Kemppi FreshAir Pressure Flow Control unit User Manual

FreshAir

Pressure Flow Control

FreshAir

Pressure Conditioner

Operating manual

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Gebrauchsanweisung

Manual de instrucciones

Käyttöohje

Manuel d’utilisation

Manuale d’uso

Gebruiksaanwijzing

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Instrukcja obsługi

Manual de utilização

Инструкции по эксплуатации

Bruksanvisning

操作手册

EN

DA

DE

ES

FI

FR

IT

NL

NO

PL

PT

RU

SV

ZH

OPERATING MANUAL

English

3© Kemppi Oy / 1309

CONTENTS

1. Introduction ......................................................................... 5

1.1 General ...................................................................................... 5

1.2 About the product ................................................................... 5

1.3 Requirements for compressed air supplied from

the compressor ......................................................................... 6

1.4 Manufactured by ...................................................................... 6

2. Preconditions for Use ........................................................ 6

3. Unpacking and Assembly ............................................... 7

3.1 Unpacking FA Pressure Flow Control ...................................... 7

3.2 Assembly ................................................................................... 8

4. Usage ...................................................................................... 9

4.1 Inspection before every use .................................................... 9

4.2 Air ow test ............................................................................... 9

5. Maintenance and Cleaning...........................................11

6. Spare Parts ..........................................................................11

6.1 Assembling FA Pressure Conditioner ....................................11

6.2 Filter for FA Pressure Conditioner ..........................................12

7. Troubleshooting ...............................................................13

8. Storage .................................................................................13

9. Warranty ...............................................................................14

10. Technical Data ...................................................................14

11. Ordering codes ..................................................................15

4 FreshAir Pressure Flow Control / Conditioner

1. INTRODUCTION

1.1 General

Congratulations on choosing the FreshAir (FA) respiratory protective system.
Used correctly, Kemppi products can signicantly increase the productivity
of your welding, and provide years of economical service.

This operating manual contains important information on the use,
maintenance and safety of your Kemppi product. The technical
specications of the equipment can be found at the end of the manual.

Please read the operating manual and other instructions carefully before
using the equipment for the rst time.

For more information on Kemppi products, contact Kemppi Oy, consult an
authorised Kemppi dealer, or visit the Kemppi web site at www.kemppi.com.

The specications presented in this manual are subject to change without
prior notice.

Important notes

Items in the manual that require particular attention in order to minimise
damage and personal harm are indicated with the ’NOTE!’ notation. Read
these sections carefully and follow their instructions.

1.2 About the product

FreshAir (FA) is a respiratory protective system which is based on the

principle of circulated pressurized air in the hood. A supply of clean, ltered
breathing air creates positive pressure inside the headpiece, which prevents
the external contaminated air from entering the user’s breathing zone.

A suitable compressed air source complying to EN 12 021 standard and
supplying hygienically clean breathing air, can be connected to the FA
Pressure Flow control valve. If the air does not comply with this standard,
install the FA Pressure Conditioner ltration unit before the FreshAir Pressure
Flow Control valve unit.

FA Pressure Flow Control is equipped with a pressure gauge for checking
the input pressure. The air at the outlet of a FA Pressure Conditioner lter
unit complies with EN 12 021 standard, if it is used within the temperature
range 10 – 60 °C and the air from the compressor complies with the
requirements explained later in this manual. Up to two users can be
connected to the FA Pressure Conditioner ltration unit.

NOTE: FreshAir Pressure Conditioner does not remove carbon monoxide (CO)
and carbon dioxide (CO₂).

EN

Disclaimer

While every eort has been made to ensure that the information contained
in this guide is accurate and complete, no liability can be accepted for any

5© Kemppi Oy / 1309

EN

errors or omissions. Kemppi reserves the right to change the specication of
the product described at any time without prior notice. Do not copy, record,
reproduce or transmit the contents of this guide without prior written
permission from Kemppi.

1.3 Requirements for compressed air supplied from
the compressor

• FA Pressure Conditioner can only be connected to a compressor which
supplies air at an oxygen concentration of 20 – 22 % vol.

• The carbon dioxide concentration must not exceed 500 ppm and the
carbon monoxide concentration must not exceed 15 ppm.

• The maximum concentration of water in the air may be 50 mg/m at
the rated pressure of 1 – 20 MPa. The humidity of the supplied air must
be controlled to prevent the unit from freezing.

1.4 Manufactured by

Manufactured for and on behalf of Kemppi Oy by:

CleanAir Ltd.

2. PRECONDITIONS FOR USE

Before you can use the system correctly and safely, you must fully
understand all of the following precautions.

• It is forbidden to use the unit in explosive environments.

• The system may only be used in environments where the probability

of damaging the supply hose is small and the user’s movement is not
limited.

• If the unit is used in environments with high temperatures, the supply
hose must be resistant to such eects.

• During an extreme work load, the pressure in the hood may reach
negative values and the user may feel air deciency. In such case the
protection of air passages is reduced.

• In the FreshAir system it is forbidden to use oxygen-enriched air or
oxygen. There is a risk of explosion.

• If another accessory apart from FreshAir (e.g. a spray gun) is connected
to the compressed air supply, the user must make sure that a sucient
air ow to the hood is secured even at the maximum air consumption
by this accessory.

• Before every use of the unit, check that the air ow is higher than the
minimum value specied in the technical parameters.

• If the unit stops supplying air for any reason, the user must leave the
contaminated area immediately.

• The unit, in a combination with a welding helmet or a hard hat, is

6 FreshAir Pressure Flow Control / Conditioner

not recommended for users with beard or long hair extending to the
respiratory zone.

• Beware of a higher CO concentration in the air supply, which may
occur if the compressor does not work properly when lubricating oil
burns due to high temperatures.

• The supply air pressure must be within the range 300 – 1000 kPa.

• The supply pressure hoses may only be located in such places of the

workplace where they cannot be damaged.

• The maximum working pressure of the hose supplied to the
conditioner is 1000 kPa.

• Before connecting the unit to the air distribution, it is necessary to
check what medium is in the line and what is its quality. For the FA
Pressure units, it is necessary to provide breathable air according to
EN 12 021 standard.

• The FA Pressure unit can be combined with Beta 90 FreshAir or Delta
90 FreshAir head tops.

• Information on head parts are provided in the instructions for use of
the FreshAir head parts.

FA Pressure Conditioner

• Pressure hose for FA Pressure Conditioner is not antistatic and the
maximum temperature to which they are resistant without damage is
70 °C.

• The maximum length of the hose from the compressed air distribution
or FA Pressure Conditioner to the head unit must not exceed 10 m.

• The recommended temperature range of use ideally is 10 – 40 °C. At
lower temperatures, the use of the protective hood with air supply
may be unpleasant. The lowest allowable temperature for use of FA
Pressure is 10 °C.

NOTE! If the recommendations stated in this manual are ignored, the warranty
is automatically invalidated and the level of personal protection may not meet
the designated standards.

EN

3. UNPACKING AND ASSEMBLY

3.1 Unpacking FA Pressure Flow Control

Check that the delivery is complete and no damage occurred during
transport.

7© Kemppi Oy / 1309

EN

Content of the FA Pressure Flow Control assembly

FreshAir Pressure unit 1 pc

Belt for the unit 1 pc

Air hose 1 pc

Air ow indicator 1 pc

Operating manual 1 pc

We recommend using the FA Pressure Conditioner together with the FA
Pressure Flow Control in order to guarantee the supplied breathing air
quality. The supplied compressed air in the breathing air distribution system
must meet EN 12 021 standard.

Content of the FA Pressure Conditioner assembly

FA Pressure Conditioner unit 1 pc

Unit stand 1 pc

Screws for connecting the unit to the stand 2 pcs

Washer 4 pcs

Operating manual 1 pc

3.2 Assembly

FA Pressure Flow Control + FA Pressure Conditioner

1. Check that all components are in good condition with no visible
damage.

2. Connect FA Pressure Conditioner to a suitable breathing air
distribution system. The air source must be equipped with safety
valve. If the FA Pressure Conditioner is not used, the air supply must
comply with EN 12 021 standard.

3. Attach the enclosed hose connector and screw it in.

4. It is recommended to use only original hoses supplied by the
manufacturer and certied according to the applicable standard.

5. Check that the air pressure in the distribution system corresponds to
the range 300 – 1000 kPa.

6. Attach the unit onto your belt and t the connecting hose to it.

7. Using the quick coupling, connect the pressure hose from the
compressed air source to the FA Pressure unit. The hose from FA
Pressure Conditioner to FA Pressure Flow Control must not be longer
than 10 metres.

8. Check the air ow as explained in section 4.2: "Air ow test". The lowest
allowable ow rate is 170 l/min.

8 FreshAir Pressure Flow Control / Conditioner

4. USAGE

4.1 Inspection before every use

Do the following checks always before you start using the equipment:

• Visually check individual parts, particularly the air hose and sealing
elements for damages.

• Check that the hose is tted correctly to the air unit and to the head
part connector.

• The air pressure in the distribution system must be in the range
300 – 1000 kPa.

• Check that the air ow in the hose is sucient.

• Ensure that air is supplied into the head part breathing zone.

4.2 Air ow test

When measuring the air ow, follow the instructions delivered with the ow
indicator. If the ow rate is dierent, proceed as follows.

EN

1. Pull plastic screw cap out to the adjustment position and turn counter­clockwise by hand until it stops.

2. Lever the cap o from the regulation valve with a at screwdriver.

9© Kemppi Oy / 1309

EN

3. Let the noise silencer stay in place and connect the ow meter to the
regulation valve. Turn on the air supply and adjust the ow rate to
170 l/min using a at screwdriver.

4. Air ow is sucient, if the top of the cone is placed in the green area. Read
the ow meter manual.

5. Close the air supply. Remember that there is still some pressure in the
conditioner for a few seconds after the air supply is closed.

6. Firmly replace the plastic cap to the regulation valve body with a rm
pressing action.

WARNING: This test is an indication of mechanical lter state. However, the
absorption capacity of the activated carbon lter in the FA Pressure Conditioner
may already be exhausted, even at a sucient ow rate. The lter should be
replaced when you smell a noticeable odour, but at least every 3 months.

10 FreshAir Pressure Flow Control / Conditioner

5. MAINTENANCE AND CLEANING

FA Pressure Flow Control unit

Every time you nish work, it is recommended to clean the FA Pressure Flow
Control unit, to check individual parts and to replace the damaged ones.

• Cleaning must be carried out in a well ventilated room. Avoid
inhaling the harmful dust settled on individual parts of the unit and
accessories.

• It is forbidden to use cleaning agents containing solvents or abrasives.
Mild soap detergent and warm water is recommended.

• The air hose can be rinsed with clean water.

• Use a damp cloth for cleaning. Each part must be wiped dry after

cleaning.

FA Pressure Conditioner

• Once a week, drain the condensate from the bottom of the unit, using
the drain cock located at the base of the unit. Before completing
this operation, it is recommended to disconnect the unit from the
compressed air supply.

• Replace the lter at least once every three months. After this period,
viruses and bacteria may proliferate in the units lter and if it is used
regularly, the absorption capacity of the activated carbon to eliminate
odour may be exhausted. If the air leaving FA Pressure Conditioner
smells in any way, replace the lter immediately. When replacing the
lter, clean the inner part of the container with a dry cloth.

EN

6. SPARE PARTS

6.1 Assembling FA Pressure Conditioner

Screw the pressure conditioner body onto the stand.

11© Kemppi Oy / 1309

6.2 Filter for FA Pressure Conditioner

The FA Pressure Conditioner contains a combined lter which removes oil
mist, smells and avours from industrially produced compressed air.

NOTE: The lter does not remove CO and CO₂.

Read the instructions for use and replacement.

Replacing FA Pressure Conditioner lters:

EN

1.

2.

x 6

3.

1. Unscrew the top part of the lter pressure container (6 screws).

2. Remove the contaminated lter, wipe the inside of the container.

3. Check the condition of the rubber seal in the top cover. If the seal is
damaged, replace it.

4. Install a new lter on the container cover and screw it back.

5. Check the container for leakage. If the container is not absolutely tight,
tighten all screws that fasten the top cover.

4.

12 FreshAir Pressure Flow Control / Conditioner

7. TROUBLESHOOTING

Fault Probable cause Recommendation

The unit does not work
at all.

The unit does not supply
the sucient amount of air.

During the use, if there is a sudden decrease or increase in air supply and the
user is located in a contaminated area, it is necessary to leave the workplace
immediately and check the following:

• The unit is assembled correctly.

• The lter condition in FA Pressure Conditioner is in good condition.

• The air hose is not damaged during the use.

• The noise damper in FA Pressure FC is not clogged.

• The seal on the safety hood is in good condition.

Compressed air supply failure. Check the compressed air source.

Hose damage. Check that connecting hoses are

Air hose or air channel blocked. Check and remove the possible

Air escapes through leakages. Check all sealing elements and

The bae is clogged. Replace the bae in FA Pressure

The lter in FA Pressure
Conditioner is clogged.

not damaged.

obstacle.

connections, check that the hose
is not damaged and without
leaks.

Flow Control.

Replace the lter.

EN

8. STORAGE

All parts of a FreshAir system must be stored in an environment with
temperature between 0 – 40 °C and humidity between 20 – 80 % Rh. The
storage life is 2 years for the product if stored in its original unopened
package. Temporary transportation to and from site is permitted, providing
the units are stored in a dry container.

NOTE! Batteries get discharged even if not in use. Therefore for long-term
storage it is highly recommended to charge the NiMH batteries every
12 months.

13© Kemppi Oy / 1309

EN

9. WARRANTY

There is a 12 month warranty covering production defects and a 6 month
warranty for batteries.

The warranty begins from the date of purchase. The claim must be lodged
with the dealer. The paid invoice or receipt must be produced if claiming on
the warranty.

Warranty is void if there is evidence of mechanical intervention or abuse of
the unit(s). Warranty does not cover, in particular, defects caused by a late
replacement of the lter or by using a lter damaged by attempted cleaning
with compressed air.

10. TECHNICAL DATA

FreshAir Pressure Flow Control

Minimum air ow 170 l/min-1

Maximum air ow > 400 l/min-1

Weight of unit 250 g

Inlet connection

Outlet connection MINI DN 5

Noise level of unit 61 dB

Belt size 60 – 150 cm

Supply pressure range 300 – 1000 kPa

Recommended temperature range at work 10 – 60 °C

Recommended air humidity range at
workplace

Certication Class 2A

20 – 80 % Rh

FreshAir Pressure Conditioner

Maximum air ow 500 l/min

Weight without lter 6300 g

Weight including lter 6800 g

Inlet connection Compatible with RECTUS series 25,26 a CEYN320

Outlet connection Compatible with RECTUS series 25,26 a CEYN320

Recommended temperature range at work 10 – 60 °C

Recommended air humidity range at
workplace

14 FreshAir Pressure Flow Control / Conditioner

20 – 80 % Rh

Certication If the requirements of TP-610050-1 are met, it

Notied body for CE testing:

Výzkumný ústav bezpečnosti práce, v.v.i. – ZL
Testing Laboratory No. 1024
Jeruzalémská 9, 116 52 Praha 1
Authorized Body 235
Notied Body 1024

11. ORDERING CODES

Packages
FA PRESSURE FLOW PACK

FA PRESSURE FLOW SPIRAL HOSE
FA PRESSURE CONDITIONER UNIT

complies with EN 12 021

includes:
FA Pressure ow control set (W007496)
and
FA Pressure ow hose (W007501)

10 m W007506

W007515

W007504

EN

FreshAir Pressure Flow Control set

valve and belt W007496

Spare parts and consumables

FreshAir Pressure Noise silencer W007498

FreshAir Pressure Control valve cap W007499

FreshAir Pressure Air tting W007500

FreshAir Pressure Flow hose exible connection W007501

FreshAir Pressure Flow Control belt W007502

FreshAir Pressure Flow indicator RD40x1/7“ W007503

FreshAir Pressure Conditioner unit W007504

FreshAir Pressure Conditioner lter W007505

FreshAir Pressure Flow Spiral hose 10 m W007506

15© Kemppi Oy / 1309

KEMPPI OY

Kempinkatu 1
PL 13
FI-15801 LAHTI
FINLAND
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www.kemppi.com

Kotimaan myynti:

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myynti.@kemppi.com

KEMPPI SVERIGE AB

Box 717
S-194 27 UPPLANDS VÄSBY
SVERIGE
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KEMPPI NORGE A/S

Postboks 2151, Postterminalen
N-3103 TØNSBERG
NORGE
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KEMPPI DANMARK A/S

Literbuen 11
DK-2740 SKOVLUNDE
DANMARK
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KEMPPI BENELUX B.V.

Postbus 5603
NL-4801 EA BREDA
NEDERLAND
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[e-mail]

KEMPPI (UK) Ltd

Martti Kemppi Building
Fraser Road
Priory Business Park
BEDFORD, MK44 3WH
UNITED KINGDOM
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[e-mail]

KEMPPI FRANCE S.A.S.

65 Avenue de la Couronne des Prés
78681 EPONE CEDEX
FRANCE
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KEMPPI GmbH

Perchstetten 10
D-35428 Langgöns
DEUTSCHLAND
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KEMPPI SPÓŁKA Z O.O.

Ul. Borzymowska 32
03-565 WARSZAWA
POLAND
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KEMPPI AUSTRALIA PTY LTD.

13 Cullen Place
P.O. Box 5256, Greystanes NSW 2145
SMITHFIELD NSW 2164
AUSTRALIA
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OOO KEMPPI

Polkovaya str. 1, Building 6
127018 MOSCOW
RUSSIA
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ООО КЕМППИ

ул. Полковая 1, строение 6
127018 Москва
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KEMPPI, TRADING (BEIJING) COMPANY,
LIMITED

Room 420, 3 Zone, Building B,
No.12 Hongda North Street,
Beijing Economic Development Zone,
100176 Beijing
CHINA
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[phone]
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肯倍贸易（北京）有限公司
中国北京经济技术开发区宏达
北路12号
创新大厦B座三区420室 (100176)

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KEMPPI INDIA PVT LTD

LAKSHMI TOWERS
New No. 2/770,
First Main Road,
Kazura Garden,
Neelankarai,
CHENNAI - 600 041
TAMIL NADU
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[e-mail]

www.kemppi.com

1918830

1309