KEMPER

KemTab Basic-Table
Part No. 152 0435
1. Application 2

2. Safety Information 3

3. Assembly and Installation 4

4. Operation of the Unit 6

5. Cleaning and Maintenance 7

6. Spare parts 9

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1. Application
Smoke and dust is generated during cutting processes on the KemTab Basic-table.
This smoke and dust is extracted downdraft into the table. The table is divided by
vertical bars into several, approximately 500 mm long sections. An inside integrated
extraction channel is established alongside one side of the table. This channel is pro-
vided with mechanical activated dampers for each section. During the cutting process
only the sections is extracted on which cutting work takes place.

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An actuator bar connected to the gantry of the cutting unit, with help of the push
rod, opens the damper in the table where the machine is cutting. The actuator bar is
slightly longer than the table sections ensuring that the change over from section to
section, there is two sections open for a short period. As soon as the gantry moves
on one damper is closed by means of a spring.

Therefore the extraction and filtration system connected to the table, only extracts
from one section of the table. The extracted fumes reach the extraction and filtration
system by means of a connection duct. The filtered clean air can be returned to the
workshop or expelled to atmosphere depending on the type of extraction and filtration
system, the processed materials and the working process. To capture small cut parts
that fall between the material support bars, Kemper offers optional gratings that are
placed into the top of the slag containers.

A build up of small cut parts on the gratings can influence the extraction rate at the
point of the cut and therefore should be cleared from time to time. The produced
slag when cutting falls through the gratings into the slag collection containers at the
bottom of the table. These can be removed through the top of the table and emptied
when required.

2. Safety Information
Caution:
The following instructions have to be observed during use of the KemTab Basic-table
to protect against air pollution and injuries.

Please read through these instructions carefully, before operating the machine:

• Keep this operation and maintenance manual handy.

• Do not operate the KemTab Basic-table without appropriate extraction unit.
• You have to position the individual elements of the table by means of set screws
that way that these elements can not be moved.
• Do not put thicker plates onto the table than described in the attached datasheet.
• Please replace damaged flat steel bars in time.
• The statics of the table has been constructed for a laminar loading. Always place
the material that has to be processed horizontal onto the table. It is not allowed to
place the material vertical onto the table and tip it down.
• You have to check regularly if the section dampers are opening and closing
properly.

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3. Assembly and Installation
We are preparing a datasheet for each KemTab Basic-table before starting the real
construction of each individual table. Out of this datasheet you can get information
regarding dimensions and intended assembly and layout. Please have a look at this
datasheet while mounting the table.

For the assembly of the table you have to consider and follow the order as
mentioned below:

• The KemTab Basic-table with a width of 2,5 m and above is devided into individual
sections which can be assembled and mounted after each other. To be able to
handle the sections more easily you can lift the material support frames, the
gratings and the slag containers out of the table. You will find eyelets for transport-
ation at the bottom of the table sections where you can put the chains onto in order
to lift and transport the table section by means of a chain hoist or a forklift. Please
use the outer eyelets of a section for transportation purpose.

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• Please refer also to the datasheet of the table. You can arrange the individual
sections one after the other. To seal the extraction channel of the table, you can
stick the enclosed foam rubber gasket to the cross section of the channel at one
side of the table.

• You have to adjust the height and the direction of the individual sections of the table
by adjusting the machine feet exactly. The exact side alignment is most important, to
ensure the actuator bar, which is used to operate the dampers is unhindered when
moving along the KemTab Basic-table. The table must be positioned exactly parallel
to the guiding profile of the gantry. You can fix the machine feet with the enclosed
bolts M20 to avoid disguising of the feet due to vibrations and agitation.

• Next step is to assemble the individual sections of the table. The sections are fixed
to each other at the extraction channel with bolts M 6 x 25 and at the joint between
the sections with M 12 x 30. For the first connection of the tables there are M6 nuts
on the inside of the extraction channel at one end of the table modules and on the
opposite end there is a suitable borehole for the M6 x 25 bolts. On the end where
the boreholes are, a removal of the damper in this area is essential to screw in and

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 secure the bolts (This is done from the inside of the table). Remove the splints and
securing plates on the damper. The damper is pulled slightly upwards and swung
away. The damper is then replaced and secured after the tables are screwed
together.

• The supplied earth cable 300 mm length must be connected between the table
modules. This is essential for the earthen when cutting with plasma. This is very
important as having the bonding for plasma flame cutting.

• The extraction channel is sealed at one end, using the supplied end plate and the
supplied connection spigot is secured to the opposite end of the fully assembled
table.

• When all table modules are assembled and aligned, the damper actuator bar is
connected and aligned correctly to the gantry of the cutting machine. The height of
the actuator bar is given from the height of the actuation rollers. The fixation
position of the actuator bar in the longitudinal direction of the table, is exact the
centre of actuator to position of the plasma or gas cutter on the gantry. It is
essential to position the actuator correctly, because only the damper where the
plasma or gas is cutting needs to be opened. To ensure that the damper is fully
opened, the distance between the table and actuator bar needs to be set to the
maximum allowed by the actuation roller limiter.

• KEMPER KemTab Basicmmends that before replacing all slag containers and
material
support frames, a trial run of the gantry along the table is carried out to ensure all
dampers are working correctly. The actuator bar can be adjusted if required.

• Replace all slag containers, gratings and also the material supports.

4. Operation of the Unit

Installation work is completed after assembling and connecting the KemTab Basic-
table and all its components. If you start the connected filter unit respectively the
ventilator and also the flame cutting machine, the generated harmful substances will
be extracted at that section where cutting is taking place at that moment. To automa-
tically turn the KEMPER extraction and filtration system type 6000, 8000 or 9000 on/
off, or to ensure that the system only runs when the cutting unit is cutting, KEMPER
offers an optional external on/off set.

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1. Operation in safety mode
The filter unit will be connected to the control of the KemTab Basic-table that way
that the flame cutting machine can only be switched on if the filter unit is operating
already. The filter unit will be switched on manually. After this, a potentialfree contact
will be closed in the filter unit and as a result of this the flame cutting machine can be
started manually.

2. Automatic operation
Also in this case the control of the KemTab Basic-table and the filter unit are con-
nected to each other. For the automatic operation the flame cutting machine will be
switched on manually and the potentialfree contact in the control of this unit is closed.
The connected filter unit will be switched on and off automatically.

5. Cleaning and Maintenance

At the components of the KemTab Basic-table several cleaning and maintenance
work have to be undertaken in regular intervals to keep the table functional and ready
for operation. The time interval between these services are dependent on the kind
of use. The scale of the necessary work is an indication if the intervals between two
services can be extended or have to be shortened.

• Material support plate

The material support plate consists of a frame made from flat steel with gaps in
which flat steel bars (dimensions: 100 x 5 mm) can be inserted. During a cutting
proces these steel bars can be damaged. As a result of this the steel bars have to
be replaced as soon as they are weak, dirty or twisted and a plane material support
is not possible any more.

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• Gratings
Gratings are inserted into the table below the material support plate to collect small
wastage pieces. These pieces have to be removed from the grating to ensure the
necessary extraction capacity of the cutting table. Furthermore the gratings have to
be replaced if these are damaged or twisted by heat.

• Slag container
The dross which is produced during the cutting proces will drip through the meshes
into the slag containers in the bottom area of the table. These containers can be lifted
out of the table after the material support plate and the gratings have been removed.
You can use the eyelets at the bottom to lift the container by any crane. After empty-
ing the container the components have to be inserted in reverse order.

• Damper mechanism
The damper mechanism is to be maintained regularly to ensure a trouble free ope-
ration. Dust deposits on the mechanism that can hinder the operation of the damper
are to be removed. This is easily done when the slag containers are removed to be
emptied.
6. Spare parts
Item. Description Part No.
1 Material supports 1.600 mm, 3 sections 99 843 A 16 03
2 Material supports 1.600 mm, 4 sections 99 843 A 16 04
3 Material supports 2.100 mm, 3 sections 99 843 A 21 03
4 Material supports 2.100 mm, 4 sections 99 843 A 21 04
5 Material supports 2.600 mm, 3 sections 99 843 A 26 03
6 Material supports 2.600 mm, 4 sections 99 843 A 26 04
7 Gratings for table width 1.600 mm 144 0597
8 Gratings for table width 2.100 mm 144 0605
9 Gratings for table width 2.600 mm 144 0596
10 Synthetic guider for the damper mechanism 142 0445
11 Actuation roller for the damper 149 0343
12 Pressure spring for damper return 108 0026