Kemper ProfiMaster KE 60650100, Manual, Page: 9 / 45

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Page: 9 / 45

Kemper ProfiMaster KE 60650100 Manual Download Page 9

KEMPER ProfiMaster Manual

EN

Art. No.: 150 2121

- 5 -

Rev.:

1

Subject to technical modifications and errors.

Issued: 10/2013

2.5 Safety instructions for maintaining and troubleshooting the

ProfiMaster

Setting up, maintenance and repair work and troubleshooting must only be
performed when the system is off.

During maintenance and repair work, always tighten the loose screw! If required,
tighten the relevant screws with a torque wrench.

In particular, clean connections and fittings from dirt or any corrosion inhibitors before
starting maintenance/repair/care.

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Summary of Contents for ProfiMaster KE 60650100

Page 1: ...ding Kemper ProfiMaster KE 60650100 KE 60650101 KE 60650102 MSH equipment Appelmarkt 7 1681 PE Zwaagdijk Oost Tel 0228 561100 Fax 0228 561112 Mail info msh equipment nl Website www msh equipment nl Taal Engels ...

Page 2: ...ProfiMaster Manual Translated from German ...

Page 3: ... 2 5 Safety instructions for maintaining and troubleshooting the ProfiMaster 5 3 PRODUCT DESCRIPTION 6 3 1 Intended use 8 3 2 Reasonably foreseeable misuse 9 3 3 Markings and labels on the ProfiMaster 10 3 4 Residual risk 11 4 TRANSPORT UND STORAGE 12 4 1 Transport 12 4 2 Storage 12 5 ASSEMBLY 13 5 1 Unpacking and assembly of the wheels 13 5 2 Assembly of the extraction arm 15 6 USAGE 16 6 1 Quali...

Page 4: ...etal 27 8 3 Final decommissioning 28 9 APPENDIX 29 9 1 Technical Data 29 9 2 Spare parts and accessories 30 9 3 Schematics 31 Table of Figures Figure 1 Production des cription 6 Figure 2 Markings and labels 10 Figure 3 Unpacking and As s embly 14 Figure 4 Operational controls 19 Figure 5 Pos itioning of the extraction hood 20 Figure 6 Changing the filter 25 ...

Page 5: ...rson who is authorized to work on or with the ProfiMaster This includes the operation and troubleshooting during operation the maintenance care maintenance repair the transport the assembly 1 2 Notes on copyright and industrial property rights This instruction manual should be kept confidential It should be accessible only by authorized persons It may only be transferred to third parties with the ...

Page 6: ...requirements e g concerning work organization work processes and personnel used Apart from the manual and the regulations concerning accident prevention applicable in the country as well as at the site the recognized technical rules for safe and professional work must be adhered to The operator must not make any changes additions and modifications to the ProfiMaster that can affect safety without ...

Page 7: ... DANGERG This is a warning of a potentially dangerous situation with an inevitable consequence of severe injury or death if the specified statement is not followed exactly WARNING Indicates a potentially hazardous situation that could result in severe personal injury or death if the specified statement is not followed exactly TAKE CARE This is a warning of a possible hazardous situation with the r...

Page 8: ...l must always be readily available close to the ProfiMaster No liability is accepted for any damages or injuries caused by non observance of this manual The relevant accident prevention regulations and other generally recognized health and safety rules and regulations are to be followed Define clearly and adhere to the responsibilities for the different activities within the scope of servicing and...

Page 9: ...ng the ProfiMaster Setting up maintenance and repair work and troubleshooting must only be performed when the system is off During maintenance and repair work always tighten the loose screw If required tighten the relevant screws with a torque wrench In particular clean connections and fittings from dirt or any corrosion inhibitors before starting maintenance repair care ...

Page 10: ...produced during welding is extracted near the point of origin and separated to a separation degree of more than 99 For this purpose the unit is equipped with a flexible extraction arm the extraction hood of which is easy to move and is self supporting so as to be able to maintain any desired position The extracted air is cleaned in a 2 stage filtering process and then supplied to the working area ...

Page 11: ...1 Extractor hood 8 Control to adjust follow up time during start stop operation 2 Extraction arm 9 Connection for the service staff 3 Maintenance door 10 Signal horn 4 Filter set 11 Handlebar 5 Unit switch I 0 with operation indication light 12 Cable holder 6 Signal light 13 Castor with brake 7 Connection socket for start stop sensor 14 Rear wheel ...

Page 12: ...during welding of alloy steels e g stainless steel according to official regulations only units which have been tested and approved may be operated in the so called air circulation process This filter unit is approved for the extraction of welding fumes generated during welding of steels with an alloy content of 5 to 30 and meets the requirements of the welding smoke separation class W3 according ...

Page 13: ...vapours is mixed with easily flammable combustible dusts and or with substances which may form explosive mixtures or atmospheres is mixed with other aggressive or abrasive dust which could damage the ProfiMaster and the filter elements used is mixed with organic toxic substances or partially toxic substances that are released during the separation of the material Waste materials such as separated ...

Page 14: ...Nameplate with the details KEMPER GmbH Von Siemens Str 20 DE 48691 Vreden Type ProfiMaster Terminal voltage Year of manuf 08 2013 Mach No 192341 Weight 95 kg On the back of the unit at the bottom Sticker with the identification of the welding smoke class W 3 according to EN ISO 15012 1 indication of the date of the next test On the front of the unit in the middle on the left 1 Examples of nameplat...

Page 15: ...2 according to EN 149 Skin contact with welding fumes etc can cause skin irritation for sensitive individuals wear protective clothing Before beginning the welding work ensure that the extraction arm and the extraction hood are set properly the filter elements are complete and in undamaged condition and the unit is in operation Only when the green LED is lit is sufficient air flow being extracted ...

Page 16: ...rofiMaster In the case of improper lifting and transport the pallet can tilt and the filter unit can fall down Never walk under suspended loads A pallet truck or forklift is suitable for the transport of the pallet with the filter unit 4 2 Storage The ProfiMaster should be stored in its original packaging at an ambient temperature from 20 C to 55 C in a dry and clean place The packaging must not b...

Page 17: ...rners of the cardboard bottom with a knife so that you can fold the sides down Also carefully cut the straps Located in one of the smaller boxes are two large rear wheels with a pre mounted axle and two smaller castors with brakes also with pre assembled axle At the back of the unit is a handlebar Pull this handlebar and tilt the unit in this way slightly back so that the unit lifts about 150mm of...

Page 18: ...1 Subject to technical modifications and errors Issued 10 2013 Figure 2 Unpacking and Assembly Pos Description Number 3 Maintenance door 1 4 Filter set 1 4 1 Prefilter mat 1 4 2 Main filter 1 5 Handlebar 1 6 Castor with brake front wheel 2 7 Rear wheel 2 ...

Page 19: ...extraction arm The extraction arm consists of three main components turntable support frame and extraction hood These are each individually packaged in a carton In the box with the support frame is a separate guide for installing and adjusting the extraction arm Follow these instructions for mounting the extraction arm on a mobile unit ...

Page 20: ...of the operating personnel The operator of the ProfiMaster must only appoint persons who are familiar with the task with the independent use of the unit Being familiar with this task assumes that the persons concerned have been instructed according to the task and understand the manual and any company specific instructions Only let trained or instructed personnel use the ProfiMaster Only then will...

Page 21: ...l light indicates a device fault or error These errors are displayed visually by various blink codes The indicator lamp flashes evenly at regular intervals The unit needs servicing The signal light flashes 2 times in quick succession at regular intervals The motor protection relay has been triggered The signal light flashes 3 times in quick succession at regular intervals Incorrect phase sequence ...

Page 22: ...Once it falls below a minimum value the signal horn sounds and the signal light illuminates at regular intervals Now a filter change is necessary The same happens when the butterfly valve in the extraction hood is closed too far and thus the suction is also reduced too much Remedy this by opening the butterfly valve Connector for start stop sensor Here an optional start stop sensor may be connecte...

Page 23: ...l controls Pos Description Number 1 Unit switch with signal light 1 2 Signal light 1 3 Control to adjust the follow up time in the start stop mode 1 4 Maintenance connection 1 5 Connection for pressure measurement 1 6 Signal horn 1 7 Connector for start stop sensor 1 8 Interface of pressure can for setting the differential pressure 1 ...

Page 24: ...o that the extraction hood is located 25 cm diagonally above the weld The extraction hood must be positioned with consideration given to the thermally induced movement of welding fumes and the suction range so that it safely captures the welding fumes Always move the extraction hood to each welding position 6 4 Commissioning Turn the unit on via the switch labelled 0 and I The fan starts and the g...

Page 25: ...in optimal condition These specified time intervals refer to operation on a one shift basis The maintenance and repair work described in this chapter must only be performed by specially trained repair personnel of the operator Any replacement parts must meet the specified requirements of KEMPER GmbH This is guaranteed if original spare parts are used Ensure the safe and environmentally sound dispo...

Page 26: ...traction hood Check the hose on the extraction arm for damage e g burns holes from sparks or chafing Information Major defects and leaks lead to a reduction in the extraction capacity of the extraction hood Replace the hose with a new one in good time WARNING Skin contact with cutting smoke etc can lead to skin irritation for people with sensitive skin Serious injury to the respiratory tract and r...

Page 27: ...and maintenance instructions that came with the extraction arm WARNING Skin contact with cutting smoke etc can lead to skin irritation for people with sensitive skin Repair and maintenance work on the ProfiMaster must be performed only by trained and authorized personnel in accordance with the applicable safety and accident prevention regulations Serious injury to the respiratory tract and respira...

Page 28: ...filter elements is not allowed This inevitably results in damage to the filter medium which makes the function of the filter no longer possible and dangerous substances are released into the air Only use original replacement filters because only they guarantee the requisite degree of separation are designed for the unit and match its performance Turn the ProfiMaster off via the switch in item 1 Pr...

Page 29: ... apparatus the filter is provided with plastic bolts which sliding on a guide rail move into corresponding recesses when it reaches the correct position Only then put the filter with the seal on the plate Nevertheless be careful when dealing with the main filter not to damage the seal or the filter media Close the maintenance door Plug the power cord back into the outlet and turn on the unit The g...

Page 30: ...nsufficient extraction butterfly valve in the extraction hood closed Open butterfly valve in the extraction hood fully Filter inserts saturated Change the filter inserts Dust comes out on the clean air side Filter inserts damaged Change the filter inserts Motor protection relay triggers Motor blocked Ask an electrician to check it The motor protection relay F4 has to be manually reset Unit does no...

Page 31: ...atory tract and respiratory organs possible To avoid contact with and inhalation of dust use protective clothing gloves and an air respirator The release of hazardous dust when cleaning is to be avoided so that people not charged with the task are not harmed TAKE CARE Comply with the legal obligations regarding waste prevention and proper recycling disposal when working with the ProfiMaster 8 1 Pl...

Page 32: ...armed The work area should be cordoned off labelled Any dust stirred up needs to be immediately sucked up with a vacuum cleaner for dust class H Before starting disassembly all dust remaining in the ProfiMaster must be removed For this purpose a suitable vacuum cleaner for dust class H should be used and personal protective equipment such as protective clothing gloves air respiratory systems etc m...

Page 33: ...lass F Permitted ambient temperature 10 40 C Fan power max 1 800 m h Unit capacity max 1 500 m h without extraction arm 1 100 m h with extraction arm Under pressure max 2 100 Pa Minimum extraction capacity trigger threshold flow monitoring 750 m h Extraction arm NW 150 2m long 3m long 4m long Welding smoke extraction class according to EN ISO 15012 1 W3 Sound pressure level at 1m distance accordin...

Page 34: ...are parts and accessories Seq No Fig Pos Description Art No 1 1 1 Extraction hood 79 103 00 2 1 2 Hose for extraction arm 2m Hose for extraction arm 3m Hose for extraction arm 4m 114 0002 114 0003 114 0004 3 4 4 1 Prefilter mat pack of 10 109 0033 4 4 4 2 Main filter 109 0457 5 Disposal bags for filter Pack of 10 119 0431 ...

Page 35: ...KEMPER ProfiMaster Manual EN Art No 150 2121 31 Rev 1 Subject to technical modifications and errors Issued 10 2013 9 3 Schematics ...

Page 36: ...KEMPER ProfiMaster Manual EN Art No 150 2121 32 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

Page 37: ...KEMPER ProfiMaster Manual EN Art No 150 2121 33 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

Page 38: ...KEMPER ProfiMaster Manual EN Art No 150 2121 34 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

Page 39: ...KEMPER ProfiMaster Manual EN Art No 150 2121 35 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

Page 40: ...KEMPER ProfiMaster Manual EN Art No 150 2121 36 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

Page 41: ...KEMPER ProfiMaster Manual EN Art No 150 2121 37 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

Page 42: ...KEMPER ProfiMaster Manual EN Art No 150 2121 38 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

Page 43: ...KEMPER ProfiMaster Manual EN Art No 150 2121 39 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

Page 44: ...KEMPER ProfiMaster Manual EN Art No 150 2121 40 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

Page 45: ...KEMPER ProfiMaster Manual EN Art No 150 2121 41 Rev 1 Subject to technical modifications and errors Issued 10 2013 ...

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