Académique Documents
Professionnel Documents
Culture Documents
Contents
Contents
Kjellberg Finsterwalde
Plasma cutting technique
Welding electrodes
Welding technique
Page
Page
Page
Page
4
5
6
7
Submerged-arc welding
Technology
Standard automats
Power sources
Manual SA welding
Page
Page
Page
Page
Page
8
8
9
12
13
MIG welding
Technology
Machines
Page
Page
Page
14
14
16
Electrode welding
Page
20
Page
22
Page
24
Page
Page
Page
26
26
27
Page
28
Welding periphery
Page
30
System solutions
Page
36
Options
Page
42
Rental service
Page
46
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.
!
!
Organizational Structure
Product Groups
Kjellberg Foundation
100% shareholder
Kjellberg Group
PLASMA TECHNIQUE
WELDING ELECTRODES
-4-
WELDING TECHNIQUE
Plasma Technique
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.
Product Portfolio
CNC and Mechanized Technique
HiFocus series
particularly high cut quality with highprecision HiFocus systems (now with
integrated Contour Cut technology)
FineFocus series
robust units for reliable cut quality even
under the most severe conditions and under
water
PA-S series
cost-efficient units for simple applications
CutFire series
powerful, technically simple plasma cutting
inverters with low investment costs
The newly developed Contour Cut technology convinces with precise cut results
when cutting small holes and contours.
CUTi series
small mobile units for the best possible cuts,
on construction sites or for confined
production space
CutLine series
technically simple and cost-efficient plasma
cutting systems for versatile use, also for
gouging
!
!
-5-
Kjellberg Finsterwalde
Business Divisions
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, highalloyed 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.
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
Special Electrodes
On customer request, we develop and/or
produce welding electrodes for special
requirements as regards the use or colour.
Filler Materials
For companies that have their own production
we produce and supply mixtures for electrode
coating.
Quality electrodes with different features have been developed and produced
since 1922.
-6-
Welding Technique
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 Schweitechnik und Verschleischutzsysteme 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 plasmatransferred arc welding. Our quality-tested and
further developed welding units are designed
for the worldwide use under nearly all working
Product Portfolio
Submerged-arc Welding Technique
SAW automats
flexible modular concept for individual system
solutions with a wide range of technological
applications
Manual SA welding
for welding of large seam geometries on
which mechanization is impossible
Power sources
make it possible to weld with a current of up
to 1.400 A
GMA Welding
Power sources
flexible use for mechanised, partly and fully
mechanised welding processes with high
seam quality
PTA Welding
Power sources
predefined welding programmes facilitate the
industrial use for producing high-quality
protective layers
Welding Periphery
Complex Plants
-7-
Kjellberg Finsterwalde
Business Divisions
Process Principle
Quelle: DVS
-8-
Picture
Max.
welding current
Method
Wire Recommended
diameter (mm) power sources
KA 1-UP
3mm: .11.300.103
5mm: .11.300.105
1.400 A
1,63,0
or
2,55,0
GTH 522
GTH 802
GTH 1002
GTH 1402
1.400 A
2,55,0
GTH 1002
GTH 1402
800 A
1,63,0
or
2,55,0
500/800 A
KA 1-UP
as steerable
version
.11.303.105
KA 2-UP/UPP
3mm: .11.300.203
5mm: .11.300.205
2x3mm: .11.300.270
1.400 A
GTH 802
GTH 1002
GTH 1402
GTH 1002
GTH 1402
KA 4-UPDG
.11.300.400
600 A
1,62,5
(on each
welding head)
(on each
welding head)
2 x GTH 522
2 x GTH 802
KA 7-UPP
.11.300.700
GTH 1002
GTH 1402
1,64,0
GTH 802
UPK
.11.300.104
SA fillet welding
800 A
-9-
by
6.
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Ren lberg!
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Submerged-Arc Welding
T-Beam
Box girder
Double T-Beam
Container,
longitudinal weld
Container,
circular weld
(inside and outside)
Cladding
6
7
8
9
10
11
12
5
- 10 -
!
!
!
Fixed welding head, pivoting to the side and for piercing and dragging fillet welding (KA 1-UP)
Quick positioning of the welding head due to manual linear axes (effective adjustment
track per 100 mm)
Minimisation of auxiliary times due to optional accessories: pneumatic flux recovery unit
(low-wear injection principle)
!
!
pre-selection of parameters for welding current, arc voltage and welding speed
pre-selectable procedure for start mode and crater filling
10
Flexible installation of strain relief for hose parcels (can be screw-connected to the side
or front)
11
12
Along profiles, webs, flanges and, on request, suitable for rails due to stepless adjustable supporting rolls
!
!
!
!
- 11 -
Submerged-Arc Welding
Type
Art. no.
Characteristic
Mains voltage
Connecting power acc. to EN 60974-1
Mains connection
Welding current range
25 %
40 %
100 %
Protection class
Weight
Dimensions L x W x H (mm)
GTH 522
.11.907.602A
constant voltage (CV)
3 x 400 V,
10 %/+10 %, 50 Hz
23,6 kVA
CEE 63 A
70 A/18 V 500 A/45 V
500 A
400 A
IP 23
260 kg
1.130 x 665 x 865
GTH 802
.11.705.902A
constant voltage (CV)
3 x 400 V,
10 %/+10 %, 50 Hz
31,7 kVA
CEE 63 A
80 A/18 V 800 A/44 V
800 A
720 A
IP 22
319 kg
980 x 720 x 1.000
GTH 1002
.11.903.102A
constant voltage (CV)
3 x 400 V
10 %/+10 %, 50 Hz
78 kVA
terminal connection
100 A/19 V 1.000 A/44 V
1.000 A
IP 21
440 kg
1.110 x 820 x 1.000
(with carriage for construction sites) (with carriage for construction sites)
(stationary)
GTH 1402
.11.903.802A
constant voltage (CV)
3 x 400 V,
10 %/+10 %, 50 Hz
83,8 kVA
terminal connection
100 A/19 V 1.400 A/44 V
1.400 A
1.200 A
IP 21
440 kg
1.110 x 820 x 1.000
(stationary)
GTF 401
.11.708.002 / .11.708.001
constant current (CC)
2 x 400 V/3 x 230/400/500 V
Type
Art. no.
Characteristic
Mains voltage
Connecting power acc. to EN 60974-1
Mains connection
Welding current range
25 %
40 %
100 %
Protection class
Weight
Dimensions L x W x H (mm)
11,2 kVA
CEE32 A
10 A/20 V 400 A/36 V
400 A
250 A
IP 23
169 kg
925 x 658 x 1.000 (stationary
W 1005 VC
.11.691.002
constant voltage (CV)
2 x 400 V/PE
10 %/+10 %, 50 Hz
77,2 kVA
terminal connection
200 A/25 V 1.000 A/44 V
1.000 A
IP 21
510 kg
1.130 x 750 x 990
(stationary)
GTF 551
.11.709.002
constant current (CC)
3 x 400 V,
10 %/+10 %, 50 Hz
16,5 kVA
CEE 32 A
10 A/20 V 550 A/42 V
550 A
400 A
300 A
IP 22
194 kg
925 x 658 x 1.100
GTF 551
.11.709.001
constant current (CC)
3x 230/400/500 V,
10 %/+10 %, 50 Hz
16,5 kVA
CEE 32 A
10 A/20 V 550 A/42 V
550 A
400 A
300 A
IP 22
194 kg
925 x 658 x 1.100
with carriage for construction) (with carriage for construction sites) (with carriage for construction sites)
Type
Art. no.
Characteristic
Mains voltage
Connecting power acc. to
Mains connection
EN 60974-1
GTF 1002
GTF 752
.11.903.202C
.11.705.602
constant current (CC)
constant current (CC)
3 x 400 V, 10 %/+10 %, 50 Hz
78 kVA
51,5 kVA
terminal connection
CEE 125 A
fuse 125 A
(optionally 63 A possible)
200 A/28 V 1.000 A/44 V
60 A/22,4 V 750 A/44 V
750 A
1.000 A
630 A
IP 21
IP 22
438 kg
304 kg
1.110 x 820 x 1.000
980 x 720 x 1.000
83,8 kVA
terminal connection
fuse 125 A
200 A/28 V 1.400 A/44 V
1.400 A
1.200 A
IP 21
438 kg
1.110 x 820 x 1.000
(stationary)
(stationary)
GTF 1402
.11.903.702C
constant current (CC)
y
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- 12 -
The Equipment
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
!
!
!
!
!
!
!
!
!
!
Technical Data
Max. at 100%
duty cycle
Open circuit voltage, max.
Wire feeding speed
Wire coil diameter
Wire diameter
steel
CrNi
filler wire
Feed rollers standard
Protection class
Weight
Dimensions L x W x H (mm)
- 13 -
Submerged-arc Welding
MIG Welding
Technology
Spatter-free welds are absolutely essential for a
welding production that requires no rework and
is therefore cost-optimised.
KH600 newArc
Process Principle
Quelle: DVS
- 14 -
Application Advantages
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.
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
!
!
!
!
!
!
newArc technology
40 mm
15 mm
25-30
ca. 60
20 mm
7 layers
Heat-affected zone
3 layers
MIG Welding
Welding
properties
Hot-Start
internally optimised
Welding of thin
sheets
Excellent suitability for thin sheets also with larger welding wire diameter, thus
reduced costs for filler materials
Digital display
Display of actual values as well as HOLD function for welding voltage and welding current
Diagnostic
display
integrated, with flow meter in the cooling water return (not only pressure switch!) for a safe
welding operation
Hose parcel
extension
Welding
Best welding properties due to high-precision direct current for all rutile and basic Electrode
types and high-performance electrodes
Design
Easy maintenance due to simple inner design with clearly arranged components
Wire feeding
control unit
no electronics in the wire feeding units, therefore extremely robust and reliable;
complete electronic wire feeding control unit is in the welding power source
Electronics
inverter welding power source with secondary clocking and IGBT module, therefore high
clock frequency for precise direct current, control electronics with many monitoring and
protective functions
- 16 -
KJELLmig Series
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-sized
steel construction companies, for the repair of
vehicles, in agriculture, in handicraft and
industry etc.
Versatile applications:
! for unalloyed, low-alloyed and high-alloyed
steels, aluminium, aluminium alloys, nonferrous metals and galvanised sheets
! with argon and mixed gases
!
!
!
!
!
!
!
!
!
!
!
!
!
!
MIG Welding
Area of Use
light industry
heavy industry
especially demanding processes
!
!
!
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
Technical Data
Art. No.
Connecting voltage
Welding current range
Welding voltage
Duty cycle
50 %
100 %
Weight
Dimensions L x W x H (mm)
.11.707.502
3~400 V/50
30 400 A
15,5 34 V
400 A
283 A
45 kg
653 x 300 x 595
Technical Data
Art. No.
Connecting voltage
Welding current range
WIG DC
WIG AC, AC/DC
MMA (REO) DC
Welding voltage
Duty cycle
40 %
60 %
100 %
Weight
Dimensions L x W x H (mm)
- 18 -
.11.403.302
3~400 V/50
4 300 A
10 300 A
10 250 A
21 30,5 V/10,2 22 V
300 A
245 A
190 A
43 kg
640 x 250 x 544
MIG Welding
Power Sources
Technical Data
KJELLmig 180
.11.930.103
KJELLmig 230
.11.930.202
3 x 400 V
50/60 Hz
5,2
16
KJELLmig K350
.11.931.102
3 x 400 V
50/60 Hz
12,8
20
110/180
60/100
40/80
20110/85180
1519,5/1823
1730/2638
6
0,61,0
2
IP 21
760 x 425 x 655
54,5
230
170
135
15230
14,825,5
1740
10
0,61,0
2
IP 21
760 x 425 x 655
65
350
240
30350
14,831,5
1650
30
steel, CrNi 0,61,2 / Al 11,2
see DVG-K01
see DVG-K01
880 x 530 x 678
90
Art. No.
Protection class
Dimensions L x W x H (mm)
Weight
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.
Type
Art. No.
method
Kennlinie
Mains voltage
Connecting power acc. to EN 60974-1
Mains connection
Welding current range
25 %
40 %
100 %
Protection class
Weight
Dimensions L x W x H (mm)
.11.707.603 / .11.707.703
GMAW method
constant current (CV)
3 x 400 V,
10%/+10%, 50 Hz
23,6 kVA
CEE 63 A
70 A /18 V 500 A/45 V
500 A
300 A
IP 23
260 kg
1.130 x 665 x 865
(with carriage for construction sites)
GMAW pulse
constant voltage (CV)
3 x 230/400 V,
10%/+10%, 50 Hz
23,6 kVA
CEE 63 A
30 A/15 V 600 A/44 V
600 A
450 A
IP 23
183 kg
1.020 x 750 x 1.130
(with carriage)
DV 4W-1H
.11.745.100
DVW-2KH
.11.745.600 bzw. .11.745.600A
0,81,6
1,01,6
1,02,4
1 20 m/min
23 kg
0,81,6
1,01,6
1,02,4
1 20 m/min, 1 50 m/min2)
14,5 kg
synergistic
synergistic
1)
2)
KH 600
GTH 522 W
.11.907.702
- 19 -
6.
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Electrode Welding
Welding Unit Tiny 181
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.
Features
! Welding with rutile and basic electrodes
! Increased welding current with arc ignition
! Automatic turn-off of welding current when
electrode sticks
! DC WIG welding (arc ignition with contact)
Technical Data
Art. No.
Connecting voltage
Open circuit voltage (V)
.11.401.904
230 V/50 Hz
69 V
5 180 A
160 A
135 A
1,5 4 mm
step-less
7 kg
405 x 155 x 254 mm
Tiny 181
Welding Electrodes
Available in different diameters
Unalloyed Electrodes
Stick Electrodes
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
GARANT BR (rutile-basic)
Special Electrodes
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)
Nickel-base Electrodes
acc. to DIN EN ISO 14172, AWS A 5.11
!
!
- 20 -
High-alloyed Electrodes
Surfacing Electrodes
Stick Electrodes
!
!
!
!
!
!
!
!
!
!
!
!
Special Electrodes
Fidur 10/70
!
!
!
!
!
!
!
FIDUR 7/200 (crack-resistant layers on hardmanganese steel, hardness 200 HB, workhardenable)
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)
Black-and-white electrodes
!
!
!
!
!
FINOX 4370 AC (for joint welding, also for hardmanganese steel with 18% Cr, 8% Ni, 6% Mn)
FINOX 4431 AC (for joint welding, also for hardmanganese 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)
!
!
!
Cutting Electrodes
!
!
- 21 -
Electrode Welding
Electrode Welding
InFocus-arc
Features
!
!
!
!
!
- 22 -
!
!
!
!
!
!
!
- 23 -
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.
- 24 -
Planning
04
07
Flange welding
10
02
Plate cutting
05
08
11
Colouring
03
Rolling
06
09
12
01
Process Principle
- 26 -
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
Technical Data
Art. No.
Mains voltage 100%
.11.150.202
3~400 V
+10 %/-10 %,
PEN 50 Hz
50 350
5 15
!
!
!
!
!
!
- 27 -
by
6.
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m
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Re lberg
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Kje
Accessories
! cap for template cuts
! bevel cap
! circle cutting attachment
! special consumables for cutting in corners (up
to 70 A)
Fields of Application
1)
Max.
cutting
current
Material thickness in mm
10
35 A
20
30
50
CUTi 35C
40 A
CUTi 40
70 A
CUTi 70
90 A
CUTi 90
120 A
CUTi 120
Recommended
cutting range2)
40
Maximum
cutting range2)
Technical Data
CUTi 35C
.11.035.704.
Power source
Art. No.
Mains connection
Connecting 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
CUTi 40
.11.035.304.
CUTi 70
.11.035.402.
CUTi 90
.11.035.502.
CUTi 120
.11.035.602.
1 x 230 V
1 x 230 V
3,3 kVA/4,8 kVA1)
6,5 kVA
16 A 16 A (safety socket)/
32 (CEE)
270 V
270 V
35 A (25% ED)
40 A (40% ED)
20 A (100% ED)
25 A (100% ED)
IP 23
IP 21
550 x 150 x 245
460 x 180 x 220
3 x 400 V
11,1 kVA
16 A
3 x 400 V
15 kVA
32 A
3 x 400 V
16,7 kVA
32 A
250 V
70 A (35% ED)
50 A (100% ED)
IP 21
470 x 180 x 250
320 V
90 A (40% ED)
55 A (100% ED)
IP 21
470 x 180 x 270
450 V
120 A (35% ED)
80 A (100% ED)
IP 23
610 x 230 x 410
115 l/min
130 l/min
140 l/min
195 l/min
195 l/min
air
air
air
air
air
5,0 bar (0,5 MPa)
5,0 bar (0,5 MPa)
5,0 bar (0,5 MPa)
5,0 bar (0,5 Mpa)
4,0 bar (0,4 MPa)1)
11,5 kg
16,4 kg
28,5 kg
17 kg
12,5 kg
PHT 31
PHT 31
PHT 51
PHT 51
PHT 25
consumables kit
consumables kit
consumables kit
consumables kit
consumables kit
filter pressure switch filter pressure switch filter pressure switch filter pressure switch filter pressure switch
- 28 -
CUTLINE Series
Versatile Applications
The 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.
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
The CUTLINE series can be used for cutting metals and other materials.
Technical Data
Type
Art. No.
Mains voltage, 50 Hz (V), 3 Ph.
Fuse, slow
CUTLINE 20G
.11.033.003.
CUTLINE 40G
.11.033.102.
CUTLINE 20W
.11.032.803.
CUTLINE 40W
.11.032.902.
230/400
400
230/400
400
35/25
500
25
16
IP 22
F
275
25/50
60
15
20
35
500
25
24
IP 22
F
275
50/100
60
30
40
84
670 x 490 x 880
PHT-30 W/L
132
820 x 490 x 880
PHT-45 W/L
35/25
500
25
16
IP 22
F
275
30/60
50
15
20
74
670 x 490 x 880
PHT-31 G/L
- 29 -
35
500
25
24
IP 22
F
275
60/120
50
30
40
air
high voltage
122
820 x 490 x 880
PHT-51 G/L
Plasma Technique
Appliances
RSV Series
For Pipeline and Container Welding
The 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.
On request, our Kjellberg standard products can also be produced according to customer specifications.
- 30 -
RSV Series
RSV 150
The RSV 150 is a mobile clamping device for pipe
welding. It was designed for the use on construction 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.
Technical Data
Weight: 110 kg
up to 130 cm/min
NW 20 NW 200
20 300 mm
150 Nm
300 kg
150 kg
50 Nm
220 V, 50 Hz
200 W
RSV 500
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).
Technical Data
Weight: 260 kg
- 31 -
up to 130 cm/min
NW 20 NW 400
25 1.000 mm
740 Nm
1.000 kg
500 kg
200 Nm
220 V, 50 Hz
400 W
Welding Periphery
Appliances
Appliances
RSV 1000
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.
Technical Data
Weight: 800 kg
Re
Kje nt qu
llb alit
erg y ! M ma
ore de
on by
pa
ge
4
6.
Art. No.
Dimensions L x W x H (mm)
Weight incl. battery and
torch holder:
Welding speed range
(others possible):
Track width:
Battery operation without
reloading (60% duty cycle):
Battery load time:
- 32 -
.11.301.100.100
290 x 190 x 170 mm
4,8 kg
10 125 cm/Min.
> 85 mm
> 16 h
< 25 Min.
Welding Periphery
Appliances
Welding Gantries/Travelling Carriages
General Technical Data
!
!
!
!
!
!
!
!
Model
Diameter
face plate
(mm)
Maximum
capacity
(kg)
Rotating speed
(revolutions/min.)
Maximum
welding
current (A)
Tilt-and-turn
angle
()
DK 50
300
20
06
400
135
DK 300
500
300
03
400
135
DK 500
650
500
0 2,5
400
135
DK 1500
1.000
1.500
0 1,5
600
135
DK 3000
1.100
3.000
01
600
135
DK 5000
1.500
5.000
01
600
135
DK 10000
1.200
10.000
01
600
135
- 33 -
Appliances
Column and Booms
General Technical Data
!
!
!
!
!
!
!
2) Dependent on size
Minimum
effective
height
below
boom (mm)
Maximum
effective
height
below
boom (mm)
Total height
(mm)
Boom length
(mm)
Boom speed
(mm/min)
Rotation
angle
()
Maximum
working
load (kg)
500
2.500
3.500
2.000
100 2.000
180
300
500
2.500
3.500
2.500
100 2.000
180
250
500
3.000
4.000
2.500
100 2.000
180
200
500
3.000
4.000
3.000
100 2.000
180
200
Model
Maximum
working
load of
drive unit
(kg)
Maximum
rotating
load of
drive unit
(kg)
Minimum
container
diameter
(mm)
Maximum
container
diameter
(mm)
Rotational
speed
(mm/min)
Roller
diameter
(mm)
Roller
width
(mm)
BDV 2000
1.000
2.000
200
2.500
75 1.500
250
120
BDV 5000
2.500
5.000
200
3.000
75 1.500
250
120
BDV 10000
5.000
10.000
300
4.000
75 1.500
415
200
BDV 15000
7.500
15.000
300
4.000
75 1.500
415
370
BDV 20000
10.000
20.000
300
4.500
75 1.500
415
370
Model
- 34 -
Application Advantages
Features
! 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
!
!
!
!
!
!
!
!
Technical Data
Strip welding head BSK 30-60
.11.300.810
strip welding
1.250
42 AC/50
30 60
500
275 x 145 x 350
30 (100)
20
Art. No.
Methode
Welding current max. (A)
Control voltage (V/Hz)
Strip width (mm)
Minimum diameter of inner pipe (mm)
Dimensions of welding head L x W x H (mm)
Weight of coil max. (mm)
Weight (without wire and flux)
- 35 -
Welding Periphery
Appliances
Travelling Carriage
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
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
Complete flux circuit with pressure conveying process, suction and pneumatic
flux barrier.
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
Plant with central control panel
Application Advantages
! 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
- 36 -
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)
Robot system with stable base frame which carries all plant components
Application Advantages
! 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
- 37 -
System Solutions
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
Performance
! 70 A/18 V up to 400 A/34 V at 100 % duty
cycle
! welding speed of up to 85 cm/min
! wire diameter up to 3.2 mm
Application Advantages
! 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
- 38 -
!
!
!
!
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
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
Application Advantages
! 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
- 39 -
System Solutions
Objective
! considerable reduction of working time by
regenerating grooved rails in mobile use onsite 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
Application Advantages
! 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
! wire diameter up to 2.5 mm
! build-up of layers in position PC
- 40 -
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
Application Advantages
! 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 operation
Performance
! wire diameter up to 3.2 mm
! welding speed up to 1 m/min
! rapid motion up to 6 m/min
- 41 -
System Solutions
Accessories
Torch Heads
Tandem welding heads
Water-cooled filler
wire torch
Keyhole torch
Plasma-transferred arc
welding torch
Accessories
Hand brush with wire
bristles
Standard chipping
hammer
Pneumatic chipping
hammer
Chisels
Welding helmet
Welding gloves
Safety at Work
- 42 -
Options
Accessories
Seam Tracking Systems
Tactile sensor
Laser scanner
Photo-optical monitoring
system
Circle cutting
attachment
- 43 -
by 46.
de age
a
p
m
y - re on
t
i
l
o
ua
t q rg! M
n
Re llbe
Kje
Suction nozzle
butt weld
- 44 -
Options
Turnable ground
connection
Other Options
- 45 -
Rental Service
Renting as Alternative
Maintenance downtimes and production peaks
are no longer a problem if you choose our rental
service.
Rental Conditions:
KA 1-UP (5 mm)
KA 1-UP (5 mm) with workpiece cable 10 m, 20 m hose
parcel extension and flux
recovery unit
GTH 1002
with 5 m
mains cable
and 125 A
CEE plug
Welding periphery
like column and boom
- 46 -
70 cm on the
submerged-arc track
Let yourself
be surprised!
Internet: www.kjellberg.de
and
are trademarks of the Kjellberg
Foundation or one of its affiliates and may be registered in
Germany and other countries.
Copyright
2012
Kjellberg Finsterwalde Schweitechnik und
Verschleischutzsysteme GmbH
All rights reserved.
12-01-11