the carriage due to! speedometer-controlled all-wheel drive from 0.1 to 1.6 m/min! rubber or keyway wheels with a diameter of 160 mm! dust-protected manual clutch for releasing the drive! temperature-resistant rubber wheels (up to 200°C)

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TypeArt. no.CharacteristicMains voltage

Mains connectionWelding current range 25 % 40 %100 %Protection classWeightDimensions L x W x H (mm)

Connecting power acc. to EN 60974-1

GTF 551.11.709.002

constant current (CC)3 x 400 V,

–10 %/+10 %, 50 Hz16,5 kVA

CEE 32 A10 A/20 V – 550 A/42 V

550 A400 A300 AIP 22

194 kg925 x 658 x 1.100

(with carriage for construction sites)

GTF 551.11.709.001

constant current (CC)3x 230/400/500 V,

–10 %/+10 %, 50 Hz16,5 kVA

CEE 32 A10 A/20 V – 550 A/42 V

550 A400 A300 AIP 22

194 kg925 x 658 x 1.100



Mains connection

Welding current range 80 %100 %Protection classWeightDimensions L x W x H (mm)


GTF 752.11.705.602

(CC)

51,5 kVACEE 125 A

(optionally 63 A possible)60 A/22,4 V – 750 A/44 V

750 A630 AIP 22

304 kg980 x 720 x 1.000

constant current


GTF 1002.11.903.202C

(CC)3 x 400 V, –10 %/+10 %, 50 Hz

78 kVAterminal connection

fuse 125 A200 A/28 V – 1.000 A/44 V

–1.000 A

IP 21438 kg

1.110 x 820 x 1.000(stationary)

constant current

GTF 1402.11.903.702C

(CC)

83,8 kVAterminal connection

125 A200 A/28 V – 1.400 A/44 V

1.400 A1.200 A

IP 21438 kg

1.110 x 820 x 1.000(stationary)

constant current

fuse



Mains connectionWelding current range 60 % 80 %100 %Protection classWeightDimensions L x W x H (mm)

GTH 522 .11.907.602A

constant voltage (CV)3 x 400 V,

–10 %/+10 %, 50 Hz23,6 kVA

CEE 63 A70 A/18 V – 500 A/45 V

500 A–

400 AIP 23

260 kg1.130 x 665 x 865


GTH 802.11.705.902A


–10 %/+10 %, 50 Hz31,7 kVA

CEE 63 A80 A/18 V – 800 A/44 V

–800 A720 AIP 22

319 kg980 x 720 x 1.000


Power Sources


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Mains connectionWelding current range 25 % 40 % 100 %Protection classWeightDimensions L x W x H (mm)


GTH 1002.11.903.102A

78 kVAterminal connection

--

1.000 AIP 21

440 kg1.110 x 820 x 1.000

(stationary)

constant voltage (CV)3 x 400 V

–10 %/+10 %, 50 Hz

100 A/19 V – 1.000 A/44 V

GTH 1402.11.903.802A


-1.400 A1.200 A

IP 21440 kg

1.110 x 820 x 1.000(stationary)


–10 %/+10 %, 50 Hz

100 A/19 V – 1.400 A/44 V

GTF 401.11.708.002 / .11.708.001

constant current (CC)2 x 400 V/3 x 230/400/500 V

11,2 kVACEE32 A

10 A/20 V 400 A/36 V400 A

-250 AIP 23

169 kg925 x 658 x 1.000 (stationary

)

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with carriage for construction

W 1005 VC

–10 %/+10 %,

.11.691.002constant voltage (CV)

2 x 400 V/PE50 Hz


200 A/25 V – 1.000 A/44 V--

1.000 AIP 21

510 kg1.130 x 750 x 990

(stationary)

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Advantages of the Equipment:

suited for all welding power sources of the

GTH serieseasy to handle torchflux supply with external, mobile pressure

tank, manual lock at hand torchrobust four-wheel wire feeder with constant

contact pressuresuited for solid and filler wiresstepless set value pre-adjustment for welding

voltage and current as well as start

parameters on the front panelswitchable from two-stroke to four-stroke

operationprotected electronicscurrent-less wire threading and returnexisting GTH power sources can be

retrofitted

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Max. at 100%duty cycleOpen circuit voltage, max.Wire feeding speedWire coil diameter

Wire diameter steelCrNifiller wire

Feed rollers standardProtection class WeightDimensions L x W x H (mm)

according to power source400 A

according to power source1 – 16 m/minmax. 300 mm(option K 435)0,6 – 2,0 mm0,8 – 2,0 mm1,0 – 2,4 mm

1,2 and 1,6 mm (steel)IP 2325 kg

710 x 250 x 500 mm

The Equipment

Manual Submerged-Arc Welding

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The wire feeding unit DV UP-H with integrated control unit and four-wheel drive can be operated the manual submerged-arc welding torch UP-H 500. The equipment is suited for welding large seam geometries where mechanisation is not possible, e.g. on frames

for windmill towers or large connecting pieces for containers and pipes.

The DV UP-H is also compatible with the mini-carriage KMF on page 32.

Technical Data

Wire feeding unit DV UP-H with power source GTH 522, pressure tank, SAW torch UP-H 500 and mini-carriage KMF.

MIG Welding

Spatter-free welds are absolutely essential for a welding production that requires no rework and is therefore cost-optimised.

MIG/MAG pulse weldingun-pulsed MIG/MAG welding with short arc or spray arcMAG welding with gas-protected and with self-protecting filler wires (also with negative pole)high-performance welding at standard wire feeding speeds of up to 20 m/min

The systems offer a large number of process variants:

Technology

Process Principle

- 14 -

Quelle: DVS

Our latest pulsed welding units remove the filler material drop by drop and short-circuit-free. They master complex current flows perfectly. The results are clean and nearly spatter-free welds. A low heat input reduces the material distortion. All these are reasons to choose a welding system made by Kjellberg Finsterwalde.

KH600 newArc

Kjellberg Technology newArc

With newArc, Kjellberg Finsterwalde has developed a technology which significantly increases the productivity compared to conventional MIG welding due to a higher constriction of the arc.

With a stick-out of up to 40 mm, newArc allows a considerably deeper penetration. The newArc torch convinces with its extreme directional stability and powerful seam guidance.

Further, the newArc technology has the following clear advantages compared to the conventional GMA spray arc: considerably reduced energy input per unit length, increased welding speed, deep and stable root formation, high seam quality, no undercuts, pores and spatter.

The result: a narrow and nearly perfect welded joint.

Application Advantages

MIG

Weld

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Spray arc newArc technology

ca. 60°25-30°

3 layers7 layers Heat-affected zone

20 mm

15 mm 40 mm

high process reliability, also in narrow weld weld cross-sections reduced by up to 50%grooves and on complex parts with material work-piece with nearly no undercuts and poresthickness from 6.0 mm improved appearance of the weldhigh quality due to stable root formation and easy to handleoptimum joining of the edge fewer welding layersquicker welding compared to joining with spray concentrated and stable arcarc reduced costs, reduced welding timereduced heat input and energy input per unit length

Technological Advantage of newArc

Fields of Application! mechanical and plant engineering! apparatus and container construction! ship building and vehicle construction! construction machinery production! metalworking of all kinds! also possible in connection with robots

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KH600 newArc in use

The power source KH 600 newArc allows nearly spatter-free welding at a permanently high seam quality. The abundance of materials that can be processed, also in a quick change, guarantees high productivity.

Absence of spatters

Welding properties

Hot-Start

Pulse frequency

crater filling

Welding of thin sheets

Digital display

Diagnostic display

Water recircu-lation cooling

Hose parcel extension

Welding

Design

Wire feeding control unit

Electronics

Nearly spatter-free pulse arc welding due to short-circuit-free drop transferwith synergistic behaviour within the entire welding range and low-spatter short arc welding and spray arc welding as well as rotation arc welding for! steel, CrNi and aluminium as well as! argon and mixed gases, consisting of Ar, CO , He and O2 2

! all solid wires and filler wires (also with negative pole)

! high process reliability due to optimised control loop! programmes for hard and soft arc dynamics! constant wire feeding due to electronically controlled four-wheel wire feed

Indispensable for the processing of aluminium

synergistically self-adjusting 10 to 500 Hz

internally optimised

Excellent suitability for thin sheets also with larger welding wire diameter, thusreduced costs for filler materials

Display of actual values as well as HOLD function for welding voltage and welding current

To avoid excess temperature, insulation faults and water shortage

integrated, with flow meter in the cooling water return (not only pressure switch!) for a safewelding operation

optionally with a length of up to 40 m

Best welding properties due to high-precision direct current for all rutile and basic Electrode types and high-performance electrodes

Easy maintenance due to simple inner design with clearly arranged components

no electronics in the wire feeding units, therefore extremely robust and reliable;complete electronic wire feeding control unit is in the welding power source

inverter welding power source with secondary clocking and IGBT module, therefore highclock frequency for precise direct current, control electronics with many monitoring andprotective functions

Kjellberg Technology newArc

Power Source KH 600 newArc

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For Workshops and Medium-Sized Companies

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Step-switched GMA welding technique with simple handling for everyday welding tasks.Because of their versatility, these units are in great demand everywhere – in medium-sizedsteel construction companies, for the repair of vehicles, in agriculture, in handicraft and industry etc.

KJELLmig Series

K350 including wire feeding unit DVG-K01, Art. no.: 11.746.000! L 635 x W 360 x H 520 mm! 4 wire feeding rollers! Protection class IP 21, weight 18 kg

! according to EN 60974 and BGV-D1

! S sign for electrical safety – allows welding under increased electrical hazard

! all transformers and throttles in the vacuum impregnated with high-quality electrical insulation coating and therefore absolutely insulated

! powerful fans for effective cooling under all operating conditions

! thermal overload protection for reliable operation

All you Need in One Package

All welding units are equipped with 3 m work-piece cable, GMAW torch (3 m), gas hose, pressure regulator, basket coil adapter and basic consumables kit for all listed wire diameters.

! ideally suited for workshops for welding with gas-cooled GMAW torches (L: 3 m)

! flexibly adjustable; therefore high seam quality

! excellent welding properties when using mixed gas

! user-friendly operation due to simple switching mechanism

! robust feed gear mechanism for safe wire feeding

! side panel folding for change of wire roll

! space-saving and large practical tray – accessories are ready to hand at any time

! easy transportation on stable rolls

! wear-free electronic control

! gas bottle holder; stable carriage due to low centre of gravity (max. 20 l bottle)

Working with Regard to Practical and Ergonomic considerations

Versatile applications:

! for unalloyed, low-alloyed and high-alloyed steels, aluminium, aluminium alloys, non-ferrous metals and galvanised sheets

! with argon and mixed gases

Always on The Safe Side

MIG

Weld

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Power Sources for the Industry

PULS 400

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When using the pulsed power source, the user can choose between the three welding processes GMAW, GMAW pulse and E-manual welding. The PULS 400 is mobile on rolls and weighs only 45 kg which makes it suited for different welding tasks in the automotive industry, in shipbuilding and engineering.

Area of Use

! light industry! heavy industry! especially demanding processes

Suited for welding of:! construction steel! CrNi! aluminium, aluminium alloys

TIG 300 AC/DC

An excellent seam quality can be achieved with the TIG power source TIG 300AC/DC. On the digital display the user can see and control all functions at any time.

Features

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up to 100 welding programmes can be programmed and storeddigital display of all functionshigh-frequency ignition without contacttwo-stroke and four-stroke operationstart, main and end current adjustableHot Start and Anti Sticking functions

Art. No.

WIG DCWIG AC, AC/DCMMA (REO) DC

40 % 60 %100 %

Connecting voltageWelding current range

Welding voltageDuty cycle

WeightDimensions L x W x H (mm)

.11.403.3023~400 V/50

4 – 300 A10 – 300 A10 – 250 A

21 – 30,5 V/10,2 – 22 V

300 A245 A190 A43 kg

640 x 250 x 544

Technical Data

Features

! welding power source with inverter technique! digital regulation and DC pulse welding! programmed synergy programmes! individual adjustment of welding parameters! up to 100 welding programmes can be

programmed and stored! synchronised external control possible! analogue and digital remote control! start, main and end current adjustable

Art. No.Connecting voltageWelding current range

Duty cycle 50 %100 %WeightDimensions L x W x H (mm)

Welding voltage

.11.707.5023~400 V/5030 – 400 A

15,5 – 34 V

400 A283 A45 kg

653 x 300 x 595

Technical Data

PULS 400 with digital regulation

TIG with digital regulation

Power Sources

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TypeArt. No.

methodKennlinie

Connecting power acc. to EN 60974-1Mains connectionWelding current range 25 % 40 %100 %

WeightDimensions L x W x H (mm)

Mains voltage

Protection class

KH 600 .11.707.603 / .11.707.703

GMAW pulseconstant voltage (CV)

3 x 230/400 V,–10%/+10%, 50 Hz

23,6 kVACEE 63 A

30 A/15 V – 600 A/44 V-

600 A450 AIP 23

183 kg1.020 x 750 x 1.130

(with carriage)

GTH 522 W.11.907.702

GMAW methodconstant current (CV)

3 x 400 V,–10%/+10%, 50 Hz

23,6 kVACEE 63 A

70 A /18 V – 500 A/45 V500 A

-300 AIP 23

260 kg1.130 x 665 x 865


Art. No.

(V)

Connecting power 100% (kVA)Fuse, slow (A)Welding current range I2

20 % duty cycle (A) 35 % (A) 45 % (A) 60 % (A)100 % (A)Welding current range (A)Welding voltage range (V)Open circuit voltage (V)Number of voltage levelsWire diameter (e.g. steel in mm)Number of wire feeding rollers

Mains voltage

duty cycleduty cycleduty cycleduty cycle

Protection classDimensions L x W x H (mm)Weight

KJELLmig 180.11.930.103

1 x 230 V/1 x 400 V50/60 Hz

2,0/2,416/16

110/180--

60/10040/80

20–110/85–18015–19,5/18–23

17–30/26–386

0,6–1,02

IP 21760 x 425 x 655

54,5

KJELLmig 230.11.930.202

3 x 400 V 50/60 Hz

5,216

-230

-170135

15–23014,8–25,5

17–4010

0,6–1,02

IP 21760 x 425 x 655

65

KJELLmig K350.11.931.102

3 x 400 V 50/60 Hz

12,820

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350-

24030–350

14,8–31,5 16–50

30steel, CrNi 0,6–1,2 / Al 1–1,2

see DVG-K01

880 x 530 x 67890

see DVG-K01

Standard: two-stroke seam welding, spot welding time as well as interval welding time and interval pause time are adjustable(0.5-2 s), for DVG-K01 also wire threading

On request, other Kjellberg wire feeding units (e. g. DV4G-3, DV4G-3M) can also be used in connection with the KJELLmig power sources.

Technical Data

Wire feeding unitsArt. No.

Wire diameter Steel, stainless steel Aluminium Filler wireWire feeding speed WeightTwo-stroke/four-stroke operationFour-stroke + Hot-Start + crater filling functionsWelding current adjustableArc length adjustableFree-burning adjustableButton for wire feed (current-less)Dimensions L x W x H (mm)

DV 4W-1H .11.745.100

0,8–1,61,0–1,6

1,0–2,41 – 20 m/min

23 kg

synergistic1)

705 x 240 x 445

DVW-2KH.11.745.600 bzw. .11.745.600A

0,8–1,61,0–1,6

1,0–2,42)1 – 20 m/min, 1 – 50 m/min

14,5 kg

synergistic2)

850 x 350 x 290

= Standard 1) advantageous via remote control FSH 30 2) art. no. .11.745.600A for high-performance welding

Rent quality

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MIG

Weld

ing

Electrode Welding

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Welding Unit Tiny 181

Welding Electrodes

Features

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Welding with rutile and basic electrodesIncreased welding current with arc ignitionAutomatic turn-off of welding current when electrode sticksDC WIG welding (arc ignition with contact)

The Tiny 181 is a mobile inverter for welding with direct current. It is especially suited for everyday tasks for assembly work, on construction sites and in workshops.

Art. No.

60 %100 %Electrode diameterWelding current regulationWeight

Connecting voltageOpen circuit voltage (V)Welding current range

Dimensions L x W x H (mm)

.11.401.904230 V/50 Hz

69 V5 – 180 A

160 A135 A

1,5 – 4 mmstep-less

7 kg405 x 155 x 254 mm

Technical Data

Unalloyed Electrodes acc. to DIN EN ISO 2560-A, DIN 1913, AWS A 5.1

LLOYD (rutile for shipbuilding)LLOYD GRÜN (rutile-cellulosic for shipbuilding)PERFEKT (basic for vertical down position)TITAN K (rutile-basic with high strength and toughness)OPTIMAL (rutile-basic for thin sheets)KONTAKT 160 (heavy rutile-coated with high recovery)PROGRESS (basic for vertical up position)GARANT K (basic, Ni-alloyed, with high strength and toughness, low H2 content)GARANT AC/DC (basic with high strength)

GARANT BR (rutile-basic)

TRUMPF (acid-coated)

PRIMA (rutile-cellulosic)PRIMA S (rutile-cellulosic, heavy-coated)PRIMA BLUE (rutile-cellulosic)TITAN ROT (rutile, heavy-coated)TITAN S (rutile, heavy-coated, with high strength and toughness)TITAN (rutile-basic)GARANT (basic)GARANT S (basic with high strength)

Stick Electrodes

Double Coated Electrodes

Special Electrodes

General Purpose Electrodes

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High-temperature Stick Electrodes acc. to DIN EN 1599, DIN 8575, AWS A 5.5

KOMPLEX W (rutile, 0.5% Mo)IMPULS (basic, 0.6% Ni and 0.4% Mo)MOB (basc, 0,5 % Mo)CROMO 1R (rutile, 1 % Cr and 0,5 % Mo)CROMO 1B (basic, 1 % Cr and 0,5 % Mo)CROMO 2B (basic, 2,2 % Cr and 1% Mo)

For Welding of Identical and Similar Steels!

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Cast Iron Welding Electrodes

acc. to DIN EN ISO 1071, DIN 8573, AWS A 5.15

FICAST Ni (pure nickel electrode, for cold welding of cast iron)FICAST NiFe (nickel-iron, for cold welding of grey cast iron, malleable and spheroidal cast iron)FICAST NiFe K (with copper-plated NiFe core for cold welding of grey cast iron, malleable and spheroidal cast iron)FICAST Fe (for buffering layers and single-layer surfacing on scaled or corroded iron castings)

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Nickel-base Electrodesacc. to DIN EN ISO 14172, AWS A 5.11

FINOX 182 (alloy class 182, nickel-chromium-iron)FINOX 625 (alloy class 625, nickel-chromium-molybdenum)

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Available in different diameters

Tiny 181

Electrode Welding

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High-alloyed Electrodes acc. ton DIN EN 1600, DIN 8556

FINOX 4820 AC (26 % Cr, 4 % Ni)

FINOX 4842 (26 % Cr, 20 % Ni)

FINOX 4842 B (26 % Cr, 20 % Ni, basic)

FINOX 4829 AC (22 % Cr, 12 % Ni)

FINOX 4316 AC (19 % Cr, 9 % Ni)

FINOX 4551 AC (19 % Cr, 9 % Ni, niobium-stabilised)

FINOX 4551 B (19 % Cr, 9 % Ni, niobium-stabilised, basic with high toughness)

FINOX 4430 AC (19 % Cr, 12 % Ni, 3 % Mo)

FINOX 4576 AC (19 % Cr, 12 % Ni, 3 % Mo, niobium-stabilised)

FINOX 4519 AC (20 % Cr, 25 % Ni, 5 % Mo and copper)

FINOX 4430 F (for vertical down position; 19% Cr, 12% Ni,3% Mo)

FINOX 4462 AC (for duplex steels of the alloy 22% Cr, 9% Ni, 3% Mo)

FINOX 29/9 GOLD (for crack-resistant joints with 30% Cr, 9.5% Ni, 1% Mn)

Stick Electrodes

Special Electrodes

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Cutting Electrodes

MET-OX (for cutting)KJELGOUGE (for gouging)

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Surfacing Electrodesacc. to DIN EN 14700, DIN 8555

FIDUR 6/55 (for low-alloyed and unalloyed steels, hardness 55 HRC)FIDUR 6/60 (hardness 60 HRC)FIDUR 6/60 R (rutile, hardness 60 HRC, suitable for AC current)FIDUR 2/55 (for low-alloyed and unalloyed steels, good edge-holding properties, hardness 55 HRC)

FIDUR 7/200 (crack-resistant layers on hard-manganese steel, hardness 200 HB, work-hardenable)FIDUR 8/200 (for rails and hard-manganese steels, hardness 200 HB, work-hardenable)FIDUR 10/60 (in case of grinding wear, hardness 60 HRC, 160% recovery)FIDUR 10/65 (in case of grinding wear and high temperatures, hardness 65 HRC, 190% recovery)FIDUR 10/70 (in case of grinding wear and high temperatures, hardness 70 HRC, 240% recovery)

FIDUR 1/300 (Mo- and V-alloyed, hardness 300 HB, on components with sliding wear)FIDUR 3/50 (for hot and cold working tools, hardness 50 HRC)FIDUR 4/60 (for high-speed tools, hardness 60 HRC)FIDUR 23/250 (nickel-base, alloy class 275, good thermal shock resistance)FILIT 6 (cobalt-base, resistant against cavitations, erosion, corrosion, hardness 40 HRC, good thermal shock resistance)

For Tough-hard/Abrasion-proof Layers

For Wear-resistant, Stainless Layers

Other Surfacing Processes

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Black-and-white electrodes! FINOX 4370 AC (for joint welding, also for hard-

manganese steel with 18% Cr, 8% Ni, 6% Mn)! FINOX 4431 AC (for joint welding, also for hard-

manganese steel with 20% Cr, 10% Ni, 3% Mo)! FINOX 4337 AC (general purpose electrode with

23% Cr, 13% Ni, 2% Mo)! FINOX 4332 AC (for joint welding, with 23% Cr,

13% Ni)! FINOX 4459 AC (for joint welding, with 23% Cr,

13% Ni, 2% Mo)

Fidur 10/70

Finox 4370 AC

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stable torch design (robust and shock-resistant)axial torch fixingclosed cooling circuitvery high current capacityscrew-in electrode

The torch technology InFocus achieves laser-like joining results. It is excellently suited for joining very thin sheets and nearly all metals.The welding results impress with an excellent seam surface and low oxide formation.

InFocus is exclusively used for fully automated processes. One of its main features is a high process reliability at a welding speed of up to 7 m/min.

Technological Advantage of InFocus

High-Performance Joining Process

InFocus in Comparison to Conventional WIG Welding

The concentrated arc starting point on the electrode tip of the InFocus torch creates an increased energy density and a higher back pressure which guarantees especially good welding and soldering results.

Conventional WIG arc InFocus-arc

Source: M.Schnick, TU Dresden

Simulation at a voltage of 500 A and an arc length of 5 mm with argon

Features

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The adoption of a cold wire feeding unit offers the possibility to compensate minor part and position tolerances. The tool centre point guarantees the best conditions for exactly reproducible welding results.

Our InFocus system is the economic alternative to GMA welding due to nearly spatter-free results and the high welding speed. Considerably lower investment and operating costs compared to laser welding is an additional advantage.

High-Performance Joining Process

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InFocus Welding Torch 1.000 A

! practical, robust design! high back pressure! for welding and soldering! high energy density, compact size! high joining speeds! excellent gas protection! low electrode wear

Advantages at One Glance

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Kjellberg Complete

We listen to your needs and set standards with our customer support from planning to startup and maintenance. We find the right components for you and produce unique systems – according to your specifications: With Kjellberg you have the experienced provider of complete systems at your side.

Our machines and plants are prepared for almost anything. Under water, in the air or below ground – ships, wind power stations and complex piping systems in mining show the performance of Kjellberg technique.

Pro

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Co

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Syste

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01 02 03

04 0505 06

07 08 09

10 11 12

Planning Plate cutting Rolling

Outside longitudinal seam welding Inside longitudinal seam welding Tacking segments and assembly

Flange welding Inside circular seam welding Outside circular seam welding

Cutting and welding Colouring Assembly and installation

Technology

Plasma-transferred Arc Welding

The mostly mechanised plasma-transferred arc welding (PTA) is a variant of plasma welding. With an arc welding process where the ignition and constriction of the ionised argon or helium gas is realised in the cooled plasma nozzle, PTA welding systems achieve a higher energy density compared to the usual welding methods. Depending on the size of the torch or by using the multi-layering technique, this method offers a remarkable profitability in view of its energy efficiency and potential for automation.

Another big advantage shows with regard to the supply of powdery filler materials which we gladly compose according to your specifica-tions. They are added directly through the plasma torch, merge almost completely with the base material and, thus, allow the use of materials which cannot be drawn into wires.

Process Principle

Features

! surfacing of hard/wear-resistant and/or corrosion-resistant layers onto small parts which are difficult to apply with wire

! voltages up to 300 A

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Plasma-transferred Arc Welding (PTA)

Usable for the Following Materials

! low and high-alloyed materials

! cast iron and bronze

! nickel-base alloys

Plasma Keyhole WeldingFeatures

! used for longitudinal and circular seam welding, containers and bottoms

! no additional seam preparation on the nearly parallel work-piece edges: lower amount of work compared to other processes

! low heat input and less distortion

! cost-efficient because little or no additional material is needed

With the PSI 350 Kjellberg Finsterwalde offers a high-quality and flexible unit for plasma-transferred arc welding as well as for plasma keyhole welding.

Both methods can easily be automated with the integrated PLC.

Welding Inverter PSI 350

Plasma-transferred Arc Welding

PTA

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very low dilution with the base material

very small heat-affected zone

high deposition rate

genuine metallurgical bond between base and filler material

easy to produce filler material mixture in powder form according to the requirements

high reproducibility of the results due to high degree of automation

Advantages

Methode at one glance

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Art. No.100%

100 % Pilot current (A)

Mains voltage

Welding current range (A)duty cycle

.11.150.2023~400 V

+10 %/-10 %, PEN 50 Hz

50 – 350 5 – 15

Technical Data

PSI 350 welding sample

Features

! comfortable operation due to predefined welding programmes

! adjustment of welding parameters

! visual monitoring of the process parameters

! electronic gas control

! compact design due to integrated cooling unit

! digital control on external control panel

Pipe welding with the PSI 350

Cutting Inverters of the CUTi Series

Manual Plasma Cutting

From the plasma units of the CUTi product line for manual and mechanised cutting users can choose the right unit for their demands and requirements.

The cutting current can be adjusted step-less. That's why the modern inverter technique achieves excellent cut results suited with all electrically conductive materials.

Features

! excellent price-performance ratio

! productive due to high cutting speeds

! low energy consumption due to inverter technique

! cost-efficient cutting with air as cutting gas

! quick change of cathode and nozzle due to consumables supply in the consumables kit (standard accessory)

! easy handling due to light weight1)! central torch connection with safety switch-off

allows quick torch exchange and easy transport

! CUTi 40 in connection with an adapter can be connected to a safety socket (16 A) with reduced cutting current of max. 30 A

! suited for the use in environments with increased hazard of electric shock

! maintenance unit for safe removal of condensed water from the cutting gas

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Accessories

! cap for template cuts

! bevel cap

! circle cutting attachment

! special consumables for cutting in corners (up to 70 A)

1) The CUTi 35C is equipped with a fixed torch.

Mains connectionConnecting power

Fuse, slow

Open circuit voltage Cutting current at

duty cycle

Protection class

Dimensions

L x W x H (mm)Air consumption

Plasma and cooling gas

Working pressure

Weight

Plasma torch

Scope of delivery

3 x 400 V

11,1 kVA

16 A

250 V

70 A (35% ED)

50 A (100% ED)

IP 21

470 x 180 x 250

140 l/min

air

5,0 bar (0,5 MPa)

16,4 kg

PHT 31

consumables kit

filter pressure switch

3 x 400 V

15 kVA

32 A

320 V

90 A (40% ED)

55 A (100% ED)

IP 21

470 x 180 x 270

195 l/min

air

5,0 bar (0,5 Mpa)

17 kg

PHT 51

consumables kit


3 x 400 V

16,7 kVA

32 A

450 V

120 A (35% ED)

80 A (100% ED)

IP 23

610 x 230 x 410

195 l/min

air

5,0 bar (0,5 MPa)

28,5 kg

PHT 51

consumables kit


Power source Art. No.

CUTi 70.11.035.402.

CUTi 90.11.035.502.

CUTi 120.11.035.602.

Technical Data

1 x 230 V1)3,3 kVA/4,8 kVA

16 A

270 V

35 A (25% ED)

20 A (100% ED)

IP 23

550 x 150 x 245

115 l/min

air1)4,0 bar (0,4 MPa)

12,5 kg

PHT 25

consumables kit


CUTi 35C.11.035.704.

1) with external compressed air supply

1 x 230 V

6,5 kVA

16 A (safety socket)/

32 (CEE)

270 V

40 A (40% ED)

25 A (100% ED)

IP 21

460 x 180 x 220

130 l/min

air

5,0 bar (0,5 MPa)

11,5 kg

PHT 31

consumables kit


CUTi 40.11.035.304.

40 A

70 A

Max.cuttingcurrent

Recommended 2)cutting range

90 A

10 20 30 40 50

CUTi 40

CUTi 70

2) Details dependent on materials and their composition.

Material thickness in mm

Maximum 2)cutting range

CUTi 90

Fields of Application

CUTi 120120 A

CUTi 35C 35 A

CUTI 40, 90 and 120

Versatile ApplicationsThe manual plasma cutting units of the CUTLINE series can be used for straight and contour cuts, interrupted cuts as well as bevel cuts for weld preparation, for hole piercing, fusion drilling, cutting in all positions and scrap cutting.

CUTLINE Series

Manual Plasma Cutting

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Features! excellent cut results! flying cutting start or piercing into the material

is possible; no reference corner is necessary! increased lifetime of consumables due to

soft-start function and water-cooled torch! extremely short changeover times for

consumables! automatic upslope of the pilot arc upon

contact with the work-piece! quick torch change without tools by using the

central connectors! high duty cycle due to effective cooling

TypeArt. No.

Mains voltage, 50 Hz (V), 3 Ph.

Fuse, slow

SPECIAL- mains voltage, 50 Hz (V)

VERSION mains voltage, inert (A)

Connecting power (kVA)

Protection class

Insulation class

Open circuit voltage (V)

Cutting current (A)

Duty cycle (%)1) Cutting thickness quality cut in mm

separating cut in mm

Plasma gas

Ignition

Weight (kg)

Dimensions L x W x H (mm)

Suitable torch (air or gas-cooled)

CUTLINE 20G

.11.033.003.

230/400

35/25

500

25

16

IP 22

F

275

30/60

50

15

20

74

670 x 490 x 880

PHT-31 G/L

CUTLINE 40G

.11.033.102.

400

35

500

25

24

IP 22

F

275

60/120

50

30

40

122

820 x 490 x 880

PHT-51 G/L

CUTLINE 20W

.11.032.803.

230/400

35/25

500

25

16

IP 22

F

275

25/50

60

15

20

84

670 x 490 x 880

PHT-30 W/L

CUTLINE 40W

.11.032.902.

400

35

500

25

24

IP 22

F

275

50/100

60

30

40

132

820 x 490 x 880

PHT-45 W/L

Technical Data

1) Material-dependent, standard qualities

The CUTLINE series can be used for cutting metals and other materials.

Plasma gouging with the CUTLINE series is a clean alternative to gouging with carbon electrodes – no regrinding is necessary. The heat input is minimal. The low noise level as well as reduced smoke emission are further advantages.

air

high voltage

RSV Series

For Pipeline and Container WeldingThe welding appliances of the RSV series make it easier to clamp, tilt and rotate work-pieces with circular cross-section. The RSV series is ideally suited for manual and fully mechanised pipe welding. Due to the compact design, the appliances are not only attractive for industrial prefabrication but also for installations and assemblies directly on construction sites.

Work-pieces can be produced without interruption for calibration or seam interruption - if clamped in identical position. During the production process, no time and no additional employees are needed anymore for turning and recalibration for identical work-pieces.

The Kjellberg clamping devices operate on the basis of the roller clamping principle, i.e. the work-piece is positioned between two driving rollers and one pressure roller. Thus, centric clamping even of curved work-pieces can easily and quickly be done.

Appliances

On request, our Kjellberg standard products can also be produced according to customer specifications.

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The infinitely adjustable rotating speed allows welding independent of the work-piece diameter.

A manual tilting function is standard in all appliances. A tilt-up is possible with a maximum angle of 135° so that work-pieces can be processed in optimum position. Optionally, the tilting drive is also available with electric motor. The tiltable component consists of drive box, roller box, clamping bar, clamping arm and clamping roller.

The welding appliance RSV can be used in combination with the KH 600 newArc.

Weight: 110 kg

Technical Data

The RSV 150 is a mobile clamping device for pipe welding. It was designed for the use on construc-tion sites and for assembly work for improving the welding quality. The work-pieces are welded without interruption.

The rotating speed can be adjusted infinitely with a foot control.

Rotating speed infinitely up to 130 cm/minwork-piece diameter clamped: NW 20 – NW 200work-piece diameter unclamped: 20 – 300 mmMax. turning moment 150 NmMax. capacityat horizontal roller position: 300 kgat vertical roller position: 150 kgTorque at the drive roller: 50 NmMains connection: 220 V, 50 HzPower requirements: 200 W

RSV 150

Technical Data

Rotating speed infinitely up to 130 cm/minwork-piece diameter clamped: NW 20 – NW 400work-piece diameter unclamped: 25 – 1.000 mmMax. turning moment 740 NmMax. capacityat horizontal roller position: 1.000 kgat vertical roller position: 500 kgMax. turning moment: 200 NmMains connection: 220 V, 50 HzPower requirements: 400 W

The RSV 500 is a compact clamping device for stationary pipe welding. The appliance is ideally suited for fully mechanised joining of components with a weight of up to 1,000 kg. Also curved pipe segments can be easily and quickly fixed and processes with this roller clamping system. The RSV 500 is suited for professional pre-fabrication of work-pieces with a nominal diameter of up to 400 mm (DN).

RSV 500

Weight: 260 kg

RSV Series

Appliances

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Technical Data

Rotating speed infinitely up to 130 cm/minwork-piece diameter clamped: NW 25 – NW 800work-piece diameter unclamped: 30 – 2.000 mmMax. turning moment 3.430 NmMax. capacity:at horizontal roller position: 2.000 kgat vertical roller position: 1.000 kgTorque at the drive roller: 490 NmMains connection: 380 V (220 V), 50/60 HzPower requirements: 1,5 KW

With the RSV 1000, pipes with a maximum nominal diameter of 800 mm can be clamped. So the appliance is suited for fully mechanised professional processing of pipes. Work-pieces with a total weight of up to 2.000 kg can be welded without interruption, thus reliably guaranteeing the best seam quality. The clamping system allows processing with constant rotating speed which is infinitely adjustable. Strongly curved work-pieces can easily be clamped. The RSV 1000 is the ideal clamping device for industrial production.

RSV 1000

Weight: 800 kg

Appliances

Mini-carriage KMF with Magnetic System

The welding carriage KMF for GMAW and SAW hand torches is effective, flexible and can also be used efficiently for piece and serial production. It is suited for all seam types and welding positions, except for PD and PE. It is self-positioning due to electronic speed control and permanent magnetic system with a strength of more than 180 Newton (in case of ferromagnetic materials). Thanks to a long battery life the KMF can operate more than two shifts. The mechanical feed and the exact torch guidance guarantee the highest reproducibility and quality of the welded seams. The KMF is equipped with lateral guide rollers so that the machine can be positioned at the web plate and aligns independently.

Technical Data

Art. No. .11.301.100.100 290 x 190 x 170 mmDimensions L x W x H (mm)

Weight incl. battery and 4,8 kgtorch holder:

Welding speed range 10 – 125 cm/Min.(others possible):

> 85 mmTrack width: Battery operation without

> 16 hreloading (60% duty cycle): < 25 Min.Battery load time:



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The KMF is self-positioning due to a permanent magnetic system.

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always customer-specific solution with energy chains, wheel sets, switch cabinet and control unit as well as emergency stop chain for GMA/SA joint welding, version for fillet welding (main area of application), platformsfor welding power sources, version with crane trolleys or gear racks for welding equipment support for surface welding including pendulum device (via linear axis) complete with welding equipment and wire feeding device

Welding Gantries/Travelling Carriages

Model

DK 50

DK 300

DK 500

DK 1500

DK 3000

DK 5000

DK 10000

Diameter face plate

(mm)

300

500

650

1.000

1.100

1.500

1.200

Tilt-and-turn angle

(°)

135

135

135

135

135

135

135

Rotating speed (revolutions/min.)

0 – 6

0 – 3

0 – 2,5

0 – 1,5

0 – 1

0 – 1

0 – 1

Maximum welding

current (A)

400

400

400

600

600

600

600

Maximum capacity

(kg)

20

300

500

1.500

3.000

5.000

10.000

General Technical Data

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all data regarding the capacity relate to a 200 mm distance from the face platerotating speed infinitely adjustableface plate with a diameter from 300 mm control via foot pedal, from work-piece weight of more than 500 kg with hand control unitoptional clamping device from a diameter of 25 mm and turnable ground connection

Rotating Devices/Welding Turntables


Appliances

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Customer-specific welding gantry

General Technical Datadrive and idler unit arranged in pairs (pair of section)manual or optionally motor-drivendiameter adjustmenthand control unitstationary (standard) or mobile (optionally)

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Roller Block Rotating Device

Maximum rotating load of

drive unit (kg)

2.000

5.000

10.000

15.000

20.000

Maximum working

load of drive unit

(kg)

1.000

2.500

5.000

7.500

10.000

Minimum container diameter

(mm)

200

200

300

300

300

Model

BDV 2000

BDV 5000

BDV 10000

BDV 15000

BDV 20000

Maximum container diameter

(mm)

2.500

3.000

4.000

4.000

4.500

Rotational speed

(mm/min)

75 – 1.500

75 – 1.500

75 – 1.500

75 – 1.500

75 – 1.500

Roller diameter

(mm)

250

250

415

415

415

Roller width(mm)

120

120

200

370

370

Model

KSM 2,5 x 2,0

KSM 2,5 x 2,5

KSM 3,0 x 2,5

KSM 3,0 x 3,0

Minimum effective

height below

boom (mm)

500

500

500

500

Maximum effective

height below

boom (mm)

2.500

2.500

3.000

3.000

Total height(mm)

3.500

3.500

4.000

4.000

Boom length(mm)

2.000

2.500

2.500

3.000

Boom speed(mm/min)

100 – 2.000

100 – 2.000

100 – 2.000

100 – 2.000

Rotation angle

(°)

± 180

± 180

± 180

± 180

Maximum working load (kg)

300

250

200

200


version with rectangular pipe with guide railsstationary version

1) turnable 360° – manual fixing deviceboom speed 10 – 200 cm/minfixed lifting speed 150 cm/minVersion with safety arresteroptionally with motor-driven carriage, track width

2)from 1.435 mm

1) Please note cable feed 2) Dependent on size

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Column and Booms

Appliances

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Other sizes on request

Other sizes on request

Column and boom produced on customer request

Strip Welding Head BSK 30-60

Appliances

This welding head is used for slag welding and SA strip welding on strips with a width between 30 and 60 mm.

It is also used for applying corrosion and wear protection layers. It is possible to adapt this welding head to guiding devices, i.e. welding gantries, column and booms, linear guides etc.

Application AdvantagesFeatures

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welding of strips with a width between 30 and 60 mm

applying of layers with a thickness of approx. 3 – 8 mm per layer with the usual strips of 0.5 mm thickness, use of solid strips as well as filler strips or sinter electrodes possible

control with presetting of nominal values for welding current, arc voltage and welding speed as well as separation of active and passive operating elements onto two operating levels possible with the Kjellberg control unit KAS

flux tank with a capacity of ten litres, equipped with window for filling level control and adjustment of pneumatic flux recovery unit possible (based on the injector principle) for SA strip welding

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high deposition rate

low dilution rate of only approx. 10%

high-quality functional layers can be applied to cost-efficient base materials

depending on the additional material, corrosion or wear protection layers are possible

the required chemical composition or desired degree of hardness of the work-piece surface can often be achieved already with the first layer

used for welding of sheets, inside and outside of pipes

economic surface welding with high deposition rate

versatile applications as protection against corrosion in pipe and container production as well as against wear in the steel and cement industry

Technical Data

Art. No.

Methode

Welding current max. (A)

Control voltage (V/Hz)

Strip width (mm)

Minimum diameter of inner pipe (mm)

Weight of coil max. (mm)

Weight (without wire and flux)

Dimensions of welding head L x W x H (mm)

Strip welding head BSK 30-60

.11.300.810

1.250

42 AC/50

30 – 60

500

275 x 145 x 350

30 (100)

20

strip welding

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Strip welding head for welding sheets, inside and outside of pipes

Example: Production of Steel Profiles

Application Example

welding of butterfly profiles

longitudinal seams in position PA

double-wire SA welding 2 x 2.5 mm wire diameter

part length up to 13.000 mm

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Features

travelling carriage with side boom on rail system

rail length 16.000 mm

two linear carriages with height axis on a continuous lateral axis on side boom

lateral axis 2.000 mm

Objective

use of the double-wire technique for better gap bridging

simultaneous welding on two parts with two welding heads

process stability by using the SA welding method with seam tracking

Plant Components

! travelling carriage as stable steel construction for travelling on rails (track width 1.600mm) with side boom

! two welding power sources DC up to 1.000 A type GTH 1002 moving along the carriage

! complete flux circuit with pressure conveying process, suction and pneumatic flux barrier including pre-heating possibility for flux

! central control panel for setting of welding parameters, adjustment of axes for both welding heads and control of the flux circuit

! tactile seam tracking system separately for each welding head


! space-saving version with boom for the optimum use of the installation area as alternative to a welding gantry

! all plant components are installed on the carriage and, thus, reduce the space required

! welding of different geometries and lengths

Performance

! welding with up to 2 x 1.000 A/44 V at 100 % duty cycle

! wire diameter up to 2 x 3.2 mm

! welding speed up to 1.5 m/min

! rapid motion of the carriage up to 10 m/min

Travelling Carriage

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Complete flux circuit with pressure conveying process, suction and pneumatic flux barrier.

Plant with central control panel

Example: Production of Steel Profile Beams

Robot Welding System

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Application Example

fillet welding on beams and profiles up to a throat thickness of 8 mm

GMA welding with the newArc technology

profile size up to 450 x 450 x 570 mm

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Features

robot application with turnover positioner

welding of one part and positioning of a second part at the same time

multi-layer welding on thick-walled parts

Objective

realisation of complex part geometries by using robot technology

at the same time pre-defined positioning of parts to minimise auxiliary process time

storing parameter records in the control unit

Plant Components

! stable base frame which carries all plant components

! industrial robot with a reach of 1.450 mm and a payload of 6 kg

! turnover positioner with a load capacity of 250 kg on each side as additional robot axis

! service station for measuring and cleaning of the torch

! welding power source KH 600 newArc, 450 A at 100% duty cycle

Performance

! wire diameter up to 1.6 mm

! use of solid or filler wire

! high repeatability during positioning (± 0.05 mm)


! reproducible welding results due to fully mechanised plant

! reduced auxiliary process time due to simultaneous welding and positioning

! can easily be extended with additional workstations by installing an additional turnover positioner

Fillet welding with robot system

Robot system with stable base frame which carries all plant components

Example: Container Welding Plant

Type SOLApplication Example

joint welding of rolled steel plates

circular and longitudinal seams (two separate plants)

SA welding of sheets with a thickness from 3 mm

container diameter max. 800 mm

container length 1.800 – 2.300 mm

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Features

massive base frame with two linear axis combinations and container turnover device for parallel circular welding

massive base frame with holding mandrel, roller guide-way and support combination for longitudinal welding Objective

! considerable increase of productivity due to fully mechanised production of complete containers

! considerable increase in quality because no influences of manual welding anymore

! flexible applications due to suitability for production of boilers of different sizes

Plant Components

! welding power sources, type GTH 522

! single-wire SA welding heads, each with optical seam tracking

! operating panels for control of welding process

! pneumatic flux circuits


! high production time saving and welding with virtually no distortion due to high welding speeds and excellent seam quality

! high process reliability due to central control of both circular welding units

! simultaneous welding of bottoms and covers to minimise distortion

! two separate units for all welding tasks for production of complete containers

Performance

! 70 A/18 V up to 400 A/34 V at 100 % duty cycle

! welding speed of up to 85 cm/min


Fully Mechanised SAW Plant

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Container welding plant for circular and longitudinal welding

Nearly spatter-free welding due to submerged-arc technology

Example: Container Surface Welding Plant

Application Example

welding of containers and pipes

circular and longitudinal seams

SA welding with wire diameter of up to 5 mm

work-piece diameter 1.000 mm – 4.000 mm

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Features

! movable column and boom on rail system

! roller blocks with a maximum total load of 30 tons

! welding of inner and outer seams

Objective

! increase of productivity due to reduced auxiliary process time

! central control of the entire plant

! use of the existing rail system

! dismantling of the old system and at the same time installation of the new technique to minimise the production downtime


! rapid motion for vertical direction up to 4.500 mm/min, thus noticeably reduced auxiliary process times for change from inside to outside seam welding

! process reliability due to automatic height control and camera system

! mobile control unit for adjustment of the welding head directly on the work-piece

Plant Components

! column and boom 5 m x 6 m

! one welding power source DC up to 1.000 A type GTH 1002

! complete flux circuit with pressure conveying process and suction with pre-heating possibility for flux

! central control panel for setting of welding parameters, data recording and adjustment of axes with touch-screen panel

! combined seam tracking system with inductive height sensor and camera system

! swivelling bracket for quick change from longitudinal to circular seam welding without modification of the plant

Performance

! welding with up to 1.000 A/44 V at 100 % duty cycle

! wire diameter up to 5 mm

! rapid motion of vertical boom up to 4.5 m/min

! build-up of layers in positions PA and PB

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Column and boom with a size of 5 x 6 m

Complete system with rails

Mobile Column and Boom

Example: Rail Surface Welding Plant

For surface welding on railsApplication Example

surface welding on grooved rails for regeneration purposes

SA welding

build-up of layers on vertical groove sides

material: rail steel

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Features

! optional use of solid wire or filler wire electrodes

! adjustment possible to a maximum track width of 1.500 mm according to each rail type

! splash-proof housing of wire feeding unit

Objective

! considerable reduction of working time by regenerating grooved rails in mobile use on-site with fully mechanised plant technology

! high seam quality due to even application of layers in the range of currently tracks, curves and points

Plant Components

! welding power source of the type GTH 802 modified, suited for generator operation

! single-wire SA welding head with flexible hollow cable for wire diameters of up to 2.5 mm

! pneumatic flux recovery

! hose parcel extension with a length of 35 m


! saves production and auxiliary process time

! mechanised surface welding on left or right groove side without re-positioning of the plant

! stable welded construction as version with six wheels

! minimum flux loss and long welding paths can be realised due to pneumatic flux recovery

! flexible and light due to rubber wheels and their use with electric lifting cylinder

Performance

! 80 A/18 V up to 720 A/44 V at 100 % duty cycle

! welding speed up to 70 cm/min


! build-up of layers in position PC

Fully Mechanised Automat

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Surface welding on grooved rails

Mobility due to fully automated plant technology

Example: Fully Mechanised Surface Welding

Application Example

surface welding on plates

filler wire welding/SA welding

maximum plate size 1.500 mm x 3.000 mm

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! optionally filler wire welding or SA welding

! welding gantry as stable steel construction with a range of 3.500 mm

! rail length 6.000 mm

! two linear carriages on a continuous lateral axis with a travel way of 3.000 mm

! maximum oscillation width of each welding head 80 mm

! fume suction directly at the weld

! dust-proof version of the entire plant including axes and switch cabinet

Objective! surface welding over the entire surface of

steel plates

! welding with one or two torches in simultaneous alternating operation

! pre-setting and storing of welding parameters like voltage, welding current, wire feeding speed etc.

! automatic operation with pre-setting of plate size

Plant Components

! two welding power sources DC up to 1.000 A/100 % duty cycle

! two water-cooled torches

! central control panel for adjustment of welding parameters for two welding heads and adjustment of the axes


! choosing between two welding methods without modification of the plant

! process reliability due to stored parameters and storage of welding records

! high usage rate due to automatic operationPerformance


! welding speed up to 1 m/min

! rapid motion up to 6 m/min

Surface Welding Plant

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Plant with two linear carriages on a lateral axis

Rail length from 6.000 mm

Accessories

Tandem welding heads Water-cooled filler wire torch

Plasma-transferred arc welding torch

Chisels

Keyhole torch Welding head for pipe Insides

Hand brush with wire bristles

Pneumatic chipping hammer

Standard chipping hammer

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Accessories

Torch Heads

Welding helmet

Safety at WorkWelding gloves

Flux Supply Systems

Tactile sensor

Inductive sensor laser scanning

Laser scanner

Visual with laser pointer

Photo-optical monitoring system

Seam Tracking Systems

Pressure tank 50 and 100 litres (heated)

Pneumatic flux recovery as injector system

Accessories

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Rent quality

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Plasma torch KjellCut for the CUTi series

Plasma Cutting Technique

Bevel cutting device Plasma travel unit

Circle cutting attachment

Further accessories on request

Suction nozzle fillet weld right and left

Narrow-gap system, wire with a diameter of up to 5 mm

Current contact nozzle UPP

Suction nozzle butt weld

Flat nozzle, straight or 5° angled

Spare Parts and Consumables

SAW Current contact nozzles and flux caps

Current contact nozzle UPP long

Additional current nozzles and consumables on request and according to customer requirements

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SAW nozzle holder complete, long

SAW nozzle holder narrow-gap, wire with a diameter of up to 3 mm

SAW nozzle holder complete, wire with a diameter of up to 5 mm

Spare parts and consumables

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Kjellberg filter bags (available with several connection diameters)

Flux tank 6 and 10 litres


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Other Options

Control panel for specialplants

Touch screen control panel

Turnable ground connection

Cooling unit KWE 750


Rental Service

Renting as Alternative

Maintenance downtimes and production peaks are no longer a problem if you choose our rental service.

Of course we offer advice and delivery as well as detailed instruction and collection after the job is done. The fields of application and the possible combinations of our offer are as diverse as are your demands on Kjellberg. That's why you can inquire after exact rental fees by telephone and online by using our contact form.

Example Rental Set

KA 1-UP (5 mm)KA 1-UP (5 mm) with work-piece cable 10 m, 20 m hose parcel extension and flux recovery unit

GTH 1002with 5 m mains cable and 125 A CEE plug

Consumables kit and welding periphery like roller block

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Rental Conditions:

minimum term of rent: one calendar weekdelivery, collection and instruction are optionaladvice and offers are free of charge and not binding

Contact person: Mr. Manuel KornekTelephone: +49 3531 500-319

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Welding periphery like column and boom

What is needed for being effective is competence gained through exercise.

(Peter F. Drucker, American teacher of management, publicist and consultant of Austrian origin, 1909 – 2005)

Since 1922, we have found the right solutions with the production of

welding electrodes, welding technique and plasma cutting technique. We have a long tradition.

Kjellberg Finsterwalde Schweißtechnik und Verschleißschutzsysteme GmbH

DE-03238 Finsterwalde Leipziger Straße 66-68 Phone: +49 3531 500-319 Fax: +49 3531 500-357

Mail: [email protected] Internet: www.kjellberg.de

DE-58453 Witten Stockumer Straße 28 Phone: +49 2302 2025-940 Fax: +49 2302 2025-945

Copyright 2012 Kjellberg Finsterwalde Schweißtechnik und

Verschleißschutzsysteme GmbHAll rights reserved.

and are trademarks of the Kjellberg Foundation or one of its affiliates and may be registered in Germany and other countries.

Our products represent a high level of quality and reliability. We reserve the right to change the design and/or technical specification during the series fabrication. Claims of any kind cannot be derived from this brochure.

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Would you like to learn more? We will be happy to send you further information and to offer you consultations, also on site in your company – of course completely without obligation.

Please contact our qualified specialist staff by telephone +49 3531 500-319 or email: [email protected].

Many of our offers are custom-made products which are especially fitted to the requirements and wishes of our customers. We also fulfil extraordinary requests! Try us: you can rely on the Kjellberg engineers who will find the right solution for you.

Let yourself be surprised!

Advice With Know-how

70 cm on the submerged-arc track…

Documents

Kjellberg Product Brochure En