Kjellberg Product Brochure en

Product Catalogue
Torch technology InFocus for laser-like joining

results; more on page 22
Welding Technique and

Wear Protection Systems
www.kjellberg.de
A determined person will find better use

for a single screwdriver than the waverer
for a whole shop of tools.
(Emil Oesch, Swiss writer and publisher, 1894 1974)
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
Special welding processes
Page
22
Industrial system supplier
Page
24
PTA and keyhole welding

Technology
Power sources
Page
Page
Page
26
26
27
Plasma cutting technique
Page
28
Welding periphery
Page
30
System solutions
Page
36
Options
Page
42
Rental service
Page
46
Submerged-arc welding sample
InFocus welding sample
PTA welding sample
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.
personnel and we also help preserve a unique

handicraft culture. In addition, we strengthen the
site and the attribute Made in Germany. Our
production includes all parts of our plants, from
planning to manufacture and programming.
Only in this way can we offer the quality which
our customers expect from us and which we
gladly provide. The Kjellberg Foundation is the
sole shareholder of all Kjellberg companies:
Today, we enjoy an international reputation as

manufacturer of highest-quality welding and
plasma cutting technique, welding electrodes
and excellent welding systems of every
discription.
!
!
Furthermore, the Kjellberg Group, run by the

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

Maschinen GmbH
Kjellberg Finsterwalde Elektroden und
Zusatzwerkstoffe GmbH
Kjellberg Finsterwalde Schweitechnik und
Verschleischutzsysteme GmbH
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.
high-tech processes have been developed out

of the beginnings of the plasma fusion cutting
process and the fine-focus plasma cutting
technology. Today, our technique can be used
for cutting everywhere, also underwater. Up to
now, our international success has also been
based on the steadily increasing flexibility, the
ever new possibilities of processing and the
increasing cutting speeds of our systems. And
the rising trend continues.
Made in Germany is one of our quality

attributes which is no empty promise but holds
true for every tiny part of our machines and
consumables. We develop and produce our
machines through our own efforts. The latest
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
Manual Plasma Cutting Units
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
Please find a selection of plasma

products on pages 28, 29 and 43.
Accessories and Consumables
!
!
-5-
accessories for marking, height control,

tractor guiding and torch changing
nozzle caps, cathodes, etc.
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.
You will find welding electrodes on

pages 20 and 21.
-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
conditions. No matter whether you are looking

for special welding systems for large production
processes, compact units for manual use or
whether you need thermal tools for your art and
hobby: Kjellberg offers the optimum solution
from the welding unit itself to spare parts and
consumables. We consider it as a matter of
course that we support you from the initial idea
through to the approval, if you wish so.
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
column and booms, gantries and rotating

devices produced and installed according to
customer requirements
The submerged-arc welding method ensures a clean welding process due to

the flux-covered arc.
Complex Plants
For more information about the welding

technique product portfolio please see the
following pages.
with different components from our portfolio
-7-
Business Divisions
Automated Submerged-Arc Welding

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

wear and corrosion protection layers steels as
well as chromium-nickel steels can be welded.
The process can be used as fully automated,
mechanised or manual solution with hand
torches and achieves uninterrupted, long welds
at high speeds and low costs.
On request, we install the Kjellberg SA welding

technique on gantries, column and booms,
motor-driven axle systems or carriages. Its
modular design and diverse support systems
allow the welding of numerous different workpieces and seam geometries, e.g. in
shipbuilding, bridge and steel construction or in
container production. SA welding can be used
efficiently for material thicknesses from 6 mm.
Process Principle
Quelle: DVS
-8-
Standard Automats of the KA Series

Type/Art. no.
Picture
Max.
welding current
Method
Wire Recommended
diameter (mm) power sources
KA 1-UP
3mm: .11.300.103
Single-wire SA welding tractor

for different wire diameters
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
Single-wire SA welding tractor

for container and inner tube
welding (e. g. windmill towers)
KA 2-UP/UPP
3mm: .11.300.203
5mm: .11.300.205
2x3mm: .11.300.270
Single-wire welding head (also

available as parallel-wire SA
welding head for installation on
column and booms, gantries
etc. in this or other assembled
forms, also without carriage) for
different wire diameters
1.400 A
1.400 A 2x 2,0 2x 3,0
GTH 802
GTH 1002
GTH 1402
GTH 1002
GTH 1402
KA 4-UPDG
.11.300.400
SA welding tractor with two

articulated arms (welding of two
fillet or butt welds
simultaneously)
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
Parallel-wire SA welding tractor

(also available with automatic
steering system)
1.400 A 2x 2,0 2x 3,0
GTH 1002
GTH 1402
1,64,0
GTH 802
UPK
.11.300.104
SA fillet welding
800 A
-9-
by
6.
ade age 4
m
np
ty uali More o
q
t
Ren lberg!
l
Kje
Submerged-Arc Welding

Variable Automats for Applications
Welding Tasks
T-Beam
Box girder
Double T-Beam
Butt weld joint
Container,
longitudinal weld
Container,
circular weld
(inside and outside)
Cladding
Advantages of Application Solutions

The flexible modular concept of the KA series is
the basis for different technological system
solutions in the area of welding automation
technology.
In combination with the welding power sources
made by Kjellberg, there are numerous
possibilities for customized solutions which
guarantee an effective use in the industry, like
welding gantries and equipment for column and
booms. Please see pages 36 to 41 for some
application examples.
6
7
8
9
10
11
12
5
- 10 -
High welding quality due to stable speedometer-controlled wire feeding
!
!
!
with four-wheel drive for wires up to diameter 3 mm (SAW and GMAW)

for wires from diameter 2,5 - 5 mm for single-wire SA welding (KA 1-UP), for parallel wire (KA 7-UPP)
diameter 2 x 2.0 up to 2 x 3.0
as double drive for welding with two articulated arms KA 4-UPDG up to 2 x 2.5 mm wire diameter
Flexible, technological use due to
Fixed welding head, pivoting to the side and for piercing and dragging fillet welding (KA 1-UP)
Welding head as drag arm (KA 4-UPDG)
! long lifetime at welding currents of up to 1,400 A (KA 1-UP, KA 7-UPP)

! convertible for narrow-gap welding with screwing nozzles (KA 1-UP)
! convertible to KA 7-UPP (parallel wire)
! reliable, mechanical seam tracking; cost-efficient compared to complex electronic sensors
! UP diameter 2 x 1.6 up to 2 x 2.5
Visual seam tracking with laser cross
Quick positioning of the welding head due to manual linear axes (effective adjustment
track per 100 mm)
Further increase of the stability possible with optional axle extensions
Minimisation of auxiliary times due to optional accessories: pneumatic flux recovery unit
(low-wear injection principle)
High transportation safety due to protected eye hooks
Easy to handle, comfortable control unit with
Support of wire coil up to max. 30 kg (ISO K 435)
!
!
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
Safe guidance of the carriage
12
Safe drive of the carriage due to
Along profiles, webs, flanges and, on request, suitable for rails due to stepless adjustable supporting rolls
!
!
!
!
speedometer-controlled all-wheel drive from 0.1 to 1.6 m/min

rubber or keyway wheels with a diameter of 160 mm
dust-protected manual clutch for releasing the drive
temperature-resistant rubber wheels (up to 200C)
- 11 -
Submerged-Arc Welding

Power Sources
Type
Art. no.
Characteristic
Mains voltage
Connecting power acc. to EN 60974-1
Mains connection
Welding current range
60 %
80 %
100 %
Protection class
Weight
Dimensions L x W x H (mm)
Type
Art. no.
Characteristic
Mains voltage
Mains connection
25 %
40 %
100 %
Protection class
Weight
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
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
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
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
Mains connection
25 %
40 %
100 %
Protection class
Weight
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
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
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
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

80 %
100 %
Protection class
Weight
GTF 1002
GTF 752
.11.903.202C
.11.705.602
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)
(with carriage for construction sites)
GTF 1402
.11.903.702C
y
de b ge 46.
a
m
pa
ty uali ore on
q
t
Ren berg! M
l
Kjel
- 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
for windmill towers or large connecting pieces

for containers and pipes.
The DV UP-H is also compatible with the minicarriage KMF on page 32.
Wire feeding unit DV UP-H with power source GTH 522,

pressure tank, SAW torch UP-H 500 and mini-carriage
KMF.
Advantages of the Equipment:
!
!
!
!
!
!
!
!
!
!
Technical Data
suited for all welding power sources of the

GTH series
easy to handle torch
flux supply with external, mobile pressure
tank, manual lock at hand torch
robust four-wheel wire feeder with constant
contact pressure
suited for solid and filler wires
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
operation
protected electronics
current-less wire threading and return
existing GTH power sources can be
retrofitted
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
- 13 -
according to power source

400 A
according to power source
1 16 m/min
max. 300 mm
(option K 435)
0,6 2,0 mm
0,8 2,0 mm
1,0 2,4 mm
1,2 and 1,6 mm (steel)
IP 23
25 kg
710 x 250 x 500 mm
Submerged-arc Welding
Manual 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.
Our latest pulsed welding units remove the filler

material drop by drop and short-circuit-free.
They master complex current flows perfectly.
The results are clean and nearly spatter-free
welds. A low heat input reduces the material
distortion. All these are reasons to choose a
welding system made by Kjellberg Finsterwalde.
KH600 newArc
The systems offer a large number of process

variants:
MIG/MAG pulse welding
un-pulsed MIG/MAG welding with short arc
or spray arc
MAG welding with gas-protected and with
self-protecting filler wires (also with negative
pole)
high-performance welding at standard wire
feeding speeds of up to 20 m/min
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.
KH600 newArc in use
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
!
!
!
!
!
!
The result: a narrow and nearly perfect welded

joint.
Technological Advantage of newArc

Spray arc
newArc technology
40 mm
15 mm
25-30
ca. 60
20 mm
7 layers
Heat-affected zone
high process reliability, also in narrow weld

grooves and on complex parts with material
thickness from 6.0 mm
high quality due to stable root formation and
optimum joining of the edge
quicker welding compared to joining with spray
arc
reduced heat input and energy input per unit
length
- 15 -
3 layers
weld cross-sections reduced by up to 50%

work-piece with nearly no undercuts and pores
improved appearance of the weld
easy to handle
fewer welding layers
concentrated and stable arc
reduced costs, reduced welding time
MIG Welding
Kjellberg Technology newArc
Kjellberg Technology newArc

Power Source 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.
Absence of
spatters
Nearly spatter-free pulse arc welding due to short-circuit-free drop transfer

with synergistic behaviour within the entire welding range and low-spatter short arc welding
and spray arc welding as well as rotation arc welding for
! steel, CrNi and aluminium as well as
! argon and mixed gases, consisting of Ar, CO2, He and O2
! all solid wires and filler wires (also with negative pole)
Welding
properties
! high process reliability due to optimised control loop

! programmes for hard and soft arc dynamics
! constant wire feeding due to electronically controlled four-wheel wire feed
Hot-Start
Indispensable for the processing of aluminium
Pulse frequency synergistically self-adjusting 10 to 500 Hz

crater filling
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
To avoid excess temperature, insulation faults and water shortage
Water recirculation cooling
integrated, with flow meter in the cooling water return (not only pressure switch!) for a safe
welding operation
Hose parcel
extension
optionally with a length of up to 40 m
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
K350 including wire feeding unit

DVG-K01, Art. no.: 11.746.000
! L 635 x W 360 x H 520 mm

! 4 wire feeding rollers
! Protection class IP 21, weight 18 kg
Working with Regard to Practical

and Ergonomic considerations
Always on The Safe Side
!
!
!
!
!
!
!
!
!
!
!
ideally suited for workshops for welding with

gas-cooled GMAW torches (L: 3 m)
flexibly adjustable; therefore high seam
quality
excellent welding properties when using
mixed gas
user-friendly operation due to simple
switching mechanism
robust feed gear mechanism for safe wire
feeding
side panel folding for change of wire roll
space-saving and large practical tray
accessories are ready to hand at any time
easy transportation on stable rolls
wear-free electronic control
gas bottle holder; stable carriage due to low
centre of gravity (max. 20 l bottle)
!
!
!
according to EN 60974 and BGV-D1

S sign for electrical safety allows welding
under increased electrical hazard
all transformers and throttles in the vacuum
impregnated with high-quality electrical
insulation coating and therefore absolutely
insulated
powerful fans for effective cooling under all
operating conditions
thermal overload protection for reliable
operation
All you Need in One Package

All welding units are equipped with 3 m work-piece
cable, GMAW torch (3 m), gas hose, pressure
regulator, basket coil adapter and basic
consumables kit for all listed wire diameters.
- 17 -
MIG Welding
For Workshops and Medium-Sized Companies
Power Sources for the Industry

PULS 400
Suited for welding of:
! construction steel
! CrNi
! aluminium, aluminium alloys
When using the pulsed power source, the user

can choose between the three welding
processes GMAW, GMAW pulse and E-manual
welding. The PULS 400 is mobile on rolls and
weighs only 45 kg which makes it suited for
different welding tasks in the automotive
industry, in shipbuilding and engineering.
Area of Use
light industry
heavy industry
especially demanding processes
!
!
!
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
PULS 400 with digital

regulation
Technical Data
Art. No.
Connecting voltage
Welding voltage
Duty cycle
50 %
100 %
Weight
.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
TIG 300 AC/DC

Features
! up to 100 welding programmes can be
programmed and stored
! digital display of all functions
! high-frequency ignition without contact
! two-stroke and four-stroke operation
! start, main and end current adjustable
! Hot Start and Anti Sticking functions
An excellent seam quality can be achieved with

the TIG power source TIG 300
AC/DC. On the digital display the user can see
and control all functions at any time.
TIG with digital

regulation
Technical Data
Art. No.
Connecting voltage
WIG DC
WIG AC, AC/DC
MMA (REO) DC
Welding voltage
Duty cycle
40 %
60 %
100 %
Weight
- 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
1 x 230 V/1 x 400 V

50/60 Hz
2,0/2,4
16/16
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.
Mains voltage (V)

Connecting power 100% (kVA)
Fuse, slow (A)
Welding current range I2
20 % duty cycle (A)
35 % duty cycle (A)
45 % duty cycle (A)
60 % duty cycle (A)
100 % duty cycle (A)
Welding current range (A)
Welding voltage range (V)
Open circuit voltage (V)
Number of voltage levels
Wire diameter (e.g. steel in mm)
Number of wire feeding rollers
Protection class
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
Mains connection
25 %
40 %
100 %
Protection class
Weight
.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
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)
705 x 240 x 445
850 x 350 x 290
Wire feeding units

Art. No.
Wire diameter
Steel, stainless steel
Aluminium
Filler wire
Wire feeding speed
Weight
Two-stroke/four-stroke operation
Four-stroke + Hot-Start + crater filling functions
Welding current adjustable
Arc length adjustable
Free-burning adjustable
Button for wire feed (current-less)
= Standard
KH 600
GTH 522 W
.11.907.702
1) advantageous via remote control FSH 30
2) art. no. .11.745.600A for high-performance welding
- 19 -
6.
by
de age 4
a
p
-m
ity re on
l
a
o
qu
nt erg! M
e
R llb
Kje
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

60 %
100 %
Electrode diameter
Welding current regulation
Weight
.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
High-temperature Stick Electrodes
acc. to DIN EN ISO 2560-A, DIN 1913, AWS A 5.1
acc. to DIN EN 1599, DIN 8575, AWS A 5.5
Stick Electrodes
For Welding of Identical and Similar Steels
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
LLOYD (rutile for shipbuilding)

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

acc. to DIN EN ISO 1071, DIN 8573, AWS A 5.15
!
!
Double Coated Electrodes
GARANT BR (rutile-basic)
Special Electrodes
KOMPLEX W (rutile, 0.5% Mo)

IMPULS (basic, 0.6% Ni and 0.4% Mo)
MOB (basc, 0,5 % Mo)
CROMO 1R (rutile, 1 % Cr and 0,5 % Mo)
CROMO 1B (basic, 1 % Cr and 0,5 % Mo)
CROMO 2B (basic, 2,2 % Cr and 1% Mo)
TRUMPF (acid-coated)
FICAST Ni (pure nickel electrode, for cold welding

of cast iron)
FICAST NiFe (nickel-iron, for cold welding of grey
cast iron, malleable and spheroidal cast iron)
FICAST NiFe K (with copper-plated NiFe core for
cold welding of grey cast iron, malleable and
spheroidal cast iron)
FICAST Fe (for buffering layers and single-layer
surfacing on scaled or corroded iron castings)
General Purpose Electrodes
!
!
!
!
!
!
!
!
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 -
FINOX 182 (alloy class 182, nickel-chromium-iron)

FINOX 625 (alloy class 625, nickel-chromiummolybdenum)
High-alloyed Electrodes
Surfacing Electrodes
acc. to DIN EN 14700, DIN 8555
acc. ton DIN EN 1600, DIN 8556
Stick Electrodes
!
!
!
!
!
!
!
!
!
!
FINOX 4820 AC (26 % Cr, 4 % Ni)

FINOX 4842 (26 % Cr, 20 % Ni)
FINOX 4842 B (26 % Cr, 20 % Ni, basic)
FINOX 4829 AC (22 % Cr, 12 % Ni)
FINOX 4316 AC (19 % Cr, 9 % Ni)
FINOX 4551 AC (19 % Cr, 9 % Ni, niobiumstabilised)
FINOX 4551 B (19 % Cr, 9 % Ni, niobium-stabilised,
basic with high toughness)
FINOX 4430 AC (19 % Cr, 12 % Ni, 3 % Mo)
FINOX 4576 AC (19 % Cr, 12 % Ni, 3 % Mo,
niobium-stabilised)
FINOX 4519 AC (20 % Cr, 25 % Ni, 5 % Mo and
copper)
!
!
For Tough-hard/Abrasion-proof Layers
Special Electrodes
Fidur 10/70
!
!
FINOX 4430 F (for vertical down position; 19% Cr,

12% Ni,3% Mo)
FINOX 4462 AC (for duplex steels of the alloy 22%
Cr, 9% Ni, 3% Mo)
FINOX 29/9 GOLD (for crack-resistant joints with
30% Cr, 9.5% Ni, 1% Mn)
FIDUR 6/55 (for low-alloyed and unalloyed steels,

hardness 55 HRC)
FIDUR 6/60 (hardness 60 HRC)
FIDUR 6/60 R (rutile, hardness 60 HRC, suitable
for AC current)
FIDUR 2/55 (for low-alloyed and unalloyed steels,
good edge-holding properties, hardness 55 HRC)
For Wear-resistant, Stainless Layers
!
!
!
!
!
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)
Other Surfacing Processes

Finox 4370 AC
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
!
!
MET-OX (for cutting)

KJELGOUGE (for gouging)
- 21 -
FIDUR 1/300 (Mo- and V-alloyed, hardness 300

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

Technological Advantage of InFocus
The torch technology InFocus achieves laserlike joining results. It is excellently suited for
joining very thin sheets and nearly all metals.
The welding results impress with an excellent
seam surface and low oxide formation.
The adoption of a cold wire feeding unit offers

the possibility to compensate minor part and
position tolerances. The tool centre point
guarantees the best conditions for exactly
reproducible welding results.
InFocus is exclusively used for fully automated

processes. One of its main features is a high
process reliability at a welding speed of up to 7
m/min.
Our InFocus system is the economic alternative

to GMA welding due to nearly spatter-free
results and the high welding speed.
Considerably lower investment and operating
costs compared to laser welding is an additional
advantage.
InFocus in Comparison to Conventional WIG Welding

Simulation at a voltage of 500 A and an arc length of 5 mm with argon
Source: M.Schnick, TU Dresden
InFocus-arc
Conventional WIG arc
The concentrated arc starting point on the

electrode tip of the InFocus torch creates an
increased energy density and a higher back
pressure which guarantees especially good
welding and soldering results.
Features
!
!
!
!
!
stable torch design (robust and shock-resistant)

axial torch fixing
closed cooling circuit
very high current capacity
screw-in electrode
- 22 -
Advantages at One Glance

InFocus Welding Torch 1.000 A
!
!
!
!
!
!
!
practical, robust design

high back pressure
for welding and soldering
high energy density, compact size
high joining speeds
excellent gas protection
low electrode wear
- 23 -
Special Welding Processes
High-Performance Joining Process
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
Outside longitudinal seam welding
07
Flange welding
10
Cutting and welding
02
Plate cutting
05
Inside longitudinal seam welding
08
Inside circular seam welding
11
Colouring
03
Rolling
06
Tacking segments and assembly
09
Outside circular seam welding
12
Assembly and installation
Providing Complete Systems
01
Plasma-transferred Arc Welding

Technology
Plasma-transferred Arc Welding (PTA)
Features
! surfacing of hard/wear-resistant and/or
corrosion-resistant layers onto small parts
which are difficult to apply with wire
! voltages up to 300 A
The mostly mechanised plasma-transferred arc

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

! low and high-alloyed materials
! cast iron and bronze
! nickel-base alloys
Another big advantage shows with regard to the

supply of powdery filler materials which we
gladly compose according to your specifications. They are added directly through the
plasma torch, merge almost completely with the
base material and, thus, allow the use of
materials which cannot be drawn into wires.
Plasma Keyhole Welding

Features
! used for longitudinal and circular seam
welding, containers and bottoms
! no additional seam preparation on the nearly
parallel work-piece edges: lower amount of
work compared to other processes
! low heat input and less distortion
! cost-efficient because little or no additional
material is needed
Process Principle
- 26 -
Welding Inverter PSI 350

With the PSI 350 Kjellberg Finsterwalde offers a
high-quality and flexible unit for plasma-transferred
arc welding as well as for plasma keyhole welding.
Both methods can easily be automated with the
integrated PLC.
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
Welding current range (A)

100 % duty cycle
Pilot current (A)
PSI 350 welding sample
50 350
5 15
Methode at one glance

Advantages
!
!
!
!
!
!
very low dilution with the base material

very small heat-affected zone
high deposition rate
genuine metallurgical bond between base and
filler material
easy to produce filler material mixture in
powder form according to the requirements
high reproducibility of the results due to high
degree of automation
Pipe welding with the PSI 350
- 27 -
by
6.
ade age 4
m
p
on
lity
qua ! More
t
n
Re lberg
l
Kje
PTA and Keyhole Welding
Plasma-transferred Arc Welding
Manual Plasma Cutting

Cutting Inverters of the CUTi Series
From the plasma units of the CUTi product line
for manual and mechanised cutting users can
choose the right unit for their demands and
requirements.
CUTI 40, 90 and 120
The cutting current can be adjusted step-less.

That's why the modern inverter technique
achieves excellent cut results suited with all
electrically conductive materials.
Features
! excellent price-performance ratio
! productive due to high cutting speeds
! low energy consumption due to inverter
technique
! cost-efficient cutting with air as cutting gas
! quick change of cathode and nozzle due to
consumables supply in the consumables kit
(standard accessory)
! easy handling due to light weight
! central torch connection with safety switch-off
allows quick torch exchange and easy
transport
! CUTi 40 in connection with an adapter can be
connected to a safety socket (16 A) with
reduced cutting current of max. 30 A
! suited for the use in environments with
increased hazard of electric shock
! maintenance unit for safe removal of
condensed water from the cutting gas
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)
1) The CUTi 35C is equipped with a fixed torch.

2) Details dependent on materials and their composition.
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
1) with external compressed air supply
- 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.
Plasma gouging with the CUTLINE series is a

clean alternative to gouging with carbon
electrodes no regrinding is necessary. The
heat input is minimal. The low noise level as
well as reduced smoke emission are further
advantages.
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
SPECIALmains voltage, 50 Hz (V)

VERSION
mains voltage, inert (A)
Connecting power (kVA)
Protection class
Insulation class
Cutting current (A)
Duty cycle (%)
1)
Cutting thickness
quality cut in mm
separating cut in mm
Plasma gas
Ignition
Weight (kg)
Suitable torch (air or gas-cooled)
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
1) Material-dependent, standard qualities
- 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
Manual Plasma Cutting
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.
The infinitely adjustable rotating speed allows

welding independent of the work-piece diameter.
A manual tilting function is standard in all
appliances. A tilt-up is possible with a maximum
angle of 135 so that work-pieces can be
processed in optimum position. Optionally, the
tilting drive is also available with electric motor.
The tiltable component consists of drive box,
roller box, clamping bar, clamping arm and
clamping roller.
Work-pieces can be produced without

interruption for calibration or seam interruption if clamped in identical position. During the
production process, no time and no additional
employees are needed anymore for turning and
recalibration for identical work-pieces.
The Kjellberg clamping devices operate on the
basis of the roller clamping principle, i.e. the
work-piece is positioned between two driving
rollers and one pressure roller. Thus, centric
clamping even of curved work-pieces can easily
and quickly be done.
The welding appliance RSV can be used in

combination with the KH 600 newArc.
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
Rotating speed infinitely

work-piece diameter clamped:
work-piece diameter unclamped:
Max. turning moment
Max. capacity
at horizontal roller position:
at vertical roller position:
Torque at the drive roller:
Mains connection:
Power requirements:
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

Max. turning moment
Max. capacity
Max. turning moment:
Mains connection:
Power requirements:
- 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

up to 130 cm/min
NW 25 NW 800
30 2.000 mm
Max. turning moment
3.430 Nm
Max. capacity:
2.000 kg
1.000 kg
Torque at the drive roller:
490 Nm
Mains connection:
380 V (220 V), 50/60 Hz
Power requirements:
1,5 KW
Mini-carriage KMF with Magnetic System
The KMF is self-positioning due to a permanent magnetic system.
The welding carriage KMF for GMAW and SAW

hand torches is effective, flexible and can also be
used efficiently for piece and serial production. It is
suited for all seam types and welding positions,
except for PD and PE. It is self-positioning due to
electronic speed control and permanent magnetic
system with a strength of more than 180 Newton
(in case of ferromagnetic materials). Thanks to a
long battery life the KMF can operate more than
two shifts. The mechanical feed and the exact torch
guidance guarantee the highest reproducibility and
quality of the welded seams. The KMF is equipped
with lateral guide rollers so that the machine can be
positioned at the web plate and aligns
independently.
Technical Data
Re
Kje nt qu
llb alit
erg y ! M ma
ore de
on by
pa
ge
4
6.
Art. No.
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
!
!
!
Customer-specific welding gantry
always customer-specific solution with energy

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

!
!
!
!
!
all data regarding the capacity relate to a 200

mm distance from the face plate
rotating speed infinitely adjustable
face plate with a diameter from 300 mm
control via foot pedal, from work-piece weight
of more than 500 kg with hand control unit
optional clamping device from a diameter of
25 mm and turnable ground connection
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
!
!
!
!
!
!
!
version with rectangular pipe with guide rails

stationary version
turnable1) 360 manual fixing device
boom speed 10 200 cm/min
fixed lifting speed 150 cm/min
Version with safety arrester
optionally with motor-driven carriage, track width
from 1.435 mm2)
1) Please note cable feed
2) Dependent on size
Column and boom produced on customer request
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)
KSM 2,5 x 2,0
500
2.500
3.500
2.000
100 2.000
180
300
KSM 2,5 x 2,5
500
2.500
3.500
2.500
100 2.000
180
250
KSM 3,0 x 2,5
500
3.000
4.000
2.500
100 2.000
180
200
KSM 3,0 x 3,0
500
3.000
4.000
3.000
100 2.000
180
200
Model
Other sizes on request
Roller Block Rotating Device

! drive and idler unit arranged in pairs (pair of
section)
! manual or optionally motor-driven
! diameter adjustment
! hand control unit
! stationary (standard) or mobile (optionally)
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
Other sizes on request
- 34 -
Strip Welding Head BSK 30-60

Strip welding head for welding sheets, inside
and outside of pipes
This welding head is used for slag welding and

SA strip welding on strips with a width between
30 and 60 mm.
It is also used for applying corrosion and wear
protection layers. It is possible to adapt this
welding head to guiding devices, i.e. welding
gantries, column and booms, linear guides etc.
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
!
!
!
!
!
!
!
!
high deposition rate

low dilution rate of only approx. 10%
high-quality functional layers can be applied to
cost-efficient base materials
depending on the additional material, corrosion
or wear protection layers are possible
the required chemical composition or desired
degree of hardness of the work-piece surface
can often be achieved already with the first
layer
used for welding of sheets, inside and outside
of pipes
economic surface welding with high deposition
rate
versatile applications as protection against
corrosion in pipe and container production as
well as against wear in the steel and cement
industry
Technical Data
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
! 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 -
Example: Production of Steel Profile Beams

Application Example
! fillet welding on beams and profiles up to a
throat thickness of 8 mm
! GMA welding with the newArc technology
! profile size up to 450 x 450 x 570 mm
Features
! robot application with turnover positioner
! welding of one part and positioning of a second
part at the same time
! multi-layer welding on thick-walled parts
Objective
! realisation of complex part geometries by
using robot technology
! at the same time pre-defined positioning of
parts to minimise auxiliary process time
! storing parameter records in the control unit
Fillet welding with robot system
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
! 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
Robot Welding System
Fully Mechanised SAW Plant

Example: Container Welding Plant
Type SOL
Application Example
! joint welding of rolled steel plates
! circular and longitudinal seams (two separate
plants)
! SA welding of sheets with a thickness from 3
mm
! container diameter max. 800 mm
! container length 1.800 2.300 mm
Features
! massive base frame with two linear axis
combinations and container turnover device
for parallel circular welding
! massive base frame with holding mandrel,
roller guide-way and support combination for
longitudinal welding
Container welding plant for circular and longitudinal welding
Objective
! considerable increase of productivity due to
fully mechanised production of complete
containers
! considerable increase in quality because no
influences of manual welding anymore
! flexible applications due to suitability for
production of boilers of different sizes
Plant Components
! welding power sources, type GTH 522
! single-wire SA welding heads, each with
optical seam tracking
! operating panels for control of welding
process
! pneumatic flux circuits
Nearly spatter-free welding due to submerged-arc technology
Performance
! 70 A/18 V up to 400 A/34 V at 100 % duty
cycle
! welding speed of up to 85 cm/min
! 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 -
Example: Container Surface Welding Plant

Application Example
welding of containers and pipes
circular and longitudinal seams
SA welding with wire diameter of up to 5 mm
work-piece diameter 1.000 mm 4.000 mm
!
!
!
!
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
Column and boom with a size of 5 x 6 m
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
Complete system with rails
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
! 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
Mobile Column and Boom
Fully Mechanised Automat

Example: Rail Surface Welding Plant
For surface welding on rails
Application Example
! surface welding on grooved rails for
regeneration purposes
! SA welding
! build-up of layers on vertical groove sides
! material: rail steel
Features
! optional use of solid wire or filler wire
electrodes
! adjustment possible to a maximum track
width of 1.500 mm according to each rail type
! splash-proof housing of wire feeding unit
Mobility due to fully automated plant technology
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
Surface welding on grooved rails
! saves production and auxiliary process time
! mechanised surface welding on left or right
groove side without re-positioning of the plant
! stable welded construction as version with
six wheels
! minimum flux loss and long welding paths
can be realised due to pneumatic flux
recovery
! flexible and light due to rubber wheels and
their use with electric lifting cylinder
Performance
! 80 A/18 V up to 720 A/44 V at 100 % duty
cycle
! welding speed up to 70 cm/min
! build-up of layers in position PC
- 40 -
Example: Fully Mechanised Surface Welding

Application Example
! surface welding on plates
! filler wire welding/SA welding
! maximum plate size 1.500 mm x 3.000 mm
Features
! optionally filler wire welding or SA welding
! welding gantry as stable steel construction
with a range of 3.500 mm
! rail length 6.000 mm
! two linear carriages on a continuous lateral
axis with a travel way of 3.000 mm
! maximum oscillation width of each welding
head 80 mm
! fume suction directly at the weld
! dust-proof version of the entire plant
including axes and switch cabinet
Plant with two linear carriages on a lateral axis
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
Rail length from 6.000 mm
! 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
! welding speed up to 1 m/min
! rapid motion up to 6 m/min
- 41 -
System Solutions
Surface Welding Plant
Accessories
Torch Heads
Tandem welding heads
Water-cooled filler
wire torch
Keyhole torch
Welding head for pipe

Insides
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
Visual with laser

pointer
Inductive sensor laser

scanning
Laser scanner
Photo-optical monitoring
system
Flux Supply Systems

Pressure tank 50 and
100 litres (heated)
Pneumatic flux recovery

as injector system
Plasma Cutting Technique

Further accessories on request
Plasma torch KjellCut for

the CUTi series
Circle cutting
attachment
Bevel cutting device
Plasma travel unit
- 43 -
by 46.
de age
a
p
m
y - re on
t
i
l
o
ua
t q rg! M
n
Re llbe
Kje
Spare parts and consumables

Spare Parts and Consumables
Suction nozzle fillet weld
right and left
Suction nozzle
butt weld
Current contact nozzle

UPP long
Flat nozzle, straight

or 5 angled
Current contact nozzle

UPP
SAW Current contact

nozzles and flux caps
Additional current nozzles and consumables on

request and according to customer requirements
Narrow-gap system, wire with a

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

a diameter of up to 5 mm
SAW nozzle holder narrow-gap, wire with

a diameter of up to 3 mm
- 44 -
Options

Kjellberg filter bags
(available with several
connection diameters)
Flux tank 6 and 10

litres
Control panel for special

plants
Touch screen control

panel
Turnable ground
connection
Cooling unit KWE 750
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:
! minimum term of rent: one calendar week

! delivery, collection and instruction are
optional
Of course we offer advice and delivery as well

as detailed instruction and collection after the
job is done. The fields of application and the
possible combinations of our offer are as
diverse as are your demands on Kjellberg.
That's why you can inquire after exact rental
fees by telephone and online by using our
contact form.
! advice and offers are free of charge and not

binding
Contact person: Mr. Manuel Kornek

Telephone: +49 3531 500-319
Example Rental Set
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
Consumables kit and

welding periphery
like roller block
Welding periphery
like column and boom
- 46 -
What is needed for being effective is competence

gained through exercise.
(Peter F. Drucker, American teacher of management, publicist and
consultant of Austrian origin, 1909 2005)
Since 1922, we have found the right solutions

with the production of
welding electrodes, welding technique and plasma cutting technique.
We have a long tradition.
Advice With Know-how
Would you like to learn more? We will be happy

to send you further information and to offer you
consultations, also on site in your company of
course completely without obligation.
Please contact our qualified specialist staff by
telephone +49 3531 500-319 or email:
schweissen@kjellberg.de.
Many of our offers are custom-made products

which are especially fitted to the requirements
and wishes of our customers. We also fulfil
extraordinary requests! Try us: you can rely on
the Kjellberg engineers who will find the right
solution for you.
70 cm on the
submerged-arc track
Let yourself
be surprised!
Our products represent a high level of quality and reliability.

We reserve the right to change the design and/or technical
specification during the series fabrication. Claims of any kind
cannot be derived from this brochure.
DE-03238 Finsterwalde Leipziger Strae 66-68

Phone: +49 3531 500-319 Fax: +49 3531 500-357
DE-58453 Witten
Stockumer Strae 28
Phone: +49 2302 2025-940 Fax: +49 2302 2025-945
Mail: schweissen@kjellberg.de
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
All rights reserved.
12-01-11


Kjellberg Product Brochure en

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Kjellberg Product Brochure en

Hochgeladen von

Copyright:

Verfügbare Formate

Product Catalogue

Torch technology InFocus for laser-like joining

Welding Technique and

A determined person will find better use

Special welding processes

Industrial system supplier

PTA and keyhole welding

Plasma cutting technique

Submerged-arc welding sample

InFocus welding sample

PTA welding sample

personnel and we also help preserve a unique

Today, we enjoy an international reputation as

Furthermore, the Kjellberg Group, run by the

Kjellberg Finsterwalde Plasma und

high-tech processes have been developed out

Made in Germany is one of our quality

Manual Plasma Cutting Units

Please find a selection of plasma

Accessories and Consumables

accessories for marking, height control,

You will find welding electrodes on

conditions. No matter whether you are looking

column and booms, gantries and rotating

The submerged-arc welding method ensures a clean welding process due to

For more information about the welding

with different components from our portfolio

Automated Submerged-Arc Welding

It is also suited for joint welding or for applying

On request, we install the Kjellberg SA welding

Standard Automats of the KA Series

Single-wire SA welding tractor

Single-wire SA welding tractor

Single-wire welding head (also

1.400 A 2x 2,0 2x 3,0

SA welding tractor with two

Parallel-wire SA welding tractor

1.400 A 2x 2,0 2x 3,0

Automated Submerged-Arc Welding

Automated Submerged-Arc Welding

Butt weld joint

Advantages of Application Solutions

High welding quality due to stable speedometer-controlled wire feeding

with four-wheel drive for wires up to diameter 3 mm (SAW and GMAW)

Flexible, technological use due to

Welding head as drag arm (KA 4-UPDG)

! long lifetime at welding currents of up to 1,400 A (KA 1-UP, KA 7-UPP)

Visual seam tracking with laser cross

Further increase of the stability possible with optional axle extensions

High transportation safety due to protected eye hooks

Easy to handle, comfortable control unit with

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

Safe guidance of the carriage

Safe drive of the carriage due to

speedometer-controlled all-wheel drive from 0.1 to 1.6 m/min

Automated Submerged-Arc Welding

Automated Submerged-Arc Welding

Welding current range

(with carriage for construction sites)

for windmill towers or large connecting pieces

Wire feeding unit DV UP-H with power source GTH 522,

Advantages of the Equipment:

suited for all welding power sources of the