Kemper ProfiMaster KE 60650100 User manual

Handleiding
Kemper ProfiMaster
KE 60650100
KE 60650101
KE 60650102
MSH equipment
Appelmarkt 7
1681 PE Zwaagdijk-Oost
Tel: [phone]
Fax: [phone]
Mail: [email protected] Website: www.msh-equipment.nl
Taal: Engels

ProfiMaster
Manual (Translated from German)

KEMPER ProfiMaster Manual EN
Contents
1BASICS............................................................................................................... 1
1.1 Introduction...................................................................................................... 1
1.2 Notes on copyright and industrial property rights............................................. 1
1.3 Information for the operator ............................................................................. 2
2SAFETY .............................................................................................................. 3
2.1 Basics.............................................................................................................. 3
2.2 Information on signs and symbols ................................................................... 3
2.3 Labels and signs to be affixed by the operator ................................................ 4
2.4 Safety instructions for the operating personnel................................................ 4
2.5 Safety instructions for maintaining and troubleshooting the ProfiMaster.......... 5
3PRODUCT 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
4TRANSPORT UND STORAGE......................................................................... 12
4.1 Transport ....................................................................................................... 12
4.2 Storage.......................................................................................................... 12
5ASSEMBLY ...................................................................................................... 13
5.1 Unpacking and assembly of the wheels......................................................... 13
5.2 Assembly of the extraction arm...................................................................... 15
6USAGE.............................................................................................................. 16
6.1 Qualification of the operating personnel......................................................... 16
6.2 Operational controls....................................................................................... 17
6.3 Positioning of the extraction hood.................................................................. 20
6.4 Commissioning .............................................................................................. 20

KEMPER ProfiMaster Manual EN
7MAINTENANCE................................................................................................ 21
7.1 Care............................................................................................................... 22
7.2 Service........................................................................................................... 23
7.3 Changing the filter.......................................................................................... 24
7.4 Troubleshooting............................................................................................. 26
8. DISPOSAL........................................................................................................ 27
8.1 Plastics .......................................................................................................... 27
8.2 Metal.............................................................................................................. 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, P roduction 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

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 1 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
1 Basics
1.1 Introduction
This manual is an essential aid for the proper and safe operation of welding fume
filter unit KEMPER ProfiMaster, hereinafter called ProfiMaster.
The manual contains important information for the safe, proper and efficient
operation of the ProfiMaster. Observance of this manual helps to avoid danger,
reduce repair costs and downtime, and increase the reliability and the service life of
the ProfiMaster. The manual must always be available and should be read and
applied by any person 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 written consent
of KEMPER GmbH.
All documents are protected under copyright law. The reproduction and distribution of
documents, including excerpts, as well as exploitation and communication of its
contents is not permitted, unless this is expressly permitted in writing.
Violations are liable to prosecution and incur an obligatory payment of damages.
KEMPER GmbH reserves all rights to exercise industrial property rights.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 2 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
1.3 Information for the operator
The instruction manual is an integral part of the ProfiMaster. The operator shall
ensure that the operating personnel take note of these instructions.
The manual is to be supplemented by the operator with company regulations based
on national regulations for accident prevention and environmental protection,
including information on regulatory and reporting requirements to meet specific
operating 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 permission from KEMPER GmbH! Any
replacement parts used must meet the specified requirements of KEMPER GmbH.
This is always guaranteed with original spare parts!
Use only trained or instructed personnel to operate, maintain, repair and transport the
ProfiMaster. Clearly establish who is responsible for the operation, maintenance,
repair and transport.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 3 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
2 Safety
2.1 Basics
The ProfiMaster is designed and built with state-of-the-art technology and according
to the recognized safety rules. When operating the ProfiMaster, danger to the
operator or damage to the ProfiMaster and other property may occur if it is:
−used by untrained personnel or personnel which has not been instructed,
−not used as intended and/or
−improperly serviced
2.2 Information on signs and symbols
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 result of
minor or moderate injury or property damage if the specified statement
is not followed exactly.
NOTE
This is a reference to useful information for safe and proper use.
•Working and/or operating steps are marked by a bullet point. The steps
are to be executed in order from top to bottom.
−
Enumerations are indicated by a dash

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 4 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
2.3 Labels and signs to be affixed by the operator
The operator is obliged, where appropriate, to affix further labels and signs on the
ProfiMaster and around it in the surrounding area.
Such labels and signs could concern the requirement to wear personal protective
equipment, for example.
2.4 Safety instructions for the operating personnel
The ProfiMaster must only be used when it is in a technically sound condition and
only for its intended purpose, with awareness of safety and danger in accordance
with these instructions! All faults, especially those that can impair safety, must be
rectified immediately!
Every person who is charged with the commissioning, operation or maintenance,
must have read and understood this manual completely – especially section 2 Safety.
Reading the instructions after work has begun is too late. This is especially true for
personnel who are only occasionally tasked with using the ProfiMaster.
The manual 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 maintenance. Only then will human error – especially in
dangerous situations – be avoided.
The operator undertakes to ensure that the operating and maintenance personnel
wear personal protective equipment. These include, in particular, safety shoes, safety
glasses and gloves.
Do not wear long hair loosely, loose clothing or jewellery! There is always the danger
of being drawn in or being caught up in moving parts.
If safety-related changes occur on a ProfiMaster, stop the extraction, secure it
immediately, and report the occurrence to the competent authority/person!
Work on the ProfiMaster must only be carried out by reliable, trained personnel.
Observe the legal age!
Personnel to be trained, instructed, introduced to the job or involved as part of a
general education must only use the ProfiMaster under the constant supervision of
an experienced person!

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.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 6 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
3 Product Description
The ProfiMaster is a compact welding fume filter apparatus, with the aid of which, the
welding smoke 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 again.
Figure 1, Production description

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 7 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
Item
Description
Item
Description
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

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 8 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
3.1 Intended use
The ProfiMaster is designed to extract and filter welding fumes, generated during
electric welding, at the source. Basically, the unit can be used in all work processes
in which particulate pollutants, i.e. smoke and dust, are released. However, it is
important to ensure that no "sparks" are drawn into the filter unit from e.g. a grinding
process.
The hazardous substances generated during the work process are captured by the
extraction hood. They are sucked with the air flow into the filter unit. Here they are
passed through a prefilter for coarse particles and a main filter, in which the fine
respirable particles of smoke are separated out with a separation efficiency of more
than 99%. The purified air is sucked in by the fan and returned into the working area.
For the extraction of welding fumes containing carcinogenic particles created
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 to DIN EN ISO 15012-1.
When extracting of welding fumes containing carcinogenic ingredients (e.g.,
chromates, nickel oxides, etc.) the requirements of TRGS 560 (Technical Rules
for Hazardous Substances) must be complied with.
In the technical data are dimensions and further details on the ProfiMaster, which
must be observed.
NOTE
Observe the information in section 9.1 Technical Data.
Strictly comply with this information.
Intended use also includes compliance with the information
−on safety,
−on operation and control,
−on maintenance and servicing,
set out in this manual.
Any other use, or use beyond this scope, is regarded as improper.
The operator of the ProfiMaster is liable for the damages resulting
therefrom. This also applies to unauthorized modifications to the
ProfiMaster.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 9 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
3.2 Reasonably foreseeable misuse
The operation of the ProfiMaster in industrial areas where requirements have to be
met for explosion protection is not allowed. Furthermore, the operation is prohibited
for:
−procedures that are not listed in the intended use and through which the sucked-in
air:
●is mixed with liquids and the resulting contaminated air stream is mixed with
aerosol and oily 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 particles, may contain harmful substances.
They must not be disposed of in the municipal waste landfill sites – environmentally
sound disposal is necessary.
If the ProfiMaster is used as intended, no reasonably foreseeable misuse, which
could lead to dangerous situations involving personal injury, is possible.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 10 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
3.3 Markings and labels on the ProfiMaster
Figure 1, Markings and labels
Label
Meaning*1
Location
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 nameplate information.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 11 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
3.4 Residual risk
Despite compliance with all safety regulations, the residual risk described below is
present during operation of the ProfiMaster:
All persons working on and with the ProfiMaster must know this residual risk and
follow the instructions that prevent these residual risks leading to accidents or
damage.
WARNING
Serious injury to the respiratory tract and respiratory organs
possible – wear respiratory protection. e.g. KEMPER autoflow XP
or a respiratory protection filter mask of the class FFP2 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 for capturing welding fumes.
When changing the filter cartridges, the deposited dust can come
into contact with the skin, and some of the dust can be stirred up
by the work. Therefore, wear respiratory protection and protective
clothing.
Embers in the filter elements can potentially lead to a smouldering
fire – shut off filter unit, close butterfly valve in the extraction
hood, and leave the unit to cool off under supervision.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 12 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
4 Transport und Storage
4.1 Transport
DANGER
Life-threatening contusions possible during loading and transport
of the ProfiMaster!
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 be adversely
affected by other items.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 13 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
5 Assembly
WARNING
Serious injury possible when mounting the extraction arm due to
pretension of the coil springs used. Mishandling the support
frame can result in it moving unexpectedly and could cause
severe facial injuries or crushing of fingers!
NOTE
When installing the ProfiMaster independently, the ProfiMaster
operator must only appoint persons who are familiar with the task.
Two employees are needed for the installation of the unit.
5.1 Unpacking and assembly of the wheels
●Remove the small boxes from the large packaging (wrappers) and set them to
one side.
●Now lift the big outer packing up and off.
●The ProfiMaster is secured by straps in a cardboard bottom on the pallet. Cut the
corners 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 off the ground at the front.
●While you are holding the unit in this position, a second employee twists the
castors with their axles from below in the existing screw sockets in the front
corners in the bottom plate of the unit.
●Now, lower the front of the unit slowly and lift it by the handlebar a little. The
second employee can now screw in the large rear wheels with their pre-installed
axle into the screw sockets located at the side.
●Now gently pull the ProfiMaster backwards off the palette.
●Open the access door and check the filter cartridges to make sure they are
undamaged and in the correct arrangement.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 14 - Rev.: 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

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 15 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
5.2 Assembly of the 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.

KEMPER ProfiMaster Manual EN
Art. No.: 150 2121 - 16 - Rev.: 1
Subject to technical modifications and errors. Issued: 10/2013
6 Usage
Any person, who uses, maintains or repairs the ProfiMaster must have read and
understood this manual thoroughly.
6.1 Qualification 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 all
employees work with safety and hazard awareness.