www.kjellberg.dewww.kjellberg.de

Welding Systems and Automats, Devices, Filler Materials, Services

Product Catalogue 2014Full-Range Supplier of Welding Technique

- 2 -- 2 -

Cooperation means to build a stage for the other one on which he looks good. (Unknown)

- 3 -- 3 -

Content

Overview..................................................................................................................................................................................................................................................4Our ambition ........................................................................................................................................................................................................................................5Product portfolio of the Kjellberg companies.......................................................................................................................................................6

Submerged-arc Welding .............................................................................................................................................................................................9SA technology and standard automats .....................................................................................................................................................................9Manual SA welding.................................................................................................................................................................................................................... 12Standard power sources...................................................................................................................................................................................................... 13Multifunctional welding inverters.................................................................................................................................................................................. 14

Gas Metal Arc Welding ..............................................................................................................................................................................................16GMAW technology ..................................................................................................................................................................................................................... 16GMAW equipment ...................................................................................................................................................................................................................... 17

TIG Welding ............................................................................................................................................................................................................................... 19TIG welding technology and equipment............................................................................................................................................................... 19

Special Welding Technologies.......................................................................................................................................................................20High-performance TIG InFocus .................................................................................................................................................................................... 20InFocus solutions ........................................................................................................................................................................................................................ 21

Manual Metal Arc Welding (MMAW) .......................................................................................................................................................22MMAW technology and inverters ................................................................................................................................................................................ 22

Cutting Equipment ..........................................................................................................................................................................................................23Manual plasma cutting........................................................................................................................................................................................................... 23

Wear Protection ...................................................................................................................................................................................................................24Surface welding technology ............................................................................................................................................................................................. 24Systems for surface welding............................................................................................................................................................................................ 25Surface-welded sheets.......................................................................................................................................................................................................... 26Plasma-transferred arc and plasma keyhole welding............................................................................................................................. 27

Welding Periphery ...........................................................................................................................................................................................................28Welding devices ........................................................................................................................................................................................................................... 28

System Solutions ..............................................................................................................................................................................................................32Customisation................................................................................................................................................................................................................................. 32In practice ........................................................................................................................................................................................................................................... 33

Filler Materials .......................................................................................................................................................................................................................36:HOGLQJ�ÀX[ ...................................................................................................................................................................................................................................... 36Welding wires ................................................................................................................................................................................................................................. 37Welding electrodes .................................................................................................................................................................................................................... 38

Options ............................................................................................................................................................................................................................................40Welding carriage GMAW and SAW .......................................................................................................................................................................... 40Control units ..................................................................................................................................................................................................................................... 41Welding heads ............................................................................................................................................................................................................................... 42Cooling unit and accessories .......................................................................................................................................................................................... 45

Service................................................................................................................................................................................................................................................... 46

- 4 -- 4 -

Overview

Products SAW

GM

AW

PTA

TIG

Key

hole

w

eldi

ng

Wea

r pr

otec

tion

MM

AW

Plas

ma

cutti

ng

Gou

ging

Spec

ial

proc

esse

s

Page

KA series Ɣ ż Ɣ 9 - 11

DV UP-H Ɣ ż Ɣ 12

GTH series Ɣ Ɣ Ɣ 13, 17

GTF series ż Ɣ Ɣ Ɣ Ɣ 13

W 1005 VC Ɣ ż Ɣ 13

KUB inverter series Ɣ Ɣ ż Ɣ ż Ɣ Ɣ Ɣ ż 14 - 15

KH 600 newArc Ɣ Ɣ ż Ɣ 17

Puls 400 Ɣ Ɣ Ɣ 18

Kjellmig series Ɣ ż 18

Tig 300 AC/DC Ɣ Ɣ Ɣ 19

InFocus Ɣ Ɣ 20 - 21

Tiny 250 Cel ż ż Ɣ 22

CUTi series Ɣ Ɣ ż 23

CUTLINE series Ɣ Ɣ ż 23

Fidur gantry Ɣ 25

PSI 350 Ɣ ż Ɣ Ɣ 27

Standard Equipment

Ɣ recommended I ż possible

Key: Fields of Application

Non-ferrous metal industry

Power industry

Workshop and repairs

Chemical industry

Steel industry

Automobile/vehicle construction Ship building

Mining

Mechanical engineering/equipment

- 5 -- 5 -

Our Ambition

Kjellberg Foundation

The history of Kjellberg Finsterwalde started when Oscar Kjellberg invented the coated welding electrode. This innovation repre-sented 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 inno-vation which is shown by our variety of high-quality products.

Our world-class plasma cutting technique, FXVWRPLVHG�ZHOGLQJ�V\VWHPV��H[FHOOHQW�ZHO-ding electrodes as well as special machines and tools in small and large series are used worldwide.

Our products are produced from a single source along the complete valued added chain. Well-trained specialist work in development, planning, manufacturing and

implementing to satisfy our customers. As a result, we are able to offer high-quality products for users in industry and crafts that meet their everyday challenges.

The goals of the Kjellberg foundation, as sole shareholder of all Kjellberg compa-nies, determine all activities of Kjellberg Finsterwalde: The foundation goals aim at improving of working environments, promo-WLQJ�VFLHQWL¿F�VWXGLHV�RU�UHJLRQDO�VXSSRUW�RI�structural development. In this way, the local site and the attribute “Made in Germany” are strengthened.

- 6 -- 6 -

Plasma and Laser Cutting Technique

Product Portfolio of the Kjellberg Companies

For more than 50 years we have concen-trated on the development and production of cutting technique. Today the Kjellberg Finsterwalde Plasma und Maschinen GmbH offers:

CNC and mechanised technique��HiFocus neo series

High-precision plasma cutting units with Contour Cut technology for highest ÀH[LELOLW\�DQG�SURGXFWLYLW\�LQ�WKH�FXWWLQJ�range from 0.5 to 160 mm

��FineFocus seriesRobust units for reliable cut quality for the upper cutting range up to 160 mm – HYHQ�XQGHU�H[WUHPH�FRQGLWLRQV

��PA-S seriesTechnically simple, step-switched plas-ma cutting units for mechanised and manual cutting of medium-sized plates

��CutFire seriesPowerful, technically simple plasma cutting inverters for economic use in the lower cutting range

��Laser series XFocus Cut unalloyed steel up to 10 mm, alloyed up to 5 mm and aluminium up to 3 mm

Manual plasma cutting units��CUTi series

Powerful and light inverters with high UHOLDELOLW\�IRU�WKH�ÀH[LEOH�DQG�PRELOH�XVH�on construction sites and in workshops

��CUTLINE seriesFine focus plasma cutting units with high duty cycle

A selection of light cutting equipment can be found on page 23, the range of electrodes from page 38 onwards.

Welding Electrodes

$�VHQVH�RI�UHVHDUFK��ÀH[LELOLW\�DQG�DP-bitiousness is also a key element of our HOHFWURGHV�DQG�¿OOHU�PDWHULDOV�GLYLVLRQ��2XU�product portfolio includes more than 60 standard electrodes and numerous speci-al electrodes for diverse applications, all of them quality-tested and most of them FHUWL¿HG�

Alloyed and unalloyed welding electrodes��Unalloyed electrodes��High-temperature electrodes��High-alloyed electrodes��Nickel-base electrodes��Cast iron electrodes��Surfacing electrodes��Cutting electrodes

Special electrodesOn request, we develop and produce wel-ding electrodes for special requirements as regards use or colour.

Filler materialsFor companies that have their own pro-GXFWLRQ�ZH�SURGXFH�DQG�VXSSO\�PL[WXUHV�for electrode coatings.

- 7 -- 7 -

Product Portfolio of the Kjellberg Companies

Tool and Mechanical Engineering

Toolmaking has a long tradition at the Kjellberg Maschinenfabrik GmbH that offers best conditions for development, construction, manufacturing, assembly and implementing:

Toolmaking��Cutting tools��Progressive compound and cutting tools��Trimming tools for die resp. sand-cast

aluminium parts��Forming tools��Special tools, special milling tools,

rotating steel��Devices of all kinds��Production of consumables and individu-

al parts for tools

Make-to-order production��CNC milling and turning��Wire eroding��Conventional milling, turning and drilling��Form, level and cylindrical grinding��Processing of cast and forged parts

The knowledge of several generations RI�.MHOOEHUJ�)LQVWHUZDOGHV�H[SHUWV��FRQ-tinuous research and a team of highly specialised skilled employees have made the Kjellberg Finsterwalde Schweißtechnik und Verschleißschutzsysteme GmbH what it is: your partner for individual solutions for metal processing.

Submerged-arc welding technique��SAW automats��SA manual welding��Power sources

Wear protection technique��*DQWULHV��PRELOH��VWDWLRQDU\��ÀH[LEOH��Standard and special sheets��Filler materials

TIG welding technique

High-performance TIG InFocus

GMA welding��Power sources

Plasma-transferred arc and keyhole welding��Power sources

MMAW technique

Welding periphery��Column and booms, gantries, rotating

devices

Welding systems��Mobile and stationary

Filler materials

Welding Technique

For more information about the wel-ding technique product portfolio please see the following pages.

Whether standard quality or unicum: Choose from our diversified product range. If you do not find the right product for your need, we will create an individual all-in-one solution that fulfills your requirements:

Ŷ TIG and GMA welding technique Ŷ Individual all-in-one solutions Ŷ Submerged-arc welding Ŷ MMAW technique Ŷ Wear protection Fidur Ŷ Column and booms, gantries, rotating devices Ŷ Filler materials Ŷ Rental service

The right solution

for every task

- 9 -

Technical data

- 9 -

Subm

erge

d-Ar

c W

eldi

ng

Submerged-arc welding (SAW) is an arc welding process where the arc burns between an endless wire electrode and the work-piece. $�ÀX[�OD\HU�FRYHUV�WKH�DUF�DQG��WKXV��HQVXUHV�an almost emission-free process. Usual sight protection measures are not necessary.

On request, we install the Kjellberg SA welding technique on gantries, column and booms, PRWRU�GULYHQ�D[OH�V\VWHPV�RU�FDUULDJHV��,WV�PR-dular design and diverse support systems allow the welding of numerous different workpieces and seam geometries.

6$�ZHOGLQJ�FDQ�EH�XVHG�HI¿FLHQWO\�IRU�PDWHULDO�thicknesses from 3 mm. It is also suited for joint welding or for applying wear and corrosion pro-tection layers. 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.

Submerged-Arc Technology and Standard Automats

Technology

Advantages

�� High quality thanks to stable arc�� Almost emission-free process�� No blinding effect�� High welding speed�� Highly economic due to high deposition rate�� Low costs

Automat KA 1-UP

The KA 1-UP is available in four versions.

KA 1-UP Standard/steerable

3 mm

KA 1-UP Standard/steerable

5 mm

Art. no. .11.300.103 .11.300.105/.11.303.105

Welding current 800 A 1.400 A

Wire diameter 1.6 – 3.0 mm 2.5 – 5.0 mm

Speed 0.1 – 2.0 m/min 0.1 – 2.0 m/min

Protection class IP 23 IP 21

'LPHQVLRQV��/�[�:�[�+� ������[�����[�����PP ������[�����[�����PP

Weight 51 kg 61 kg

Recommended power sources

GTH 522GTH 802

GTH 1002GTH 1402

The welding tractor KA 1-UP is available in different versions: as 3-mm- or 5-mm-single-wi-re tractor for different wire diameters and each as steerable version as well which is suited for container and tube welding.

- 10 -- 10 -

Unt

erpu

lver

schw

eiße

n

Standard Automats

Automatable KA series with:�� Preset of welding parameters�� Welding head with automatic ignition and

burn-free�� &RQ¿JXUDEOH�VWDUW�DQG�HQG�FUDWHU�¿OOLQJ�

phases �� Laser pointer for visual seam tracking�� Manual positioning with cross slide�� Optional: digital control with job storage

Technical data

Automat KA 4-UPDG

7KH�RSWLPXP�VROXWLRQ�IRU�¿OOHW�ZHOGLQJ�

KA 4-UPDG

Art. no. .11.300.400

Welding current ��[�����$

Wire diameter ��[�����±�����PP�

Speed 0.1 – 2.0 m/min

'LPHQVLRQV��/�[�:�[�+� ����[�����[�������PP

Weight 60 kg

Recommended power sources

GTH 522G GTH 802

Equipped with two articulated arms the KA ��83'*�ZHOGV�WZR�¿OOHW�ZHOGV�VLPXOWDQHRXVO\���Due to a speedometer-driven carriage with all-wheel drive the automat is suited for mobile use as well.

Technical data

Automat KA 2-UP/UPP

Different types of the KA 2-UP/UPP are available.

KA 2-UPP Parallel-wire

KA 2-UP 3 mm

KA 2-UP 5 mm

Art. no. .11.300.270 .11.300.203 .11.300.205

Welding current 1,400 A 800 A 1,400 A

Wire diameter ��[����±��[�����PP 1.6–3.0 mm 2.5–5.0 mm

'LPHQVLRQV��/�[�:�[�+� variable variable variable

Weight 42 kg 61 kg 40 kg

Recommended power sources

GTH 1002GTH 1402

GTH 802 GTH 1002GTH 1402

The KA 2-UP is available with a single- and parallel-wire welding head as well as a control unit for installation on column and booms and gantries. The KA 2 can be used for welding with different wires.

- 11 -- 11 -

Subm

erge

d-Ar

c W

eldi

ng

Standard Automats

Automat KA 7-UPP

7KH�.$���833�DV�VWHHUDEOH�YHUVLRQ�LV�HYHQ�PRUH�ÀH[LEOH�

KA 7-UPP Standard/steerable 5 mm

Art. no. .11.300.700

Welding current 1.400 A

Wire diameter ��[�����±�����PP

Speed 0,1 – 2,0 m/min

'LPHQVLRQV��/�[�:�[�+� ������[�����[�����PP

Weight 61 kg

Recommended power sources

GTH 1002GTH 1402

With the parallel-wire SA welding tractor plane sheets and inner tubes can be welded. The DXWRPDW�FDQ�EH�OHG�RQ�UDLOV��ÀDQJHV�DQG�SUR¿OHV�E\�PHDQV�RI�ZLWK�LWV�LQ¿QLWHO\�DGMXVWDEOH�VXSSRUW�rolls.

The modular design of the KA series allows the HDV\�DQG�TXLFN�PRGL¿FDWLRQ�RI�WKH�.$���833�

Technical Data

Technical data

Automat UPK

Welding at low costs with UPK.

UPK

Art. no. .11.300.104

Welding current 800 A

Wire diameter 1.6 – 4.0 mm

Speed 0.1 – 2.0 m/min

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP

Weight 42 kg

Recommended power source

GTH 802

The UPK is the economic alternative for sing-OH�ZLUH�¿OOHW�ZHOGLQJ��'XH�WR�LWV�FRPSDFW�GHVLJQ�and its three-wheel-guide the UPK is especially VXLWHG�IRU�¿OOHW�ZHOGLQJ��With its wheel guide and a pivoting range of 15 to 45 degrees for the manual positioning it is optimised for ship building, steel and bridge construction.

Adjustments for customised solutions can be found in the chapters welding periphery and options.

- 12 -

Technical data

- 12 -

Manual SA Welding Technique

Manual SA Welding Equipment

DV UP-H with welding carriage, power source and pressure tank.

DV UP-H

Art. no. (package1) .17.000.431.S1

0D[��ZHOGLQJ�FXUUHQW depending on power source 400 A

Wire diameterSteelCrNi)OX[�FRUHG�ZLUH

0.6 – 2.4 mm0.8 – 2.0 mm1.0 – 2.4 mm

Wire feeding speed 1.0 – 16.0 m/min

Protection class IP 23

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP

Weight 25 kg

Power source GTH 522other possible

The wire feeding unit DV UP-H with integrated control unit and four-wheel drive can be used IRU�ZHOGLQJ�ZLWK�VROLG�ZLUHV�DV�ZHOO�DV�ÀX[�cored wires. The system is especially suited for welding large seam geometries without any possibility of automation, e.g. frames of windmill WRZHUV�RU�ODUJH�¿WWLQJV�RI�FRQWDLQHUV�DQG�SLSHV�

More information about the suitable welding carriages KMF and KMF solid can be found in the chapter options on SDJH�����VXLWDEOH�¿OOHU�PDWHULDOV�IURP�page 36 onwards.

Advantages

�� Easy-to-use torch

�� )OX[�VXSSO\�ZLWK�H[WHUQDO��PRELOH�SUHVVXUH�WDQN��manual lock at the hand torch

�� Robust four-wheel wire feeder with constant contact pressure

�� Stepless set value pre-adjustment for welding voltage and current as well as start parameters on the front panel

�� Switchable from two-stroke to four-stroke ope-ration

�� Protected electronics

�� Current-less wire threading and return

�� ([LVWLQJ�*7+�SRZHU�VRXUFHV�FDQ�EH�UHWUR¿WWHG

1)�FRQVLVWLQJ�RI��SRZHU�VRXUFH��PDLQV�FDEOH��WZR�D[OH�FKDVVLV��ZLUH�IHHGLQJ�XQLW��pressure blower, work lead, wire harness and SA manual torch

- 13 -- 13 -

Subm

erge

d-Ar

c W

eldi

ng

Standard Power Sources

Technical Data

GTH 522 GTH 802 GTH 1002

Art. no. .11.907.602A .11.705.902A .11.903.103A

Characteristics Constant voltage (CV) Constant voltage (CV) Constant voltage (CV)

Mains voltage* ��[�����9�������������+] ��[�����9�������������+] ��[�����9�������������+]

Mains connection CEE 63 A CEE 63 A IMAx 118 A

Welding current range 70 A/18 V – 500 A/45 V����$��������$�����

80 A/18 V – 800 A/44 V����$��������$�����

100 A/19 V – 1,000 A/44 V������$�����

Protection class IP 23 IP 22 IP 21

Weight 260 kg 319 kg 440 kg

Dimensions (L x W x H) ������[�����[�����PP(with carriage)

����[�����[�������PP(with carriage)

������[�����[�������PP(stationary)

GTH 1402 W 1005 VC

Art. no. .11.903.802A .11.691.002

Characteristics Constant voltage (CV) Constant voltage (CV)

Mains voltage* ��[�����9�������������+] ��[�����9�3(�������������+]

Mains connection IMAx 135 A IMAx 190 A

Welding current range 100 A/19 V – 1,400 A/44 V������$����������$�����

200 A/25 V – 1,000 A/44 V������$�����

Protection class IP 21 IP 21

Weight 440 kg 510 kg

Dimensions (L x W x H) ������[�����[�������PP��VWDWLRQDU\� ������[�����[�����PP��VWDWLRQDU\�

GTF 401 GTF 551

Art. no. .11.708.001/2 .11.709.002/1

Characteristics Constant current (CC) Constant current (CC)

Mains voltage* ��[�����9���[����,���,����9�������������+] ��[�����9���[����,���,����9�������������+]

Mains connection CEE 32 A CEE 32 A

Welding current range 10 A/20 V – 400 A/36 V����$��������$�����

10 A/20 V – 550 A/42 V����$�������$��������$�����

Protection class IP 23 IP 22

Weight 169 kg 194 kg

Dimensions (L x W x H) ����[�����[�������PP��ZLWK�FDUULDJH� ����[�����[�������PP��ZLWK�FDUULDJH�

GTF 752 GTF 1002 GTF 1402

Art. no. .11.705.602 .11.903.202C .11.903.702C

Characteristics Constant current (CC) Constant current (CC) Constant current (CC)

Mains voltage* ��[�����9�������������+] ��[�����9�������������+] ��[�����9�������������+]

Mains connection CEE 125 A (63 A possible) IMAx 118 A IMAx 135 A

Welding current range 60 A/22,4 V – 750 A/44 V����$��������$�����

200 A/28 V – 1,000 A/44 V������$�����

100 A/19 V – 1,000 A/44 V������$����������$�����

Protection class IP 22 IP 21 IP 21

Weight 304 kg 438 kg 438 kg

Dimensions (L x W x H) ����[�����[�������PP(with carriage)

������[�����[�������PP(stationary)

������[�����[�������PP(stationary)

Power sources with CC characteristics

Power sources with CV characteristics

*Power source with mains voltage of 60 Hz on request.

- 14 -

The right cast

for every leading role

AC/DC from II/2014

- 14 -

KUB inverters are versatilely applicable: SA, PTA, GMA, TIG, InFocus, MMA welding, gouging

Multifunctional SA Welding Inverters

KUB Inverter Series

KUB inverter technology

Compared to conventional power sources welding inverters offer better welding behaviour DQG�KLJKHU�HI¿FLHQF\�DQG�DUH�WKXV�XVHG�SUHIHU-ably. Due to a sophisticated electronic system no heavy transformer is needed. The increased operating frequency allows optimal control of various welding processes and an enhanced OHYHO�RI�HI¿FLHQF\����

Advantages

�� Welding method freely selectable

�� Easy switching from AC to continuous DC CC/CV

�� Compact and light weight

�� Suitable for gouging

�� Primarily clocked inverter moduls

�� More powerful and energy-saving than con-ventional power sources

�� ,PSURYHG�OHYHO�RI�HI¿FLHQF\

�� Anti Stick, Hot Start and Arc Force

�� ([WHUQDO�DFWLYDWLRQ�YLD�GLJLWDO�FRQWURO

- 15 -- 15 -

Subm

erge

d-Ar

c W

eldi

ng

Multifunctional SA Welding Inverters

KUB 500i – The Smart One

KUB 500i – brave commitment for all welding methods

The KUB 500i with integrated water-cooling is the clever one of the series. With a welding current of 500 A the user can freely choose bet-ween SA, GMA, TIG or E-manual welding; also plasma gouging is possible.

KUB 1000i – The Adventurer

.8%L�����L��ZLWK�H[WHUQDO�FRROLQJ�VXLWDEOH�IRU�37$��*0$��InFocus and TIG welding

With 1,000 Ampere welding current the KUB 1000i can be used for SA und MMA welding as well as plasma gouging. Equipped with an H[WHUQDO�FRROLQJ�LW�LV�DOVR�VXLWDEOH�IRU�*0$��7,*��InFocus and PTA welding.

KUB 1500i – The Bold One

.8%�����L�±�������$�DW�������GXW\�F\FOH

:LWK�������$PSHUH�DW�������GXW\�F\FOH�WKH�KUB 1500i goes all out in SA and MMA welding as well as in plasma gouging.

Technical data

KUB 500i

Welding current 500 A

Characteristics Constant current (CC), constant voltage (CV)

'LPHQVLRQV��/�[�:�[�+� ����[�����[�������PP

Technical data

KUB 1000i

Welding current 1.000 A

Characteristics Constant current (CC), constant voltage (CV)

'LPHQVLRQV��/�[�:�[�+� ����[�����[�������PP

Technical data

KUB 1500i

Welding current 1.500 A

Characteristics Constant current (CC), constant voltage (CV)

'LPHQVLRQV��/�[�:�[�+� ������[�����[�������PP

- 16 -- 16 -

The gas metal arc welding is an arc welding process where a wire electrode melts under a shielding-gas protection. The gas protects DJDLQVW�H[WHUQDO�LQÀXHQFHV��7KHUH�LV�D�ZLGH�range of applications for this process regarding material, level of mechanisation and welding position. All materials suitable for welding can be joined by gas-shielded metal arc welding.

Un- and low-alloyed steels are welded prefer-DEO\�ZLWK�DFWLYH�JDV�VXFK�DV�FDUERQ�GLR[LGH��This method is also known as metal active gas welding (MAG welding). High-alloyed steels and materials such as aluminum, magnesium, chro-mium-nickel materials and titanium are prefer-ably welded with inert gas such as argon. The so called metal inert gas welding is also known as MIG welding.

GMA Welding

Technology

Advantages

�� Low error rate due to automatic wire feeding�� Few slag formation�� Little heat input and distortion�� Almost no rework needed

Kjellberg Technology newArc

With newArc Kjellberg Finsterwalde has de-YHORSHG�D�WHFKQRORJ\�ZKLFK�VLJQL¿FDQWO\�LQFUHD-ses the productivity compared to conventional GMA 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 most important characteristics are considerably reduced energy input per unit length, increased welding speed, deep and stable root formati-on, high seam quality, no undercuts, pores and spatter.

Advantages

�� High process reliability for material thickness from 6.0 mm

�� :HOG�FURVV�VHFWLRQV�UHGXFHG�E\�XS�WR������ Nearly no undercuts and pores�� High quality due to stable root formation and

easy to handle optimum joining of the edge�� High welding speed due to concentrated and

stable arc�� Reduced costs

- 17 -- 17 -

GM

A W

eldi

ng

GMA Equipment

Technical data

Pulsed Power Source KH 600 newArc

Reliable welding with KH 600 newArc.

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.

KH 600 newArc

Art. no. (package1) .11.707.703.S1

Mains voltage ��[���������9������������+]

Mains connection CEE 63 A

Welding current range 600 A I 40�����$�,�����

Open circuit voltage 85 V

Welding diameterSolid wire)OX[�FRUHG�ZLUH

0.8 – 2.0 mm1.0 – 2.4 mm

Protection class IP 23

'LPHQVLRQV��/�[�:�[�+� ������[�����[�������PP�ZLWKRXW�ZLUH�IHHGHU

Weight 183 kg

Advantages

�� Nearly spatter-free pulse arc welding due to short-circuit-free drop transfer for steel, CrNi, aluminium

�� Constant wire feeding due to electronically controlled four-wheel wire feeder

�� Pulse frequency synergistically self-adjusting from 10 to 500 Hz

�� 'LDJQRVWLF�GLVSOD\�WR�DYRLG�H[FHVV�WHPSHUD-ture, insulation faults and water shortage

1) Consisting of: Power source with mains power cable 5 m with CEE plug 63 A, FKDVVLV��ZLUH�IHHGLQJ�XQLW��ER[�ZLWK�ZLUH�IHHG�UROOHUV�IRU�VWHHO��UHPRWH�DGMXVWHU��hose parcel, torch, work piece cable with work piece clamp, gas hose, pressure regulator, basket coil adapter

Rutile and basic electrodes for welding with the KH 600 newArc can be found in the FKDSWHU�¿OOHU�PDWHULDOV��SDJHV����WR����

Wire Feeding Units

Data

Wire feeding units DV 4W-1DV 4W-3DV 4G-3

DV 4W-3MDV 4G-3m

Wire feeding speed 1–16 m/min

Wire diameterSteelCrNiAluminium)OX[�FRUHG�ZLUH

0.6 – 1.6 mm0.8 – 1.6 mm1.0 – 1.6 mm1.0 – 2.0 mm

Wire coil diameter up to 300 mm

The wire feeding units that can be used with water- or gas-cooled torches and are especially VXLWHG�IRU�UH¿WWLQJ�H[LVWLQJ�SRZHU�VRXUFHV�

Features

�� Four-wheel-drive with stable contact pressure�� Times for burn-free, spot-welding, inter-

val-welding and interval pause adjustable

Technical data

- 18 -- 18 -

GM

A W

eldi

ng

When using the pulsed power source, the operater can choose between the three welding processes GMA, GMA pulse and MMA welding. The PULS 400 is mobile on rolls and weighs only 45 kg which makes it suited for welding steel, CrNi, aluminium and aluminium alloys.

GMAW Equipment

Pulsed Power Source PULS 400

Technical data

PULS 400

Art. no. .11.707.502.S1

Welding voltage 30 – 400 A

Connecting voltage 3˜400 V/50

Welding 15.5 – 34.0 V

Duty cycle ����$�,���������$�,������

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP

Weight 45 kgPULS 400: Optimum for challenging tasks.

Technical data

Kjellmig Series

The Kjellmig K350 is available with a wire feeding unit.

Step-switched GMA welding technique with simp-le handling for everyday welding tasks.

Advantages

�� )OH[LEO\�DGMXVWDEOH��WKHUHIRUH�KLJK�VHDP�TXDOLW\�� Robust feed gear mechanism�� Side panel foldable for change of wire roll�� Large practical tray�� Wear-free electronic control�� Gas bottle holder; stable carriage due to low FHQWUH�RI�JUDYLW\��PD[�����O�ERWWOH�

Kjellmig 180 Kjellmig 230 Kjellmig K350

Art. no. .11.930.103 .11.930.202 .11.931.102

Mains voltage ��[�����9���[�����9��������+]� ��[�����9��������+]� ��[�����9��������+]�

Mains connection CEE 16 A CEE 16 A CEE 32

Welding current range ��������$�,������������$�,������������$�,�������

����$�,����������$�,����������$�,�������

����$�,����������$�,�������

Welding voltage range 15 – 19.5/18 – 23 V 14.8 – 25.5 V 14.8 – 31.5 V

Open circuit voltage 17–30/26–38 V 17 – 40 V 16 – 50 V

Number of voltage levels 6 10 30

Wire diameter 0.6 – 1.0 mm 0.6 – 1.0 mm 0.6 – 1.2 mm

Protection class IP 21 IP 21 IP 21 (with associated DVG-K01)

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP ����[�����[�����PP ����[�����[�����PP

Weight 54.5 kg 65 kg 90 kg

- 19 -- 19 -

TIG

Wel

ding

$Q�H[FHOOHQW�TXDOLW\�RI�WKH�ZHOG�VHDP�FDQ�EH�achieved with the TIG 300 AC/DC.

TIG Power Source TIG 300 AC/DC

Technical data

TIG 300 AC/DC

Art. no. .11.403.302

Welding current range 4 – 300 A (WIG/DC) 10 – 300 A (WIG/AC)

10 – 250 A (MMA DC)

Mains voltage 3˜400 V/50

Welding voltage 21 – 30.5 V I 10.2 – 22 V

Duty cycle ����$�,���������$�,������

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP

Weight 43 kg

Advantages

�� Setting and saving of welding parameters and programs

�� High-frequency ignition without contact All parameters at a glance on the digital display.

TIG Technology and Equipment

The tungsten inert gas welding is a fusion welding process. The material is not removed; instead both sides of theworkpiece that are to be joined are heated up until the materials melt and blends. After stiffening both sides are per-manently connected. Depending on the welding WDVN�¿OOHU�PDWHULDOV�FDQ�DGGLWLRQDOO\�EH�XVHG�IRU�joining.

Advantages

�� Joining of almost all metals that can be melted�� Few spatter formation�� ([FHOOHQW�IRU�ZHOGLQJ�LQ�FRQVWUDLQHG�DQG�URRW�

positions�� High quality of the weld seam

Technology

- 20 -- 20 -

InFocus is a TIG arc welding technology for DXWRPDWHG�DSSOLFDWLRQV��'XH�WR�WKH�PD[LPLVHG�cathode cooling, the arc is constricted at the cathode tip in such a strong way that optimum process and joint properties are achieved and the joining of all steels and non-ferrous metals with a material thickness between 0.15 and 12 mm is possible. InFocus is one of the most ÀH[LEOH�MRLQLQJ�SURFHVVHV�EHFDXVH�LW�FRYHUV�a wide range of materials and thicknesses: InFocus soldering produces laser-like seams. The InFocus keyhole welding technology allows single-layer, process-stable and high-quality welding of sheets with a thickness of up to 12 mm. In contrast to plasma welding, InFocus works without an additional arc-forming nozzle. Therefore, the process can be controlled easily and safely by adjusting only a few parameters. The high welding speed makes the spatter-free InFocus process more economical than con-ventional TIG welding. Compared to laser wel-ding, there are lower investment and operating costs.

The Torch as Carrier of the Technology

InFocus 1000 – powerful with 1,000 AInFocus 1000 realises high-performance arcs with currents of 1,000 Amperes when proces-sing thin and thick sheets.

InFocus 500 – small and manoeuvrable with 500 A We developed the TIG welding torch InFocus 500 as the little brother of the InFocus 1000 in order to make the InFocus technology available also for welding applications with limited acces-sibility. With a diameter of only 20 mm, a length of 95 mm and a weight of 300 g, the InFocus 500 allows InFocus welding and soldering of work-pieces with a thickness from 0.1 to 2 mm with a current of up to 500 A.

Technology

Advantages�� Current carrying capacity: InFocus 1000 up to

1,000 A, InFocus 500 up to 500 A�� Sheets with a thickness from 0.15 to 12 mm�� Suitable for all steels, also non-ferrous metals

like copper and aluminium�� Process-stable and spatter-free�� Speed: InFocus soldering up to 7 m/min,

InFocus welding up to 15 m/min�� High quality of the weld, low hardness, small

heat-affected zone, low distortion�� Robust torch with connected cooling circuit�� *RRG�LQHUW�JDV�FRYHUDJH��ORZ�R[LGH�IRUPDWLRQ�� 4XLFN�FKDQJH�RI�FDWKRGH�ZLWK�GH¿QHG�WRUFK�SRVLWLRQ��7&3���WRRO�FHQWUH�SRLQW������PP�

�� Low cathode wear�� No adding of helium necessary

Being the developer of the InFocus techno-ORJ\��.MHOOEHUJ�KDV�WKH�SHUIHFW�H[SHUWLVH�WR�DGDSW�WKH�WHFKQRORJ\�WR�\RXU�VSHFL¿F�MRLQLQJ�applications.

High Performance TIG

Simulation-based comparison of conventional TIG welding with the InFocus technology

InFocus torches InFocus 1000 and InFocus 500

- 21 -

InFocus Keyhole Welding

Unlike conventional TIG welding, InFocus also DOORZV�WKH�ZHOGLQJ�RI�H[WUHPHO\�WKLFN�VKHHWV��With currents of more than 350 A, the constric-ted arc creates plasma-like process properties. The result: a narrow weld with a depth to width ratio of 2 to 3. The low energy input reduces GLVWRUWLRQ�DQG�UHVLGXDO�VWUHVV�DQG�FUHDWHV�H[W-raordinarily good mechanical properties of the weld.

With adjusting only a few parameters, the In-Focus keyhole welding process allows welding speeds that are considerably higher compared to plasma welding. Moreover, the InFocus torch can be positioned deeply into the seam weld preparation making the InFocus technology especially suited for processing thick steel sheets and for root welding with high- and low-alloyed steels.

Welding of Non-ferrous Metals

The concentrated energy input of the InFocus arc opens up new opportunities for welding non-ferrous metals. Due to the high energy den-sity created by the InFocus torch a concentrated molten pool is forced and a deep penetration is created also in case of non-ferrous metals, in particular copper and aluminium. Thus, a stable welding process without heat distraction of the arc can be achieved.

During the spatter-free InFocus welding of DOXPLQLXP�VKHHWV��IRU�H[DPSOH��ZHOGLQJ�VSHHGV�of more than 60 cm/min and a perfect seam surface are achieved.

As quick as a laser, as cheap as an arc – InFo-cus makes it possible! During InFocus soldering of galvanised sheets, speeds of 4 m/min and higher can be reached under production conditions. With InFocus, the zinc layer besides and under the soldered seams is preserved. 'XULQJ�ZHOGLQJ�RI�VWHHO�SUR¿OHV��HYHQ�D�VSHHG�RI�15 m/min could be achieved under production conditions.

High-speed Soldering and Welding

- 21 -

Spec

ial W

eldi

ng T

echn

olog

ies

Plasma-like weld surface are produced with InFocus keyhole welding.

Perfect seam surface even in case of coated surfaces

InFocus welding of aluminium , v=60cm/min

Keyhole weld upper side Keyhole weld bottom side

InFocus Solutions

- 22 -- 22 -

MM

A W

eldi

ng MMA welding is a welding process where the electric arc burns between a coated electrode DQG�WKH�ZRUNSLHFH��7KH�HOHFWURGH�LV�¿[HG�LQ�DQ�electrode holder and touches shortly the area that is to be joined. A short circuit is produced and the arc starts when lifting the electrode. During the welding process the electrode and its coating melt and slag develops above the weld seam.

Advantages

�� Only few equipment needed, low costs�� Quick and mobile use�� Usable in all welding positions

MMA Welding

Technology

The Tiny 250 Cel also welds electrodes with cellulose content.

The Tiny 250 Cel is especially suited for users that weld with all types of electrodes. Due to its VHOI�H[SODQDWRU\�GHVLJQ�WKH�LQYHUWHU�7LQ\�����&HO�can be operated easily.

Technical data

Inverter Tiny 250 Cel

Tiny 250 Cel

Art. no. .11.403.402

Welding current range ����$�DW�����,�����$�DW���������

Connecting power 230 V/50 Hz

Welding current MMA I TIG

20.4 – 30.0 V I 10.2 – 20.0 V

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP

Weight 22 kg

- 23 -

Manual Plasma Cutting

- 23 -

Cutt

ing

Equi

pmen

t

The small power packages of the CUTi series are easy to handle and thus especially suitable for mobile use.

Mild steel, stainless steels, aluminium, brass, copper and other electrically conductive materi-als can be cut with air as plasma gas.

CUTi – Mobile Plasma Cutting Inverters

CUTi series: mobile application

CUTLINE – Strong and Reliable

Version with liquid-cooled plasma torch.

The robust units of the CUTLINE series are SDUWLFXODUO\�SUR¿WDEOH�ZKHQ�XVHG�IUHTXHQWO\��7KH\�are equipped with a liquid-cooled plasma torch. Due to the direct cooling of the consumables the OLIHWLPH�RI�WKH�FDWKRGH�DQG�QR]]OH�LV�XS�WR�¿YH�times higher.

CUTi 35C CUTi 35 CUTi 70 CUTi 90 CUTi 120

Mains voltage ��[�����9 ��[�����9 ��[�����9 ��[�����9 ��[�����9

Fuse, slow 16 A 16 A 16 A 25 A 32 A

Cutting current 12 – 25 [351] A 5 – 35 A 26 – 70 A 26 – 90 A 25 – 120 A

Cutting range 6[101] mm 12 mm 30 mm 35 mm 50 mm

Ignition Drawn arc Drawn arc High voltage High voltage High voltage

Air consumption 115 l/min 70 l/min 140 l/min 195 l/min 195 l/min

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP ����[�����[�����PP ����[�����[�����PP ����[�����[�����PP ����[�����[�����PP

Weight 12.5 kg 10 kg 16.4 kg 17 kg 28.5 kg1�ZLWK�H[WHUQDO�FRPSUHVVHG�DLU�VXSSO\

Technical data

Technical data

CUTLINE 20W CUTLINE 40W

Mains voltage ��[����������9 ��[�����9

Fuse, slow 32/25 A 32 A

Cutting current 25/50 A 50/100 A

Cutting range 20 mm 40 mm

Ignition High voltage High voltage

Plasma Gas Ait Air

Air consumption 25 l/min 25 l/min

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP ����[�����[����

Weight 84 kg 132 kg

Find more cutting equipment on www.kjellberg.de.

- 24 -- 24 -

Surface welding, especially cladding, means WKDW�ZRUN�SLHFHV�UHFHLYH�D�ZHDU�UHVLVWDQW�H[WUD�layer, a so-called hard surfacing. This is done for repair purposes or to create material com-SRXQGV�ZLWK�VSHFL¿F�IXQFWLRQV��7KH�ORZHU�WKH�dilution rate of the surfacing, taking into account the necessary adhesion, the higher the quality of the layer’s properties. For surface welding, processes like GMA, TIG, submerged-arc and plasma welding are used.

Surface welding is used as effective protection in particular against abrasive and erosive wear on machinery and components in mining, ore dressing, the cement and coal industry and in road construction. By applying a strongly adhe-sive layer, surfaces are repaired, armoured for wear protection purposes, cladded for corrosion protection purposes and buffered for intermedi-ate layers.

Advantages�� /RQJ�OLIHWLPH�RI�FRPSRQHQWV�H[SRVHG�WR�

strong wear�� Long intervals for maintenance of stressed

parts�� Strong adherent surface coating

Surface Welding Process

Technology

$�W\SLFDO�H[DPSOH��)URP�FRDO�H[WUDFWLRQ�LQ�PLQLQJ�WR�FRDO�UH¿QHPHQW�LQ�SRZHU�VWDWLRQV��),'85�PDGH�E\�.MHOOEHUJ�Finsterwalde offers optimum wear protection along the entire value chain.

Structure of a surface welding

- 25 -- 25 -

Wea

r Pr

otec

tion

Systems for Surface Welding

Stationary and mobile plants

Do you want to produce your own surface-wel-ded sheets? For this purpose, Kjellberg Finster-walde offers suitable surface welding systems DV�FRPSOHWH�VROXWLRQV��VWDWLRQDU\��ZLWK�ÀH[LEOH�robot technique or as mobile plant.

Application advantages�� Process reliability due to stored parameter

sets and welding data collection�� High level of plant availability due to auto-

matic operation

System components�� Gantry as stable steel construction�� Welding power sources�� Welding heads�� Central control panel for adjustment of wel-

ding parameters�� Switching cabinet, etc.

Depending on the type of surface welding, local conditions and other parameters, we construct DQG�SURGXFH�D�SODQW�WRJHWKHU�ZLWK�\RX��WKDW�¿WV�\RXU�UHTXLUHPHQWV�H[DFWO\�±�QR�PDWWHU�ZKDW�VL]H�RU�VSHFL¿F�IHDWXUHV�

Mobile plant for working with mills�� Mobile plant for surface welding of cement

mill-stones�� Usable directly in the mill�� Low weight thanks to aluminium�� (DV\�DGDSWLRQ�WR�H[LVWLQJ�VXSSRUW�V\VWHPV�� Ready-to-use equipment: power source, FRROLQJ�GHYLFH��GLJLWDO�FRQWURO��D[LV�V\VWHP�ZLWK�water-cooled welding torch

�� ,QWHJUDWLRQ�RI�WKH�PLOO�GULYH��RU�DX[LOLDU\�GULYH��with limit switch for freely selectable seam offset

�� Digital control panel with touch screen (cur-rent, voltage, width of seam offset)

�� /DWHUDO�D[LV�������PP��KHLJKW�D[LV�����PP��motorised We also recommend our training courses

on surface welding to achieve optimum results with our welding plants. More infor-mation on page 46.

Stationary gantry for surface welding of standard sheets

The mobile welding system is set up for welding on your site and removed afterwards.

Robot welding station for refurbishing train wheels

- 26 -- 26 -

Surfaced-Welded Sheets

Standard Sheets

Special qualities and dimensions are available on request.

Surface-welded sheets can be cut with plasma, GHIRUPHG�DQG��LI�VSHFL¿F�UHJXODWLRQV�DUH�PHW��welded. To avoid adhering of the conveyed material Kjellberg offers sheets with particularly smooth surfaces.

Materials of the base sheetAll weldable steels, e.g. S235, S355, QSTE 690, 1.4301, 1.4828

Materials for hard surfacingChromium carbides in martensitic/austenitic PDWUL[

Sheet Fidur 10/65 P Fidur 10/65 VP Fidur 10/65 WP

Composition of the weld metal

���&������&U ���&������&U�����1E

���&������&U�����1E��

���0R��9��:

Hardness 60 HRC 62 HRC 65 HRC

0D[��RSHUDWLQJ�temperature

350 °C 350 °C 700 °C

Qualities

Surface-welded standard sheet of the type Fidur 10/65 P

Dimensions

Length 2,000 mm 2,500 mm 3,000 mm

Width 1,000 mm 1,250 mm 1,500 mm

Thickness (base PDWHULDO���OD\HU�

������PP������PP������PP������PP�������PP�������PP

������PP������PP������PP�������PP�������PP

������PP������PP�������PP�������PP

Special Sheets

Ready-to-install constructions are made of surface-welded standard sheets or pre-assemb-led parts are coated afterwards with the help of modern robot technique.

Surface-welded plasma cuts to size for the lignite industry

0D[��OHQJWK 6,000 mm

0D[��ZLGWK 2,000 mm

Min. hole diameter 6 mm

0D[��VKHHW�WKLFNQHVV �������PP

Plasma cuts to size

Parts with surfacing

Parts Pipes, pipe elbows (inner

layer)

Containers, cyclones, other

constructions

Mechanically processed parts (turning, milling)

Min. diameter 200 mm — —

0D[��GLDPHWHU — 2,500 mm 1,500 mm

0D[��OHQJWK — 4,000 mm 4,000 mm

0D[��ZLGWK — 2,500 mm —

0D[��SDUW�ZHLJKW — 5,000 kg 2,500 kg

- 27 -- 27 -

Wea

r Pr

otec

tion

Plasma-Transferred Arc and Plasma Keyhole Welding

PSI 350

)OH[LEOH�HTXLSPHQW�IRU�ZHDU�SURWHFWLRQ

With the PSI 350 Kjellberg Finsterwalde offers D�KLJK�TXDOLW\�DQG�ÀH[LEOH�XQLW�IRU�SODVPD�WUDQV-ferred arc welding as well as for plasma keyhole welding. Both methods can easily be automated with the integrated PLC.

Advantages

�� &RPIRUWDEOH�RSHUDWLRQ�GXH�WR�SUHGH¿QHG�ZHO-ding programs

�� Electric gas control, integrated cooling unit�� 'LJLWDO�FRQWURO�RQ�H[WHUQDO�FRQWURO�SDQHO

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 heliumgas is realised in the cooled plasma nozzle, PTA welding systems achieve a higher energydensity compared to the usual welding me-thods.

Plasma-transferred arc welding

�� Surfacing of hard, wear-resistant and/or cor-rosion-resistant layers onto small parts which DUH�GLI¿FXOW�WR�DSSO\�ZLWK�ZLUH

�� Voltages up to 300 A

Plasma-keyhole welding

�� Usable for longitudinal and circular seam welding, containers and bottoms

�� No additional seam preparation on the nearly parallel work-piece edges

�� Low heat input and less distortion�� Little additional material is needed

Technology

Advantages

�� Very low dilution with the base material�� Very small heat-affected zone, high deposition

rate�� Genuine metallurgical bond between base and ¿OOHU�PDWHULDO

�� (DV\�WR�SURGXFH�¿OOHU�PDWHULDO�PL[WXUH�LQ�SRZ-der form according to the requirements

�� High reproducibility of the results due to high degree of automation

PSI 350

Art. no. .11.105.202

Mains voltage 3˜400 V (������50 Hz)

Connecting voltage 23.6 kVA

Welding current range 50 – 350 A

Protection class IP 23

'LPHQVLRQV��/�[�:�[�+� ������[�����[�������PP

Weight 180 kg

Technical data

- 28 -- 28 -

Welding Devices

Clamping Devices of the RSV Series

Customised variants of our standard equipment are produced on request.

The welding devices of the RSV series make it easier to clamp, tilt and rotate workpieces with circular cross-section. The RSV series is ideally suited for manual and fully mechanized pipe welding. Due to the compact design, the devices are not only attractive for industrial prefabricati-on but also for installations and assemblies on construction sites.

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

Advantages

�� Manual tilting function up to 135 ° (optional: electrically driven)

�� ,Q¿QLWHO\�DGMXVWDEOH�URWDWLQJ�VSHHG�LQGHSHQ-dent from workpiece diameter

�� Welding in constant position without readjus-ting and interrupting the weld

�� Time-saving turning and adjusting of identical workpieces The welding devices of the RSV series allow various pipe

weldings.

Technical Data

RSV 150 RSV 500 RSV 1000

Art. no .18.600.210.002 .18.600.200.011.21 .18.600.210.004

5RWDWLQJ�VSHHG�LQ¿QLWHO\ up to 130 cm/min up to 130 cm/min up to 130 cm/min

Workpiece diameter clampedunclamped

20 – 200 NS20 – 300 NS

20 – 400 NS25 – 1,000 NS

25 – 800 NS30 – 2,000 NS

0D[��WXUQLQJ�PRPHQW 150 Nm 740 Nm 3,430 Nm

0D[��FDSDFLW\��at horizontal roller positionat vertical roller position

300 kg150 kg

1,000 kg500 kg

2,000 kg1,000 kg

Torque at the drive roller 50 Nm 200 Nm 490 Nm

Mains connection 220 V, 50 Hz 220 V, 50 Hz 380 V, 50/60 Hz

Power requirements 200 W 400 W 1.5 KW

Weight 110 kg 260 kg 800 kg

- 29 -- 29 -

Wel

ding

Per

iphe

ry

Welding Devices

5RWDU\�WLOWLQJ�WDEOHV�ZLWK�WLOW�DQJOH�RI�����

The rotary tilting turntable of the Kjellberg DK series are designed for welding different geo-metries. The workpiece rotates on a tiltable face SODWH�DW�DQ�LQ¿QLWHO\�DGMXVWDEOH�URWDWLQJ�VSHHG��Up to a weight of 500 kg the workpiece can be positioned via a footpedal. For workpieces of more than 500 kg a hand control unit can be used.

The DK series can optionally be equipped with clamping devices with a minimum diameter of 25 mm.

With the height-adjustable rotary tilting table DKT 1000 H workpieces can be tilted and posi-tioned easily for automated welding. The DKT 1000 H is available in various versi-ons.

Height-adjustable: DKT 1000 H

Technical data

Model Face plate diameter Max. capacity Rotating speed (circa) Max. welding current

DK 50 300 mm 20 kg 0–6 U/min 400 A

DK 300 500 mm 300 kg 0–3 U/min 400 A

DK 500 650 mm 500 kg 0–2.5 U/min 400 A

DK 1500 1,000 mm 1,500 kg 0–1.5 U/min 600 A

DK 3000 1,100 mm 3,000 kg 0–1 U/min 600 A

DK 5000 1,500 mm 5,000 kg 0–1 U/min 600 A

DK 10000 1,200 mm 10,000 kg 0–1 U/min 600 A

Others variants are manufactured on request.

DKT 1000 H

Art. no. .11.105.202

Mains voltage &((����$���[�����9�3(

Welding current transmission ����$�,�������

Face plate diameter 800 mm

0D[��KHLJKW�DGMXVWPHQW 600 mm (optional)

0D[��WLOW�DQJOH 120 °

0D[��WLOW�PRPHQW 3,500 Nm

0D[��WXUQLQJ�PRPHQW 710 Nm

Rotating speed 0–5 U/min

Load-bearing capacity 1,000 kg

Hydraulic pressure 150 bar

Weight 1,000 kg

Technical data

Advantages�� Welding in constant position without inter-

ruption of the weld�� Height-adjustable by hydraulic cylinder�� Adjustable rotating speed�� Electric motor-driven tilting�� Electronic controller protected in control

cabinet

Rotary tilting tables of the DK series are optionally available with turnable ground connection.

- 30 -

Clamping tables from Kjellberg for beam and SUR¿OH�ZHOGLQJ�DUH�PDQXIDFWXUHG�RQ�LQGLYLGXDO�customer request.

Clamping Table

Clamping tables from Kjellberg are custom-made.

Roller Block Rotating Devices

Variants

�� Rotating speed 75-1000 mm/min�� Manual or optional motor-driven diameter adjust-

ment�� Hand control unit�� Stationary, optional: mobile

Variants

�� For different workpiece diameters�� Further dimensions on request

Technical data

Height-Adjustable Pedestal

Technical dataModel Max. working load Max. rotating load

drive unitMin. container

diameterMax. container

diameterRoller diameter Roller width

BDV 2000 1,000 kg 20 kg 200 mm 2,500 mm 250 mm 120 mm

BDV 5000 2,500 kg 300 kg 200 mm 3,000 mm 250 mm 120 mm

BDV 10000 5,000 kg 500 kg 300 mm 4,000 mm 415 mm 200 mm

BDV 15000 7,500 kg 1,500 kg 300 mm 4,000 mm 415 mm 370 mm

BDV 20000 10,000 kg 3,000 kg 300 mm 4,500 mm 415 mm 370 mm

Height-adjustable pedestals for different workpiece diame-ters.

The roller blocks are available in different variants.

- 30 -

Welding Devices

Pedestal

Adjustment track 300 mm

0D[��ORDG 300 kg

Min. height 600 m

- 31 -- 31 -

Wel

ding

Per

iphe

ry

Welding Devices

Welding Gantries and Travelling Carriages

Customised variants of our standard equipment are produced on request.

Travelling carriages and welding gantries made by Kjellberg Finsterwalde are always FXVWRP�PDGH��'HSHQGLQJ�RQ�WKH�VSHFL¿FDWLRQ�they are equipped with energy chains, wheel sets, switching cabinets and the control unit with emergency stop chain.

Variants

For joint welding�� 9DULDQW�IRU�¿OOHW�ZHOGLQJ��PDLQ�¿HOG�RI�DSSOL-

cation), platforms for welding power sources, crane trolleys or gear racks for the support of the welding equipment

For surface welding�� :LWK�SHQGXOXP�GHYLFH��OLQHDU�D[LV���ZHOGLQJ�

equipment and a device for uncoiling the wire

Welding gantries from Kjellberg are individually manufactured.

Technical data

Column and Booms

The custom-made column and booms consist of rectangular pipes with processed guide rails. The stationary variant can be rotated through �����DQG�LV�HTXLSSHG�ZLWK�D�PDQXDO�¿[LQJ�device.

Variants

�� Boom speed 10-1,000 mm/min�� )L[HG�OLIWLQJ�VSHHG�����FP�PLQ�� Safety arrester�� Rotation angle 180 °�� Optional with motor-driven carriage�� Track width from 1,435 m

Special designs of the column and booms are available on request.

Model Max. effective height below boom

Max. height Lifting (boom) Max. net load

.60�����[���� 2,500 mm 3,500 mm 2,000 mm 300 kg

.60�����[���� 2,500 mm 3,500 mm 2,500 mm 250 kg

.60�����[���� 3,000 mm 4,000 mm 2,500 mm 200 kg

.60�����[���� 3,000 mm 4,000 mm 3,000 mm 200 kg

- 32 -- 32 -

Telescopic Column with Retractable BoomThe Kjellberg telescopic column with boom is XQLTXH�LQ�LWV�ÀH[LELOLW\��7KH�ERRP�FDQ�EH�H[WHQ-ded through its joints. Thus it is very space sa-YLQJ�DW�LWV�ZRUNSODFH��)RU�HYHQ�PRUH�ÀH[LELOLW\�LW�FDQ�EH�URWDWHG�DURXQG�LWV�RZQ�D[LV�DQ�LV�KHLJKW�adjustable.

Advantages�� Space-saving retractable boom with telesco-

pic height adjustment�� 7HOHVFRSLF�ERRP�H[WHQGDEOH�E\���P�� 5RWDWDEOH�E\�PD[LPXP������DURXQG�LWV�RZQ�D[LV

�� Optional: welders seat

Technical data

Customisation

Complete System Solutions

Besides the variety of high-quality standard technique custom-made solutions are needed particularly in the large scale industries. For H[DPSOH��$�VSHFLDO�ZHOGLQJ�KHDG�IRU�D�VWDQGDUG�welding tractor of the KA series that has to be ¿[HG�XSVLGH�GRZQ�IRU�ZHOGLQJ�URWDWLYHO\��KLJKHU�column and booms or longer booms, special rails for plants and many other individual requi-rements more.

Our developers, mechanics, engineers, techni-cians and advisers are specialists and work WRJHWKHU�IRU�¿QGLQJ�VROXWLRQV�IRU�GLI¿FXOW�RU�H[W-raordinary requests.

We plan, construct, implement and test your individual technical solution in agreement with you as our customer. Moreover, we offer training courses and maintenance service as desired WR�PDNH�\RX�IHHO�FRQ¿GHQW�LQ�XVLQJ�WKH�PRVWO\�FRPSOH[�V\VWHPV�±�PRUH�LQIRUPDWLRQ�RQ�SDJH�46.

The telescopic boom is manufactured in special dimensions on request.

Telescopic boom

Movement of the boom 3 m

0D[��KHLJKW�EHORZ�ERRP 4 m

0D[��URWDWLRQ�DQJOH ����

0D[��ZHLJKW�DW�ERRP�HQGLQJ 400 kg

'LPHQVLRQV�UHWUDFWHG��/�[�:�[�+� ������[�������[�������PP

Weight 4,270 kg

Telescopic boom with multi-kinematic movability.

- 33 -- 33 -

Syst

em S

olut

ions

In Practice

Container and Pipe Welding Plant

Application example�� Welding of containers and pipes�� Circular and longitudinal seams�� SA welding with wire diameter of up to 5 mm

and with several wires�� Work-piece diameter 1,000 mm – 4,000 mm

Features�� Movable column and boom on rail system�� 5ROOHU�EORFNV�ZLWK�D�PD[LPXP�WRWDO�ORDG�RI�

30 tons�� Welding of inner and outer seams�� Automatic, tactile seam tracking for both

torches

:LWK�WKH�UDLO�V\VWHP�DX[LOLDU\�SURFHVV�WLPHV�IRU�FKDQJH�IURP�inside to outside seam welding are reduced.

Double-T Beam Welding Plant

Application example�� :HOGLQJ�RI�ZHE�SODWHV�DQG�ÀDQJH�DQJOHV�WR�GRXEOH�7�DQG�FURVV�VHFWLRQV�DV�ZHOO�DV�RI�ER[�girders in PA und PB position

�� Double-wire SA welding

Features�� 'LPHQVLRQV��������[�������[�������PP�� Travel length up to 32,000 mm�� 0D[��ORDG�FDSDFLW\�����NJ�� Welding speed 0.12-2m/min�� 8S�WR�PD[���[��PP�ZLUH�SHU�VLGH 7KH�SODQW�DOORZV�WKH�ZHOGLQJ�RI�ZRUNSLHFHV�ZLWK�D�PD[LPXP�

size of 4 metre.

Container SA Welding Unit

Application example�� Joint welding of rolled plates�� Circular and longitudinal seams�� &RQWDLQHU�GLDPHWHU�PD[LPXP�����PP�� Sheet thickness 3 mm�� 0D[��GLPHQVLRQV������[�����P�� Materials: mild steel, pressure vessel steel

Features�� Solid base frame with two support

combinations and container rotary device�� With holding mandrel, roller guide-way and

support combination

The container welding unit welds two circular seams simul-taneously.

- 34 -- 34 -

In Practice

3UR¿OH�5DLO�:HOGLQJ�3ODQW

Application example�� SA welding travel carriage with boom and two

welding heads with narrow-gap system�� 6$�ORQJLWXGLQDO�ZHOGLQJ�RI�ER[�VKDSHG� SUR¿OHV��7�EHDPV�DQG�WUDSH]RLGDO�SUR¿OHV

�� Bevel grooves�� Sheet thicknesses 10-30 mm�� 0D[��GLPHQVLRQ������[�����P�� 0DWHULDO��+DUGR[����

Features�� Mechanisation of longitudinal welding�� 5RWDWDEOH�E\������ZLWK�SRVLWLRQLQJ�XQLW

Beam welding unit with SA double-wire and rotary tilting table

Rail Welding Plant

Application example�� Mobile SA welding carriage for regeneration RI�SUR¿OH�UDLOV�IRU�FDEOH�FDUV

�� Equipped with SA welding technique for im-SURYLQJ�HI¿FLHQF\�FRPSDUHG�WR�*0$�ZHOGLQJ

Features�� Positioning on the rail by means motoric H[WHQGDEOH�UXEEHU�ZKHHOV��WKXV�TXLFN�DQG�ÀH[LEOH�XVH

�� Welding power source GTH 802 suited for generator operation with 35 m hose parcel )OH[LEOH�FDUULDJH��IDVW�UHJHQHUDWLRQ�RI�UDLOV

3UR¿OH�6$�:HOGLQJ�8QLW

Application example�� :HOGLQJ�RI�EXWWHUÀ\�SUR¿OHV�� 'RXEOH�ZLUH�6$�ZHOGLQJ���[�����PP�Ø�� Part length up to 13,000 mm

Features�� Travelling carriage with side boom on rail

system (rail length 16,000 mm)�� 7ZR�OLQHDU�FDUULDJHV�ZLWK�KHLJKW�D[HV�RQ�D�FRQWLQXRXV�ODWHUDO�D[LV�RQ�VLGH�ERRP

�� /DWHUDO�D[LV�������PP:LWK�WKH�SUR¿OH�ZHOGLQJ�XQLW�ORQJLWXGLQDO�ZHOG�VHDPV�FDQ�EH�welded in PA position.

- 35 -- 35 -

Syst

em S

olut

ions

In Practice

Robot GMA Welding System

Application example�� )LOOHW�ZHOGLQJ�RQ�EHDPV�DQG�SUR¿OHV�XS�WR�D�

throat thickness of 8 mm�� GMA welding with newArc technology�� 3UR¿OH�VL]H�XS�WR�����[�����[�����PP

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

$OVR�GLI¿FXOW�FRPSRQHQW�JHRPHWULHV�FDQ�EH�UHDOLVHG�ZLWK�WKH�robot GMAW system.

Surface Welding Plant

Application example�� Surface welding of plates�� :HOGLQJ�ZLWK�ÀX[�FRUHG�ZLUH�RU�6$�ZHOGLQJ�� 0D[��SODWH�VL]H�������PP�[�������PP

Features�� Range 3,500 mm and rail length 6,000 mm�� 7ZR�OLQHDU�FDUULDJHV�RQ�D�FRQWLQXHV�ODWHUDO�D[LV�

with travel length 3,000 mm�� 0D[��RVFLOODWLRQ�ZLGWK�RI�HDFK�ZHOGLQJ�KHDG�

80 mm�� Fume suction directly at the weld�� Dust-proof version of the entire plant including D[HV�DQG�VZLWFK�FDELQHW

The plant can weld simultaneously with one or two torches in alternating operation.

Two-Torch Welding Plant

Application example�� Welding of straight and bent girder sections

for vehicle construction�� GMA welding with newArc technology

Features�� Travel carriage with boom�� Two power sources KH 600 newArc for wel-GLQJ�WZR�¿OOHW�VHDPV�VLPXOWDQHRXVO\

�� Automatic, tactile seam tracking for both torches; little distortion

The double GMAW plant was designed especially for vehic-le construction.

- 36 -- 36 -

Welding Flux

KF FB-TT Flux

7KH�ÀXRULGH�EDVLF�ÀX[�LV�XVHG�IRU�ZHOGLQJ�JH-QHUDO�DQG�KLJK�VWUHQJWK�¿QH�JUDLQHG�VWUXFWXUDO�steels, as well as low-temperature and non- ageing steels. Tandem and multi-wire welding and the production of offshore components are DOVR�SRVVLEOH��7KLV�ZHOGLQJ�ÀX[�LV�DOVR�VXLWHG�IRU�FLUFXPIHUHQWLDO�ZHOGV�GXH�WR�WKH�TXLFN�VROLGL¿FD-tion of the slag.

Mechanical properties

KF S2 KF S3 KF S2Mo

ReL/Rp0,2 MPa >330 N/mm2 >430 N/mm2 >500 N/mm2

Pressure 450 – 550 N/mm2 530 – 630 N/mm2 580 – 680 N/mm2

A5 !����� !����� !�����

KV 20 °C > 160 J > 160 J > 120 J

0 °C > 140 J > 140 J > 100 J

-20 °C > 80 J > 80 J > 80 J

-40 °C > 30 J > 70 J > 50 J

-60 °C - > 30 J > 30 J

AB 123 Flux

7KH�DOXPLQDWH�EDVLF�ÀX[�IRU�ZHOGLQJ�JHQHUDO�mild steels is especially suited for single and multi-wire welding. The slag can be removed easily.

Mechanical properties

For optimum welding results we recom-mend the welding wires S2, KF S3 and KF S2Mo.

Features��Standard ISO 14174: SA FB 155 AC H5��Approvals: TÜV, DB, GL, ABS��Particle size: 0.2 – 1.8 mm��Density: 1.2 kg/dm3

��Composition: SiO2���7L22��&D2���0J2�� Al2O3 MNO; CaF2

��Packaging: 25 kg in plastic bags��7\SH�RI�FXUUHQW�SRODULW\��$&��'&��XS�WR�������$��Temperature for re-drying: 350°C/2h

Features��Standard ISO 14174: SA AB 167 AC H5��Particle size: 0.2-1.8 mm��Density: 1.3 kg/dm³��Composition: SiO2��7L22��&D2���0J2��

Al2O3 MNO; CaF2

��Packaging: 25 kg in plastic bags��7\SH�RI�FXUUHQW�SRODULW\��$&��'&��XS�WR�������$��Temperature for re-drying: 350°C/2h

KF S2 KF S3 KF S2Mo

ReL/Rp0,2 MPa >380 N/mm2 >430 N/mm2 >430 N/mm2

Pressure 510 – 610 N/mm2 530 – 630 N/mm2 550 – 650 N/mm2

A5 !���� !��� !���

KV -40 °C > 47 J > 47 J > 47 J

KF AR D1 Flux

7KH�DOXPLQDWH�UXWLOH�ÀX[�LV�VXLWDEOH�IRU�WDQGHP�and multi-wire welding of general steels. It can also be used for thin-walled and spiral-shaped towers.

Mechanical Properties

Features��Standard DIN EN 760��Particle size: 0.2-1.6 mm��Density: 1.6kg/dm³��Composition: SiO2���7L22; Al2O3 MNO; CaF2

��Packaging: 25 kg in plastic bags��7\SH�RI�FXUUHQW�SRODULW\��$&��'&��XS�WR�������$��Temperature for re-drying: 350°C/2h

KF S2

ReL/Rp0,2 MPa > 400 N/mm2

Pressure 500 – 600 N/mm2

A5 !����

KV 20 °C, 0 °C, -20 °C, -40 °C, -60 °C > 47 J

- 37 -- 37 -

Fille

r M

ater

ials

Welding Wires

SA Welding Wire

The heavily copper-plated welding wires give rust no chance.

Mechanical properties

Features��Standard EN ISO 14171-A: S2, S3, S2Mo��Approvals: TÜV, GB, GL, ABS

KF S2 KF S3 KF S2Mo

DIN 8557 S2 S3 S2Mo

ASME/AWS A 5.17/EM 12 K A 5.17/EM 13 K A 5.23/EA 2

EN 756 S2 S3 S2Mo

GMA Welding Wire

The heavily copper-plated wires are suited for welding un- and low-alloyed steels.

Mechanical properties

Features��Standard EN ISO 14341-A: G3Si1, G4Si1 ��Protection gas acc. to EN ISO 14175: M 21, C1��Approvals: TÜV, DB, GL, ABS��Tensile strength less than 530 N/mm²

KF G3Si1 KF G4Si1

ReL/Rp0,2 MPa >420 N/mm2 >460 N/mm2

Pressure 500 – 640 N/mm2 530 – 690 N/mm2

A5 !���� !����

KV -40° >47 J

-50° >47 J

Flux Cored Wire

7KH�ÀX[�FRUHG�ZLUH�)LGXU�IURP�.MHOOEHUJ�LV�LGHDOO\�suited for wear protection.

Qualities

Fidur 10/65 FD

Fidur 10/65V FD

Fidur 10/65W FD

Fidur 10/65B FD

Weld metal 5��&��30��&U

5��&��22��&U��7��1E

5��&������Cr, 7��1E��

7��0R��9��:

4,5��&�����6L��1,6��0Q������Cr, 1��%��9��:

Hardness 60 HRC 62 HRC 65 HRC 65 HRC

0D[��operating temperature

350 °C 350 °C 700 °C 350 °C

Diameter 1.6 mm; 2.4 mm 2.8 mm; 3.2 mm

Packaging 15 kg coil 25 kg basket spool, 250 kg drum

GMA welding wire from Kjellberg for un- and low-alloyed steels

Diameter 2.0 mm; 2.5 mm; 3.0 mm; 4.0 mm

Packaging 25 kg basket spool

Diameter 0.8 mm, 1.0 mm, 1.2 mm

Packaging 15 kg coil

)OX[�FRUHG�ZLUH�IURP�.MHOOEHUJ�IRU�ZHDU�SURWHFWLRQ

- 38 -- 38 -

Welding Electrodes

Unalloyed Electrodesacc. to DIN EN ISO 2560-A, AWS A 5.1

�� LLOYD rutile, for shipbuilding

��LLOYD GRÜN rutile, cellulosic, for shipbuilding

��PRIMA rutile-cellulosic, for all positions

��PRIMA BLUE rutile-cellulosic, higher strength, for all positions

��TITAN ROT rutile, heavily coated

��TITAN S rutile, high strength and toughness, heavily coated

��TITAN rutile-basic

��TITAN K rutile-basic with high strength and toughness

��OPTIMAL rutile-basic, for thin sheets

��KONTAKT 160 rutile, heavily coated, high output

��TRUMPF acid, special electrode

��PROGRESS basic, for welding in vertical up position

��GARANT basic

� GARANT S basic, high strength

��GARANT K basic, Ni-alloyed, high strength und toughness, low H2-content

��GARANT x basic-rutile double coated

��GARANT BR basic double coated

��GARANT AC/DC basic, high strength

��PERFEKT basic, for vertical down welds

��KORREx basic, for weatherproof and rust resistant steels

Unalloyed electrode Optimal

High-Temperature Welding Electrodesacc. to DIN EN ISO 3580-A, AWS A 5.5

��KOMPLEx W UXWLOH��������0R

��IMPULS EDVLF��������1L�DQG�������0R�

��MOB EDVLF��������0R

��CROMO 1R UXWLOH������&U��������0R

��CROMO 1B EDVLF������&U��������0R

��CROMO 2B EDVLF��������&U������0R

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

��FINOx 82 material number 2.4648

��FINOx 182 material number 2.4620

��FINOx 625 material number 2.4621

High-Alloyed Electrodesacc. to DIN EN ISO 3581-A, AWS A5.4

��FINOx 4820 AC �����&U������1L

��FINOx 4842 AC������&U�������1L

��FINOx 4842 B�EDVLF�������&U�������1L

��FINOx 4829 AC������&U�������1L

��FINOx 4009 AC������&U

��FINOx 4351 B�EDVLF�������&U��������1L

��FINOx 4015 AC������&U

��FINOx 4316 AC������&U������1L

��FINOx 4551 AC������&U������1L

��FINOx 4551 B basic with high toughness, �����&U�������1L��1E

��FINOx 4430 AC������&U�������1L������0R

��FINOx 4430 F for vertical down welds, �����&U�������1L������0R

��FINOx 4576 AC������&U�������1L������0R��1E

��FINOx 4462 AC�IRU�GXSOH[�VWHHOV� �����&U������1L������0R

��FINOx 4519 AC������&U�������1L������0R��&X

��FINOx 4370 AC �����&U������1L������0Q

��FINOx 4370 B EDVLF�������&U������1L������0Q

��FINOx 4370 S for surface-layer welding on rails, rutile EDVLF�������&U������1L������0Q

��FINOx 4431 AC �����&U�������1L������0R

��FINOx 4337 AC �����&U������1L

��FINOx 4332 AC �����&U�������1L

��FINOx 4459 AC������&U�������1L������0R

��FINOx 29/9 GOLD VSHFLDO�HOHFWURGH�������&U������1L

+LJK�DOOR\HG�HOHFWURGH�)LQR[������$&

- 39 -

&XWWLQJ�HOHFWURGH�0HW�2[

- 39 -

Fille

r M

ater

ials

Welding Electrodes

Electrode for surface welding Fidur 23/250

Cast Iron Electrodesacc. to DIN EN ISO 1071, AWS A 5.15

��FICAST NI pure nickel

��FICAST NIFE������1L�������)H

��FICAST NIFE K copper-plated NiFe core rod, �����1L�������)H

��FICAST NIFE B�ELPHWDO�������1L�������)H

��FICAST FE iron-based, special coating

Electrodes for Surface Weldingacc. to DIN EN 14700

��FIDUR 1/300 Mo-V low-alloyed, hardness 300 HB

��FIDUR 350 Mn-Cr low-alloyed, hardness 350 HB

��FIDUR 2/55 Cr-Ni-Mo low-alloyed, hardness 55 HRC

��FIDUR 3/50 for hot and cold working tools, Cr-W-V low-alloyed, hardness 50 HRC

��FIDUR 4/60 for high-speed tools, Cr-Mo-W-V low-alloyed, hardness 60 HRC

��FIDUR 6/55 Mn-Cr low-alloyed, hardness 55 HRC

��FIDUR 6/60 tough-hard, Cr-Mo-V low-alloyed, hardness 60 HRC

��FIDUR 6/60 R Cr-Mo-V low-alloyed, hardness 60 HRC, suitable for AC current

��FIDUR 7/200 Mn-Cr-alloyed, hardness 200 HB, work-hardenable up to 500 HB

��FIDUR 7200 Mn Mn-Cr-Ni-alloyed, hardness 200 HB, work-hardenable up to 450 HB

��FIDUR 8/200 Cr-Ni-Mn-alloyed, hardness 200 HB, work-hardenable up to 350 HB

��FIDUR 10/60 IRU�JULQGLQJ�ZHDU������&U�DOOR\HG��hardness 60 HRC

��FIDUR 10/65 for grinding wear, hardness 65 HRC

��FIDUR 10/65 W for grinding wear and high tempera-tures, Cr-Mo-Nb-W-V-alloyed, hardness 65 HRC

��FIDUR 10/70 for grinding wear, Cr-B-alloyed, hard-ness 70 HRC

��FIDUR 23/250 basic electrode, material number 2.4887, hardness 240 HB, work-hardenable up to 400 HB

��FILIT 6 cobalt-based electrode, hardness 40 HRC

��FILIT 21 cobalt-based electrode, hardness 35 HR

Special Electrodes

��MET-Ox for cutting

��KJELGOUGE for gouging

��KJELCUT for cutting

- 40 -- 40 -

Welding Carriage GMAW and SAW

Features�� Electronic speed adjustment�� Self-positioning (due to a permanent mag-

netic system in case of ferromagnetic mate-rials)

�� Piece and serial production�� Hand and machine torch available�� Adjustable guiding elements, protected

against spatter�� Highest reproducibility and quality of the weld VHDPV�GXH�WR�PHFKDQLFDO�IHHG�DQG�H[DFW�torch guidance

Technical data

KMF Operates more than 16 Hours

Due to its small track width of 85 mm the welding carriage is also suited for narrow webs.

The KMF solid can be used with hand and machine torch.

�� Digital speed adjustment/control�� Self-positioning (in case of ferromagnetic ma-

terials no tracks are required)�� Can be upgraded with an electronic pendulum

system�� Piece and serial production, also for short weld

lengths�� Hand and machine torch (remote control of the

power source integrated)

Technical data

KMF Solid with Double Magnetic Power

Art. no. .11.301.100.100

Welding speed 10 – 125 cm/min

Track width 85 mm

%DWWHU\�RSHUDWLRQ�ZLWKRXW�UHFKDUJLQJ�������GXW\�F\FOH� > 16 h

Battery charge time < 25 min

Permanent magnetic system: Adhesion > 180 N

Welding types and positions all but PD, PE

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP

Weight 4.8 kg

Art. no. .11.301.101.100

Welding speed 10–200 cm/min

Track width 140 mm

%DWWHU\�RSHUDWLRQ�ZLWKRXW�UHFKDUJLQJ�������GXW\�F\FOH� > 12 h

Battery charge time < 25 min

Connectable magnetic system: Adhesion > 350 N

Welding types and positions all but PD, PE

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP

Weight 6.8 kg

- 41 -- 41 -

Opt

ions

Control Units

Control DigiKAS

The digital control allows the combination of analogue feedback control and digital user interface. All parameters can be accessed via touchpad.

Features�� Setting of welding parameters and storing of

welding jobs �� Password-protected job storage �� Language selection�� Optional for KA series

The control can be operated by hard and soft keys.

Tactile sensor Inductive sensor

Visual laser pointer Laser scanner

Photo-optical monitoring

KAS with Digital Remote Control

Like DigiKAS also the control KAS for automats with digital activation KAS I/O allows the combi-nation of analogue feedback control and digital peripheral control such as portal, column and boom or robot controllers. The type KAS I/O is designed for switch cabinet construction. The control is mounted on a base plate with the size ����PP�[�����PP�[�FD������PP��/�[�:�[�+���This type is designed for user application.

Features�� &RQ¿JXUDWLRQ�RI�WKH�VXSHULRU�FRQWURO�GRQH�E\�

the operater�� Binary or analogue transfer of orders to KAS�� $PSOL¿FDWLRQ�RI�.$6�,�2�IRU�%86�FRQQHFWLRQ�

possible�� Article number: .17.000.480.700

Seam Tracking Systems

- 42 -- 42 -

Welding Heads

Features�� Electroslag and SA strip cladding�� 3-8 mm thick claddings per layer�� High deposition rate and low dilution rate�� Corrosion and wear protection layers possible GHSHQGLQJ�RQ�WKH�¿OOHU�PDWHULDO

Technical data

Strip Cladding Head

(I¿FLHQW�FODGGLQJ�ZLWK�VWULS�FODGGLQJ�KHDG�

Art. no. .11.300.810

0D[��ZHOGLQJ�FXUUHQW 1,250 A

Control voltage 42 V AC/50 Hz

Strip width 30–60 mm

Min. diameter of inner tube 500 mm

'LPHQVLRQ��/�[�:�[�+� ����[�����[�����PP

Weight 20 kg

Features�� 6PDOO�ÀX[�WDQN�ZLWK�SQHXPDWLF�ORFN�� Laser pointer and workplace LED lighting�� Motoric support combination with adjustment WUDFN�����[�����PP

Technical data

Welding Head for inner Tube

Control adaptable to welding task with GTH 802.

0D[��ZLUH�GLDPHWHU 2.5 mm

0D[��GLDPHWHU�RI�LQQHU�WXEH 450 mm

Features�� Torch with remote control and optional display

indication�� ([FHOOHQW�FRROLQJ�RI�WKH�SODVPD�QR]]OH�

Technical data

Plasma-transferred Arc Welding Head

The PTA torch can be used for robot welding.

Welding current 50 – 350 A

Welding voltage 15 – 40 V

Diameter tungsten electrode 3,2 oder 4,0 mm

Weight 1,5 kg

- 43 -- 43 -

Opt

ions

Features�� ,PSURYHG�HI¿FLHQF\�� Welding simultaneously with AC/DC-welding

head�� Multi-wire welding heads on request

Technical data

Tandem Welding Head

([DPSOH��WDQGHP�ZHOGLQJ�DW�D�FROXPQ�DQG�ERRP

Art. no. .17.000.487.500

0D[��ZHOGLQJ�FXUUHQW je 1,000 A

Control voltage 44 V

Wire diameter ��[��±��[���PP

Welding Heads

Water-Cooled Filler Wire Head

Features�� )RU�ZHOGLQJ�ZLWK�VHOI�SURWHFWLQJ�ÀX[�FRUHG�

wires�� Clamping diameter 12 mm

Technical data

The hose attachments for water inlet und outlet are const-ructed for the hose nipples R3/8’’.

Art. no. .17.000.082.000

0D[��ZHOGLQJ�FXUUHQW 1,250 A

Control voltage 42 V AC/50 Hz

- 44 -- 44 -

Welding Heads

Narrow-Gap System

Features�� (I¿FLHQW�GXH�WR�ORZ�VHDP�YROXPH�� Straight current contact nozzle or angled by �����IRU�¿OOHW�ZHOGLQJ

�� 6LPSOH�PRXQWLQJ�RQ�H[LVWLQJ�V\VWHPV�VXFK�DV�column and booms, gantries, tractors without changing the control

Technical dataThe narrow-gap system can be adapted to KA automats.

Art. no. .11.300.103.580

Wire diameter 2.5–5 mm

:LGWK�RI�WKH�ÀX[�V\VWHP 15 mm

'HSWK�RI�LPPHUVLRQ�ZLWK�ÀX[�V\VWHP 200 mm

0D[��GHSWK�RI�LPPHUVLRQ 250 mm

Min. gap width 25 mm

Weight 4.4 kg

SAW Nozzle Holder

Features�� 6XLWDEOH�IRU�.$�VHULHV�ZLWK�ÀX[�¿OO�DQG�HOHFWUL-

cal connection�� Variants with different lengths an angled vari-

ants available

Technical dataThe SA nozzle holder is also available for a wire diameter of PD[����PP�

SAW Narrow-Gap Nozzle Holder

The narrow-gap nozzle holder for a wire diameter of 3-5 mm is available on request.

Art. no. .11.300.103.580

Wire diameter 1.6–3 mm

0D[��ZHOGLQJ�FXUUHQW 600 A

Welding voltage 26 – 35 V

Wire feeding speed 0.1–10.1 m/min

Welding speed 0.25–1.0 m/min

UP 3 mm UP 5 mm UPP

Art. no. .11.300.103.560 .11.300.105.560 .11.300.700.560

Wire diameter 1–3.2 mm 3–5 mm ��[��±����PP

Features�� Small opening angle for V and x seams�� Little distortion due to low heat input

Technical data

- 45 -- 45 -

Opt

ions

Cooling Unit and Accessories

Cooling Unit KWE 750

3QHXPDWLF�ÀX[�UHFRYHU\ Pressure tank 50 l, 100 l )OX[�WDQN���O�����O

Suction nozzlesFlat current contact nozzles

Filter bags

Current contact nozzles )OX[�FDSV

Technical data

Recooling of heated components with coolant.

Art. no. .11.140.804

Mains connection ��[�����9��������+]���3(1

Fuse, slow 16 A

Tank capacity 11 l

Cooling capacity 3,600 W

0D[��RSHUDWLQJ�SUHVVXUH 6 bar

'LPHQVLRQV��/�[�:�[�+� ����[�����[�����PP

Weight 32 kg

Flux Feeding Systems

Consumables

Standard chipping hammer

Welding helmet

Pneumatic chipping hammer

Hand brush

Accessories

Rotatable ground connector Boom system

Welding gloves Guiding system KA

- 46 -- 46 -

Service

Maintenance downtimes and production peaks are no longer a problem if you choo-se our rental service. We offer advice and delivery as well as detailed instruction and FROOHFWLRQ�DIWHU�WKH�MRE�LV�GRQH��7KH�¿HOGV�RI�application and the possible combinations of our service are as diverse as are your demands on Kjellberg. That is why you can LQTXLUH�H[DFW�UHQWDO�IHHV�E\�WHOHSKRQH�DQG�online using our contact form.

Rental conditions��Minimum term of rent: one calendar week��Delivery, collection and instruction are

optional��Advice and offers are free of charge and

not binding

Contact person: Manuel Kornek7HOHSKRQH������������������

We offer to you not only the right equipment EXW�DOVR�RXU�H[WHQVLYH�NQRZOHGJH��.MHOOEHUJ�stands at your side from the implementing of new systems or machines, instruction, individual tests and trials to trainings on technology and usage – adapted to your individual demands.

Training topics��Technical instruction for special systems

and automats

��Development of technologies, e.g. weld test

��Trainings on operating and functioning of our welding equipment and various welding methods

Contact person: Frank Sprecher7HOHSKRQH������������������

Besides repairing machines and systems from Kjellberg our service departments helps in cases of:

��Regeneration of used Kjellberg equip-ment

��5HWUR¿WWLQJ�RI�WHFKQLFDO�LQQRYDWLRQV�� Individual reconstruction of used

machines��Maintenance service

Contact person: Frank Sprecher, 7HOHSKRQH������������������

Become an Expert with Kjellberg! Service Department: Always there for you

Renting for Production Peaks

- 47 -

Getting together is a begin-ning, staying together is an improvement, working to-gether is a success.

(Henry Ford; * 30. July 1863, † 7. April 1947, founded the automobile manufacturer Ford Motor Company)

Advisor and Full-Range Supplier

Kjellberg Finsterwalde Schweißtechnik und Verschleißschutzsysteme GmbHOscar-Kjellberg-Str. 18 | 03238 Finsterwalde | Germany 3KRQH�������������������_�)D[����������������_�www.kjellberg.de | schweissen@kjellberg.deOur products represent a high level of quality and reliability. We re-VHUYH�WKH�ULJKW�WR�FKDQJH�WKH�GHVLJQ�DQG�RU�WHFKQLFDO�VSHFL¿FDWLRQV�during the series production. Claims of any kind cannot be derived from this brochure. || 13-08-24Copyright © 2013 Kjellberg Finsterwalde Schweißtechnik und Verschleißschutzsysteme GmbH. All rights reserved.

Planning and construction Sheet cutting to size

Colouring

Rolling and deforming Welding

Assembly and installation

SA welding technique��Automats and power sources��Equipment for SA manual welding

GMA welding technique

MMA welding technique

TIG welding technique

Special welding process InFocus

PTA welding and keyhole welding

Wear protection technique Fidur

Welding periphery��Column and booms, gantries, rotating

devices

Complex systems

Filler materials, accessories, options

Kjellberg Finsterwalde Group

Welding Electrodes Welding EquipmentCutting Equipment Mechanical Engineering

Expertise for all Requirements