Extraction Unit

with automatic filter cleaning

81 1300 120
Status quo: 05/2013
Part No. 1501513
1. Application and operation .................................................................................................................... 2

2. Important notes ..................................................................................................................................... 2

2.1 General notes .......................................................................................................................................... 2
2.2 Emergency measures ............................................................................................................................. 3
2.3 Safety information ................................................................................................................................... 3
2.4 Maintenance ............................................................................................................................................ 4

3. Setting up and connecting ................................................................................................................... 4

4. Operator panel and monitoring electronics �������������������������������������������������������������������������������������� 6

4.1 Commissioning and operation ................................................................................................................. 6
4.2 Setting of system parameters ............................................................................................................... 11
4.3 Notes and malfunction reports .............................................................................................................. 13

5. Service ................................................................................................................................................. 14
5.1 Emptying the dust collection container .................................................................................................. 14
5.2 Drain of condensate from pressure air vessel ....................................................................................... 16
5.3 Drain of condensate from pressure air maintenance unit ..................................................................... 16
5.4 Tensioning the belt-drive ....................................................................................................................... 16
5.5 Tensioning the belt-drive and lubrication of bearing for high-vacuum filter units .................................. 17
5.6 Filter cartridge replacement .................................................................................................................. 17
5.7 Disassembly/disposal ............................................................................................................................ 19

6. Automatic regulation of extraction capacity (optional) ����������������������������������������������������������������� 19

7. Information for high-vacuum filter units ������������������������������������������������������������������������������������������ 21

7.1 Maintenance for the high-vacuum turbine ............................................................................................. 21
7.2 Service detection for the high-vacuum turbine ...................................................................................... 21

8. Technical Data ..................................................................................................................................... 22

9. List of spare parts ............................................................................................................................... 22

10. Datasheet ............................................................................................................................................. 23

11. Troubleshooting .................................................................................................................................. 23

12. European Community Declaration of Conformity ��������������������������������������������������������������������������� 24

13. Wiring diagram .................................................................................................................................... 25

1
1. Application and operation
KEMPER extraction and filter units of this type are mainly used for extraction and filtering of air polluted with harmful substan-
ces, which is generated during welding and cutting processes. To capture all these harmful substances the following capture
devices are used:

• Exhaust hoods
• Down-draft extraction tables
• Exhaust arms and exhaust cranes
• Suction nozzles
• etc.

Via these capturing devices, the polluted air is led through a duct system into the extraction and filter unit. Here, the rougher
particles are directly separated on an air deflection (deflector plate) while the finer particles are held back on the surface of
the attached filter cartridge. The separation of the polluted air works according to the principle of surface filtration by means of
cartridges with teflon membrane. This membrane has a very homogeneous pore structure and is permeable to air. However, it
retains even the smallest particles. Thus the welding smoke is separated at the surface of the filter cartridges. The cleaned air
flows upwards inside the filter cartridges and reaches the clean air section of the filter unit. From there it is led to the ventilator
and then back into the workroom or via a duct system to atmosphere.

Due to the contineous settling of particles on the surface a resistance is set up. Once the allowed air resistance is reached the
cleaning process starts automatically. This is done through rotating nozzles by means of compressed air. Through the rotating
nozzles the compressed air works from the inside on the whole surface of the respective filter cartridge. The filter cartridges are
cleaned individually in turn. Thus permanent running is guaranteed during cleaning. You do not have to switch off the unit.

Further more, every time the machine is switched off the described cleaning process starts automatically. After the seperated
dust has been blown off the cartridges it falls down to the dust collection bin/dust collection car which is mounted underneath the
cartridges. To remove the dust collection bin/dust collection car it can be lowered very easy by using the compressed air lift.

The dust collection bin/disposal bag has to be emptied regularly. All main functions of the unit, e. g. situation of the filters,
operation of cleaning cycle are permanently checked and controlled by an electronic control system. The unit indicates possible
operational faults. Instructions regarding a possible causation and a purpose to solve the problem are indicated on the display.

The filter unit carries out one or two additional cleaning cycles after switching the unit off. For this reason you are not allowed to
cut off the power supply and the compressed air supply to the unit.

2. Important notes
2.1 General notes
• If possible, place the collection device in such a way that the welding smoke is safely collected taking under consideration the
thermal motion of the welding smoke and the suction range. If possible, move the collection device near to the respective
welding spot. In the case of an incorrectly positioned collection device, adequate collection of the contaminated air is not
ensured. Air containing contaminants lands in the airways of the user and can be harmful to health!

• The connection of the welding power source (UVV VBG 15 §43 Para. 1) must be designed in a way that no straying welding
streams (error stream) flow across the protective conductor of the welding smoke separator. A proper setup and separation
of the welding circuit is fulfilled if the welding supply source is not switched on until all connections are established and
accordingly switched off in the welding circuit before connections in the welding circuit are separated. One should also ensure
that the welding stream return line exhibits a minimum resistance between the workpiece and the welding machine and
connections between the workpiece and the welding smoke separator are prevented.

2
2.2 Emergency measures
If the exhaust and filter system or its collection components catch on fire, one should proceed as follows:

• If possible switch off the filter system on the main switch.

• Separate the filter system from the power supply by pulling the CEE plug.
• Fight the fire source with commercially available powder extinguishers.
• Inform the local fire department if necessary.

Caution:
Do not open the maintenance doors of the filter system - explosive flame formation! In case of fire, hazardous fumes and smoke
result, which can lead to suffocation. If possible, wear appropriate personal protective equipment.

2.3 Safety information

Make sure that all persons who work at the extraction and filter unit, work according to approved regulations/specifications and
are competent in their work. Special knowledge is necessary for electrical connections, electrical maintenance work and inspec-
tions as well as for compressed air connections, the appropriate maintenance work and inspections.
Switch off the power supply to the extraction and filter unit before starting to work at the unit. This is in particular necessary for
maintenance work. Furthermore you need to cut off the compressed air supply and remove the air from the pressure vessel and
the hoses before starting any work.

CAUTION:
When using electrical devices the following basic safety measures must be followed to prevent shock, injury or fire!

Read and follow these instructions carefully before using the filter unit!

• Store the operating and maintenance manual so that it is easily accessible, allowing the operator to view it if necessary.
• Read through the operating manual diligently. Use the filter system only after you have understood all the information in the
operating manual. In case of any questions, the operator must be appropriately instructed and trained.
• Before using the filter system, the operator must be instructed about the hazardous materials which are released during the
respective cutting or welding process and has to be informed of possible danger from these.
• Read data on typeplate.
• For a flawless operation of the system, servicing and maintenance work must be performed routinely in accordance with
TRGS 560 section No. 5, Para. 9.
• Persons can be injured if the unit is operated inappropriately.
• The extraction- and filter unit may only be operated in good working order.
• Only original filter cartridges and replacement parts may be used.
• Make sure that the dust collecting container is not too full of dust. It might be difficult to empty a full container and the
extraction capacity will also reduce.
• The filter system must be disconnected from the power supply before maintenance work is performed.
• You may only operate the filter unit according to the descriptions in chapter 1 on page 2 of this manual.
• Ensure that no spark showers or other burning parts, such as cigarette remains are sucked into the filter system. They can
cause a fire there and/or lead to a „filter breakthrough“, which has the result that the hazardous material is exhausted into the
work environment.
• Do not use for the extraction of oily welding fumes unless the system is equipped with suitable filters
(and eventually a dosing unit with pre-coating powder).
• Do not use the filter system to exhaust highly ignitable/aggressive or explosive gases or dusts such as aluminum dust,
sawdust etc.
• Do not use the filter system to exhaust fluids of any type.
• Do not use the filter system to exhaust aggressive and organic materials.
• Do not operate the filter system without or with defective filter cartridges. Contaminants in the exhausted air can be harmful
to health and lead to malfunctions of the filter system.
• Keep in mind that the pressure vessel has to be checked at least once within five years (see maintenance sticker on the
vessel).
• Protect the filter system against wet conditions, humidity and frost.
• Ask an authorized electrician to connect the machine to power supply.

3
CAUTION:
Check direction of rotation of the ventilator during electrical installation of the unit (see direction indication on ventilator housing)

2.4 Maintenance
For replacement of filters at the unit it is utmost necessary to replace all filter cartridges at same time to avoid damages at the
filters and the unit. For undertaking the replacement of filters please contact KEMPER service department. Companies are
obliged to minimize the exposure of harmful substances to their employees. Your KEMPER filter unit has to be checked at least
once a year (1.600 hours of operation) by a qualified engineer. According to regulations of industrial safety a qualified person
is a person who has required experience and knowledge (acquired by training, practical experience and activities) to undertake
check-ups at the units. Depending on the hours of operation the necessary maintenance work has to be carried out earlier. For
this reason we recommend to sign a maintenance contract with KEMPER in order to ensure that your KEMPER extraction and
filter unit copes with the legal regulations. All necessary maintenance work will be undertaken steady and in time.

Only regular maintenance work ensures that your unit is working according to the rules and the warranty is not cancelled. You
have to maintain all instructions which are described in this manual.

To be able to execute the filter cleaning the KEMPER extraction and filter systems are equipped with compressed air vessels.
These vessels have to be checked at least once within five years by a qualified and authorized engineer. Operate the KEMPER
filter system only with clean, dry and oil free compressed air. Also this filter has to be checked regularly to guarantee an efficient
cleaning of the filter cartridges. These are the pre-conditions for warranty.

Note:
Maintenance of the exhaust and filter system must be performed in accordance with TRGS 560 section No. 5, Para. 9.
Written records (a test book) must be kept for the inspections and must be presented to the authorities upon request.
The release of hazardous dusts must be prevented during maintenance work as well as during disassembly of the filter system
so that no persons who are not assigned to maintenance/disassembly work can be harmed. For this purpose, a suitable mobile
filter device should be used for the collection of dispersed dusts. During maintenance and disassembly work personal protective
equipment such as gloves, disposable gloves etc. should be used to prevent contact with hazardous dusts. After maintenance/
disassembly work has been performed, the surrounding areas of the filter system must be cleaned.

3. Setting up and connecting

The system 8000 can be easily lifted by means of the external forklift receptacles on the
front side of the filter system with a forklift from the shipping pallet and brought to the inten-
ded erection site. The middle clearance in the base frame serves to transport the system
with an elevating truck.

The exhaust and filter system should be set up at the erection site in accordance with the
local conditions in such a way that a clearance to the walls etc. of around 1 m is complied
with all around the filter system. The filter system does not need to be fastened to the floor!

The required storage space of the filter system results from the dimensional drawing (see chapter 8. Dimension sheet). The
suction pipes are connected by means of a transition piece. In case the cleaned air should not be returned to the work place, a
second transition piece is used to connect the exhaust piping to the corresponding exhaust opening in the upper section of the
filter system.

Now the filter system is connected to the pressurised air supply by means of a pressure reducer and a pressurised air filter (con-
tained in the scope of delivery). The filter system is equipped with a pressurised air connection nipple for 9 mm pressurised air
hoses. Clean pressurised air which is free of oil with a pressure of 5 to 6 bar is required. Clean air, free of oil, is only ensured if
the pressurised air filter is routinely serviced. For this purpose a replacement filter set (Part no.: 132 0017) is available. The filter
system is equipped with a permanently installed connection plug. It is located on the side of the top section of the system.
A corresponding coupler is attached here.

4
Note:
The individual collection elements such as exhaust arms, fume hoods, etc. must be hydraulically balanced, i.e. they must be
adjusted on site for the determined air quantities using butterfly valves and the trigger threshold of the minimum volumetric flow
must be checked for the current system configuration and equalised if necessary. This work can only be carried out by KEMPER
since it requires empirical knowledge and appropriate measuring devices. Please contact KEMPER service.

The following feed lines and prefuses must be available for the electrical connection. The power intake of the system can be
read in chapter 6 and on the nameplate which is located on the side of the system. The cable cross-sections are given for a
maximum cable length of 25 m from the distribution box to the filter system. For longer cable lengths correspondingly larger
cross sections are used.

Rated current Wire cross-section of feed line Prefuse

0-9A 5 x 1,5 mm² Circuit breaker 3 x 16 A Kat. C
9 - 12 A 5 x 2,5 mm² Circuit breaker 3 x 16 A Kat. C
12 - 22 A 5 x 6 mm² Circuit breaker 3 x 32 A Kat. C
22 - 35 A 5 x 10 mm² Circuit breaker 3 x 50 A Kat. C
35 - 45 A 5 x 16 mm² Circuit breaker 3 x 63 A Kat. C
45 - 55 A 5 x 25 mm² Circuit breaker 3 x 80 A Kat. C
55 - 70 A 5 x 35 mm² Circuit breaker 3 x100 A Kat. C
70 - 85 A 5 x 50 mm² Circuit breaker 3 x 125 A Kat. C

5
4. Operator panel and monitoring electronics
4.1 Commissioning and operation
The system is equipped with a 3,8“ grey scale touch screen or a 5,7“ colour touch screen. The operation of the interface occurs
by touching the display or by pressing the four buttons beneath the display.

The user interface is designed as follows:

 Main menu
Shows whether the filter system is switched on or off, or if the cleaning process of the filter cartridge is currently active.
This display appears around 30 seconds after the system is switched on by the main switch.
The user interface returns to this menu automatically after 2 minutes without operating the display.




 

   

 Operating data
Display of the current system data and measured values of the filter system.

Change to the
next page

1/3

Total page number

Current page

6
 Technical data
Display of the technical data for the exhaust and filter system.

Note:
In the case of a service requirement or a malfunction, you will find all the system data in this menu, which our employees
need for the flawless identification of your filter system.

 Settings
Displaying and setting of the system parameters. For details, see chapter 4.2

7
 Accessories
Information about installed or optionally available accessories for the exhaust and filter system.

Note:
Information about the installation, configuration and operation of optional accessories can each be found in the enclosed
operator manual.

Optional accessories
installed
Optional accessories not
installed

For every optionally available accessory component an information page can be opened by pressing the respective button.

Enter the activation code for

the acquired components
KEMPER contact data

8
 Spare parts
Part no. for consumption articles of the exhaust and filter system.

 I/O switch
Switching the exhaust and filter system on and off.

Note:
Even during longer work pauses or on the weekend, the system should not be switched off with the main switch or by
pulling the power plug, since filter cleaning is still also carried out when the system is idle.

 Language selection
Setting of the display language. For the 3,8“ grey scale display the country abbreviation of the optional
languages appears and for 5,7“ colour display the country flags are displayed for the optional languages.

9
 Servicing menu
Display of the next servicing date and the time of the last servicing performed. Input of the activation code for optional
accessories.

Note:
As the filter system is a safety-relevant device, it is prescribed that the flawless function is checked at routine intervals and
the necessary maintenance work performed. The frequency of the maintenance depends on the operating time of the
system. Should the maintenance interval be exceeded, a warning signal will draw attention to the due legally prescribed
maintenance. Contact KEMPER on short notice to set up a maintenance appointment.

Input of the activation code

 Contact menu
Display of the KEMPER address and contact data.

Back to the last display

10
4.2 Setting of system parameters
The following system parameters can be changed in the menu „Settings“:
• Follow-up time of the fan (only when the option „external ON/OFF“ is activated)
• Number of filter cleaning processes in idle
• Time and date

Note:
The setting parameters of the filter system are protected against access and can only be changed by KEMPER service.

To change the parameters

press the value

Changing values and parameters:

Interrupting input

Delete the last

entered number

Accept input

11
Calibrating the touch screen:
Should the operation of the touch screen become inexact or if the display does not react correctly to inputs, it is necessary to
recalibrate the touch screen. To calibrate the touch screen, press the button „Touchscreen calibration“. Then follow the notes on
the screen.

Setting the contrast (only for 3,8“ grey scale display)

Should the presentation of the grey scale display be unclear or too bright or dark, the contrast of the display can be set.
By pressing „Contrast +“ the contrast can be increased and by pressing „Contrast -“ decreased.

Current date and time

Set date and time

Set the adjusted

date and time

Calibrate the
touch screen
Change the contrast of the display
(only for 3,8“ grey scale display)

Screen saver
A screen saver appears after 15 minutes without user input. Pressing the touch screen at any location causes the screen saver
to fade out and the normal display appears. When the screen saver is displayed the system can still be switched on and off
using the key I/0.

12
4.3 Notes and malfunction reports
In the case of a malfunction of the exhaust and filter system, critical defects and warnings are differentiated. Critical defects with
immediate deactivation of the filter system are labelled by a warning window with a black background colour (3,8“ grey scale
display) or red background (5,7“ colour display).

Critical defects:

These defects lead to the immediate deactivation of the filter system. If the defect has been removed, it can be acknowledged
by pressing .
! The system can not be switched back on until the defect has been removed and acknowledged.

For every defect message, a help text can be used by pressing to

? more clearly explain the occurring defect. The window
„Error/malfunction“ can be faded out by pressing .
X

In the case of an existing malfunction which has not been acknowledged, the defect indicator points
1 out the existence of the
defect. After pressing this indicator, the two windows „Warning“ and „Error/malfunction“ appear. Should one of these windows
not contain a warning or malfunction, then it can be closed by pressing .
X

If more than one message appears, this can be individually selected and acknowledged by pressing after the malfunction is
corrected.

Fading the malfunction

message out
Example of a mal-
function message

Display info text Acknowledging the message

about the message

13
Warning note:
The warning messages serve to inform the system operator about uncritical system conditions or upcoming maintenance work.
These warnings are not critical for the system operation and can be acknowledged and thus faded out at any time by pressing
.
! If the warning condition remains, the notice will appear again at 5-minute intervals and must be acknowledged.

For every warning message, a help text can be displayed by pressing to

? more clearly explain the occurring warning. The
whole window can be faded out by pressing .
X

If the warning has not been acknowledged and the window is faded out, then the defect-indicator points
1
out the existence of
the warning. After pressing this indicator, the two windows „warning note“ and „defect/malfunction“ appear. The warning can be
acknowledged there. Should one of these windows not contain a warning or malfunction, then it can be closed by pressing .
X

Fading out of a
warning message
Example of a
warning message

Display info text Acknowledging

about the message the message

5. Service
Concerning service, please observe in particular the note about our maintenance agreements in chapter 2.4.

5.1 Emptying the dust collection container

The fill level of the dust collection bin/dust collection car must be checked at routine intervals. The time span, in which the dust
collection bin / disposal bag must be changed, is determined by the type of use and the type and amount of dust collected.
Therefore no information can be given about the change interval. Since particularly light dust from the air flow can occasionally
be raised on the inside of the system and when changing the dust collection bin/disposal bag, the dust collection bin/disposal
bag may only be filled to 50 mm below the upper edge of the dust collection bin.

Warning:
Inhalation of welding smoke particles, in particular welding smoke particles from a welding process of alloyed steels, can be
harmful to health, since they can „reach the lungs“. Skin contact with welding smoke particles can lead to skin irritations in
sensitive persons. To prevent contact and inhalation of dusts, use disposable gloves and dust masks.

14
Proceed as follows when emptying the dust collection bin/disposal bag:

• Switch of the system with the I/O button.

• Open the maintenance door on the filter part of the system.
• Lower the dust collection bin/dust collection car by laying the lever of the pneumatic valve to the left.
(The pneumatic valve is located behind the maintenance door in the front area on the upper left.)

Then the following malfunction message appears:

For filter systems with dust collection bins:

• Now take down the dust collection bin carefully without raising dust from the lifting device and close it with the accompanying
cover and fastener.

For filter systems with dust collection cars:

• Cautiously pull down the dust collection car from the lifting device without raising dust. Take down the frame with the
separating plate from the dust collection car.
• Close the disposal bag and dispose of it properly.
• Insert a new disposal bag (Part no.: 119 0508) in the dust collection car and lay the frame with the separating plate back on
the dust collection car.
• Slide the dust collection car using the lifting device until it catches and activate the pneumatic valve until the dust collection car
rests firmly against the sealing surface.
• Now the malfunction message can be acknowledged, the maintenance door closed and the system switched back on.

CAUTION:
Please ensure that no objects are located between the sealing flange of the dust collection bin/dust collection car during the
lifting process.

Note:
In accordance with the provisions of the Waste Management Law, dusts must be stored and disposed of in an environmentally
friendly manner. Welding dust which contains big or small portions of chrome/nickel parts is waste that requires special monito-
ring with the waste code 100207, which must be disposed of in a special waste burning system/landfill. Please contact your local
waste management company with questions about proper disposal.

15
5.2 Drain of condensate from pressure air vessel
The condensate inside the pressure air vessel should be drained regularly at least once
every month. For this purpose, you can find a needle valve on the side of the pressurised air
maintenance unit. Put a suitable container below the drain valve and open the valve. Close the
valve after all moister has been drained and only air is puring out of the valve.

5.3 Drain of condensate from pressure air maintenance unit

Also the condensate inside the pressure air maintenance unit should be drained regularly
at least once every month. The drain valves are located under the inspection glasses at the
pressure air maintenance unit. This maintenance work is very important to ensure a proper filter
cleaning. Put a suitable container below the drain valve and open the valve. Close the valve
after all moister has been drained and only air is puring out of the valve.

5.4 Tensioning the belt-drive

(not for type 81 0200 xxx - 81 0300 xxx)

After about 50 working hours the belt-drive of the ventilator needs to be checked and the tension of the belt should be
re-adjusted first time. After that approx. every 3 to 4 month the belt drive should be checked. For the depth of intendation
of the belt between both belt pulleys and the appropriate test force please read to technical specification. Another way is to
↓
press „Technical data“, as you can see in illustration 5.4. Then press until the underside 4/4 to see the testforce of the drive
belt.

Illustration 5.4

By pressing the
? display shows the picture for the test.

F
+ +

16
Procedure:

• Switch off the system on the I/0 button and set the main switch to the „0“ position. Additional secure the main switch with
a padlock.
• Open the maintenance door of the fan unit.
• The correct tension of the belt has been reached, if you can achieve the depth of intendation „L“ with a intendation force „F“
(see technical specification). Please make sure that the belt pulleys are in line with the fan and the motor. This is important to
avoid any damages to the belt.
• After you have checked the tension of the belt according to the schematic drawing below and you have possibly adjusted the
tension via the two adjustment screws at the lefthand side of the motor you can shut the maintenance door. Put the power plug
back into the power socket.
• Close the maintenance door.
• Switch the machine on by using the I/0 switch.

Information:
In general a lubrication of the bearings is not necessary within a normal life time of the fans.

5.5 Tensioning the belt-drive and lubrication of bearing for high-vacuum filter units
After about 50 working hours the belt-drive needs to be checked and the tension of the belt should be re-adjusted first time. After
that the bearing of the turbine has to be lubricated and also the belt-drive has to be checked regularly (Parameters see mainte-
nance sticker on the turbine).

Procedure:

• Switch the unit off by using the I/O switch and put the main switch on “O”. The power supply is disconnected. Secure the
switch with a pad lock additionally.
• Open the maintenance door of the fan unit.
• Check the tension of the belts according to descriptions in chapter 5.4 and adjust the tension if necessary. For the test force
please read technical specification.
• Lubricate the bearings once within 300 hours of operation.
• Close the maintenance door of the fan unit and switch the machine on by using the I/O switch.

5.6 Filter cartridge replacement

Note:
We recommend that you have the cartridge filter replaced by KEMPER service. Should you nevertheless do it yourself than
keep in mind that incorrect installation can lead to malfunctions which can affect the warranty.
The release of hazardous dusts must be prevented when changing the cartridge so that no persons who are not performing the
task can be harmed. For this purpose, a suitable mobile filter device for the capture of raised dusts should be used and personal
protective equipment such as gloves, disposable gloves, etc. should be used in order to prevent contact with hazardous dusts.

Warning:
Inhalation of welding smoke particles, in particular welding smoke particles from a welding process of alloyed steels, can be
harmful to health, since they can „reach the lungs“. Skin contact with welding smoke particles can lead to skin irritations in
sensitive persons.

Proceed as follows when changing the filter cartridge:

• Switch off the exhaust and filter system on the main switch and separate
them from the power supply by pulling the power plug.
• On the pressurised air maintenance unit (1) set the pressure to 0 bar by
turning the pressure setting counterclockwise and then bleed the
pressurised air system through the blow-off valve (2) until no more air
flows out.

17
• Open the maintenance door (1) by removing the fastening screws (2).

• Remove the nuts (1) from the bracket of the filter cartridge (2). In the process, the filter cartridge must be held firmly so that
it doesn‘t fall into the dust collection slide causing dust to be raised. Then slowly lower the filter cartridge.

• Loosen the screw connection and counter nut (2) from the rotation nozzle (1) and remove it from the exhaust and filter system.

18
• Install the new filter cartridge in reverse order. When tightening the fastening screw for the filter cartridge please ensure that
it is not fastened too tightly. Do not install the filter material with ripples. Ensure that the filter cartridge is positioned correctly
and that it securely seals against the filter intake (1).

• Close the blow-off valve and set the pressure on the pressurised air maintenance unit to 5-6 bar by turning the pressure setting
counterclockwise.
• Reconnect the exhaust and filter system to the power supply and turn on the main switch.
• Clean the surroundings of the exhaust and filter system of possibly raised dust. The exhaust and filter system is once again
ready for use.

5.7 Disassembly/disposal
Disassembly work must be performed with the greatest diligence so that no loose dust which is clinging to the exhaust and
filter system is raised causing harm to persons who are not assigned to the task. It is recommended to clean loose dust from
the complete exhaust and filter system before beginning the disassembly, particularly in the area around the dust collection bin.
For this purpose, a suitable mobile filter device should be used and personal protective equipment such as gloves, disposable
gloves, etc. should be used in order to prevent contact with hazardous dusts.

Previous to a disassembly with subsequent disposal, the proper disposal of the housing parts which are contaminated with dust
should be agreed on with and clarified by the regional waste management company.

Warning:
Inhalation of welding smoke particles, in particular welding smoke particles from a welding process of alloyed steels, can be
harmful to health, since they can „reach the lungs“! Skin contact with welding smoke particles can lead to skin irritations in
sensitive persons.

6. Automatic regulation of extraction capacity (optional)

Extraction and filter units with automatic regulation of extraction capacity are units which can keep the extraction capacity on
a certain level according to the demand. To obtain this, the unit is equipped with an inverter. The system will be configurated
and ready for operation when despatched from our works. You do not have to carry out any further adjustments at the inverter.
In case any further adjustment seems to be necessary, however, please contact KEMPER service department (see address
button).

Also please read through the operation manual for the integrated inverter which is enclosed.

The automatic regulation of extraction capacity at extraction and filter units provides several advantages. The extraction of dusts
which are harmful for someone`s health can be executed more effective and moreover this more efficient by these units.

Advantages:

1. The extraction capacity of the extraction and filter units is always constant no matter how many workplaces are extracted
at a certain moment. Only as much air as necessary will be extracted. Your staff will always work under same conditions
at their workplaces.They do not recognize any differences regarding the decreasing extraction performance due to
increasing numbers of work places. The extraction capacity will be adjusted according to demand.
19
2. The extraction capacity will also be controlled after installing new filter cartridges for example. The air resistance is
considerably lower when using new filter cartridges. The extraction and filter unit is operating on the same extraction volume
nevertheless with lower consumption. If the saturation of the filters is increasing the extraction capacity will lower
correspondingly.

KEMPER extraction and filter units save current. The motor of the fan is operating as fast necessary for the actual demand.
Furthermore an inverter is saving all parts of the complete system. This prolongs the life time of the KEMPER extraction and
filter unit.

Important:
The KEMPER extraction and filter unit has to be shut down completely after it can be restarted. During this run-down time the
display shows this message:

The unit can not switched on for the displayed time.

If there is an error at the frequency inverter the following mesage is shown in the display:

In this case contact the KEMPER service, please.

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7. Information for high-vacuum filter units
7.1 Maintenance for the high-vacuum turbine

Type: 91 0100 200 91 0200 200 / 91 0300 200

Lubrication intervals: 300 h 300 h
Lubrication ammount: 15 g ≈ 15 cm³ 20 g ≈ 20 cm³
Recommended lubrication grease: SKF/LGHP-2/420 ml, part no. 161 0085
Drive belt ternsion per belt
Testforce F: 23 N 32 N
Depth of intendation L: 9 mm 10 mm
Interval, first time / afterwards every: 50 / 900 h 50 / 900 h

7.2 Service detection for the high-vacuum turbine

Date Operating hours Lubrication of bearing Drive belt tension Signature inspector

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8. Technical data
Part No. 81 1300 120
Extraction capacity (max.): 13.000 m³/h
Max. pressure increase: 2.500 Pa
Ventilator type: Belt driven centrifugal fan
Motor power: 11,0 kW
Power supply: 3 x 400 V / 50 Hz
Amperage: 20,6 A
Filter surface: 12 filter cartridges each 10 m² = 120 m²
Filter medium: KemTex® ePTFE membrane filter
Filter effeciency: > 99,99 %
Filter classification: L, M
Cleaning: pneumatical by means of rotating nozzles
Air intake: Ø 560 mm
Air outlet: Ø 560 mm
Compressed air supply: 5 – 6 bar; clean, dry and free of oil
Dust collecting container: 192 L
Dimensions (w x d x h): 2.375 x 1.864 x 2.110 mm
Weight: 1.230 kg
Noise level: 65 dB(A)
Testforce F: 16 N
Depth of intendation: 9 mm

9. List of spare parts

We will need the serial number of the machine to process your order for spare parts. You can find the serial number in the main
menu „Technical Data“. You can find the list of spare parts for the machine in the main menu „Spare parts“.

Pos. Description Part No.

1 Dust collection bin (4 pieces) 119 0335
2 Disposal bag for dust collection car (10 pieces) 119 0508
3 KemTex® ePTFE membrane filter 10 m² incl. sealing kit 109 0440
4 Filter cartridges suitable for welding smoke containing oil mist, filter surface 12 m², including sealing
kit, you will also need precoating powder 109 0320 109 0301
5 KemTex® ePTFE membrane filter 20 m² incl. sealing kit 109 0447
6 Filter cartridges suitable for welding smoke containing oil mist, filter surface 24 m², including sealing
kit, you will also need precoating powder 109 0320 109 0304
7 Precoating powder 1 kg 109 0320
8 Replacement set of filters for pressure unit for maintenance 132 0017

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10. Datasheet
11. Troubleshooting
Defect message
The motor protection relay
has triggered
Defect in the power supply
Dust collection bin is
missing or open
Malfunction in the contactor
control
Pressurised air inlet not
available
Pressurised air inlet not
sufficient
Defect in differential
pressure sensor
Possible cause Defect correction
Excessive power intake due to voltage • Have the settings checked by an electrician
fluctuations or fan defects • Contact KEMPER service
Reverse polarity in the electrical connection, • Have the electrical connection checked
phase failure by an electrician
Dust collection bin is not properly connected • Contact KEMPER service
A defect has occurred in the mains contrac- • Lift the dust collection bin with the help of
tor, star contractor or triangle contractor the pneumatic valve
The pressurised air inlet through the pres- • Inform an electrician or contact KEMPER
surised air supply provided by customers is service
not sufficient or the pressurised air main-
tenance unit is not set correctly or its filter
inserts are clogged.
• Check Pressurised air supply and pressurised
When cleaning the filter cartridge the pres-
air connections
surised air can not be provided fast enough
in sufficient quantity.
The differential pressure sensor is defective • Contact KEMPER service
or has wire breakage.
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12. European Community Declaration of Conformity
According to the European community machine standard 2006/42/EC

Manufacturer: KEMPER GmbH

Von-Siemens-Str. 20
D-48691 Vreden

Mr. Manfred Könnig is authorized to compile the technical documentation.

We hereby declare that the following machine with all relevant provisions of the EC Machinery Directive 2006/42/EC
in accordance.

Part No. 81 1300 120

Description: KEMPER System 8000

Extraction and filter unit with automatic filter cleaning
Extraction capacity (max.): 13.000 m³/h

The machine is also in accordance with all relevant provisions of the following EC-guidelines:

2006/42/EC Machine safety guideline

2004/108/EC Electromagnetic compatibility
97/23/EC Pressure equipment guideline
2006/95/EC Low-voltage - guideline
93/68/EC Marking - guideline

The following harmonized standards (or parts of these standards) were used:

EN ISO 12100 part 1+2, EN 294,

EN 349, EN 418, EN 983 Security of machines
EN 1050 Security of machines - guiding principles for risk evaluation
EN 60204 -1 Electrical equipment of machines
EMVG Law referring to the electromagnetic compatibility of machines
EN 610000-6 part 3 Specialized basic standard noise immunity
EN 610000-6 part 2 Specialized basic standard noise emissions

The following technical specifications (or parts of these standards) were used:

VDE 0100 Construction of low-voltage plants

VDE 0113 Electrical equipment of machines - complies to EN 60204-1
UVV BGV A1 Regulations for the prevention of accidents: Principles of prevention
BGR 500 2.26 Weld, cuts and related procedures
DIN 45635 Noise levels at machines

The Annex VIII of Directive 2006/42/EC has been observed. Compliance with the requirements of Low Voltage Directive
has been ensured in accordance with Annex I, point 1.5.1 of Directive 2006/42/EC.

Additional information
This explanation loses its validity, if the machine is not used in proper use and if a change not co-ordinated with the
manufacturer in written form is made.

Vreden, 01.02.2013
KEMPER GmbH

Dipl.-Ing.M. Könning
(Chief Technical Engineer)
24
13. Wiring diagram
External connections system 8000
The power supply, main switch, three connection bushings for connection of optionally available components as well as the
connection for the pressurised air supply are found on the side of the system.
The connection bushings consist of an interface bushing for an external operator terminal as well as a six-pole and 12-pole
bushing. The corresponding connection plugs and wiring diagrams are a part of the optionally available components and are
also delivered there.

Main switch

Bushing for external

operator terminal

6-pole bushing
(e.g. external
12-pole terminal on/off switching)
(e.g. dosing device)

CEE plug (16 or 32 A)

External connections system 9000

Bushing for external

operator terminal

12-pole terminal 6-pole bushing

(e.g. dosing device) (e.g. external
on/off switching)

Cable screw connection for

infeed of the power supply

25