Abicor Binzel xFUME VAC ADVANCED User manual
EN - 2 BAL.0731.0 • 2019-08-20
xFUME VAC ADVANCED
© The manufacturer reserves the right, at any time and without prior notice, to make such changes and amendments to these
operating instructions as become necessary due to misprints, inaccuracies or product enhancements. Such changes will,
however, be incorporated into subsequent editions of the operating instructions.
All brand names and trademarks that appear in these operating instructions are the property of their respective owners/
manufacturers.
Our latest product documents as well as all contact details for the ABICOR BINZEL national subsidiaries and partners
worldwide can be found on our website at www.binzel-abicor.com
1 Identification EN-3
1.1 Marking EN-3
1.2 EU declaration of conformity EN-3
2 Safety EN-4
2.1 Designated use EN-4
2.2 Responsibilities of the user EN-4
2.2.1 Country-specific responsibilities of the user EN-4
2.3 Specific safety instructions EN-5
2.4 Safety instructions for the mains connection EN-5
2.5 Personal protective equipment (PPE) EN-5
2.6 Classification of the warnings EN-6
2.7 Warning and notice signs EN-6
2.8 Emergency information EN-6
3 Product description EN-7
3.1 Technical data EN-7
3.2 Nameplate EN-8
3.3 Signs and symbols used EN-8
4 Scope of delivery EN-9
4.1 Transport EN-9
4.2 Storage EN-9
5 Functional description EN-10
6 Putting into operation EN-11
6.1 Transport and installation EN-11
6.2 Attaching the welding torch’s extraction hose EN-12
6.3 Attaching the compressed air hose EN-12
6.4 Establishing an electrical connection EN-13
6.4.1 Version 115V EN-13
6.5 Version 230 V EN-13
6.6 Automatic starting EN-13
6.6.1 Mounting the current clamp EN-14
7Operation EN-14
7.1 Control elements/ports EN-15
8 Putting out of operation EN-15
9 Maintenance and cleaning EN-16
9.1 Inspection intervals EN-16
9.2 Replacing the turbines EN-17
9.3 Replacing the carbon brushes
(for the 230 V version only) EN-17
9.4 Replacing the filter cartridges EN-18
9.5 Emptying the dust collecting drawer EN-18
10 Troubleshooting EN-19
11 Disassembly EN-20
12 Disposal EN-21
12.1 Welding dust EN-21
12.2 Materials EN-21
12.3 Consumables EN-21
12.4 Packaging EN-21
xFUME VAC ADVANCED 1 Identification
BAL.0731.0 • 2019-08-20 EN - 3
1 Identification
The xFUME VAC ADVANCED extraction system is a mobile solution used in industry and in the trade for extracting fumes
and dust generated during welding, cutting and grinding processes. These operating instructions exclusively describe the
xFUME VAC ADVANCED extraction system, which must only be operated using original ABICOR BINZEL spare parts.
When used in these operating instructions, the terms “device” and “extraction system” always refer to the 220 V and 115 V
versions of the xFUME VAC ADVANCED extraction system.
1.1 Marking
This product fulfills the requirements that apply to the market to which it has been introduced.
A corresponding marking has been affixed to the product, if required.
1.2 EU declaration of conformity
EN - 4 BAL.0731.0 • 2019-08-20
2 Safety xFUME VAC ADVANCED
2Safety
The attached safety instructions must be observed.
2.1 Designated use
• The device described in these instructions may be used only for the purpose and in the manner described in these
instructions. It is used to extract welding fumes and dust that is generated during welding. The extraction can be used to
extract fumes and dust generated during welding or cutting of steels with an alloy content of nickel and chromium
beneath 30%. In doing so, observe the operating, maintenance and servicing conditions.
• Any other use is considered improper.
• Unauthorised modifications or changes to enhance the performance are not permitted.
2.2 Responsibilities of the user
• Only the following personnel are permitted to work on the device:
• those who are familiar with the basic regulations on occupational safety and accident prevention;
• those who have been instructed on how to handle the device;
• those who have read and understood these operating instructions;
• those who have read and understood the chapter entitled “Safety Instructions”;
• those who have been trained accordingly;
• those who are able to recognize possible risks because of their special training, knowledge, and experience.
• Keep other people out of the work area.
• Please observe the occupational health and safety regulations of the relevant country.
• Observe the regulations on occupational safety and accident prevention.
2.2.1 Country-specific responsibilities of the user
The recirculation of filtered air is sometimes associated with health risks and is therefore prohibited in certain countries.
WARNING
Electromagnetic interferences
The device can cause electromagnetic interferences when used in residential areas.
• Use only in industrial zones in accordance with DIN EN 61000-6-3.
NOTICE
• Please observe the occupational health and safety regulations of the relevant country. The recirculation of filtered air is
not permitted in all countries.
• When used in France, the cleaned air must be expelled from the building.
xFUME VAC ADVANCED 2 Safety
BAL.0731.0 • 2019-08-20 EN - 5
2.3 Specific safety instructions
• Do not use or store the extraction system outdoors in wet conditions.
• If the power supply cable or device connection cables require replacement, only versions indicated by the manufacturer
must be used.
• When using the welding fume filter, the volume flow fed back into the work area must not exceed 50 % of the supply air
for the installation area. In the case of natural ventilation, a supply air flow of one room volume per hour is to be
assumed. This corresponds to an air change number of 1 per hour.
Supply air flow [m³/h] = room volume [m³] x air change number [1/h]
2.4 Safety instructions for the mains connection
• The power supply cable must be checked for damage and wear at regular intervals.
• The extraction system must only be operated if the power supply cable is undamaged.
• The 115 V/230 V 50 Hz/60 Hz mains connector must be protected by a 16 A fuse.
• Only qualified persons are authorised to replace the power supply cable and mains plug.
• Splash-water protection and mechanical stability must be ensured when replacing the mains plug on the power supply
cable.
• Always use an H07RN-F3G1.5 rubber cable when replacing the power supply cable.
2.5 Personal protective equipment (PPE)
To avoid danger to the user, these instructions recommend the use of personal protective equipment (PPE).
• This consists of protective clothing, safety goggles, a class P3 respiratory mask, protective gloves and safety shoes.
DANGER
Risk of injury and property damage
The extraction of flammable, aggressive chemical or oil-laden substances and materials as well as dusts containing
aluminium or magnesium can pose a risk of injury and property damage.
• Use the device according to its designated use only.
WARNING
Health risk due to harmful dust
Before and during operation, please observe the following:
• The extraction system contains harmful dust as of the first use.
• The extraction system must not be operated without the filter system.
• The extraction system must not be operated with an open dust collecting drawer.
• The extraction system must be closed during operation and during the cleaning process.
NOTICE
• Make sure that the power supply cable is not damaged by being driven over, crushed, torn or similar.
EN - 6 BAL.0731.0 • 2019-08-20
2 Safety xFUME VAC ADVANCED
2.6 Classification of the warnings
The warnings used in the operating instructions are divided into four different levels and shown prior to potentially dangerous
work steps. Arranged in descending order of importance, they have the following meanings:
2.7 Warning and notice signs
The following warning and notice signs can be found on the product:
2.8 Emergency information
In the event of an emergency, immediately disconnect the following supplies:
• Electrical power supply
• Burning oil or emulsions must be extinguished using a CO2 or powder fire extinguisher.
DANGER
Describes an imminent threatening danger. If not avoided, this will result in fatal or extremely critical injuries.
WARNING
Describes a potentially dangerous situation. If not avoided, this may result in serious injuries.
CAUTION
Describes a potentially harmful situation. If not avoided, this may result in slight or minor injuries.
NOTICE
Describes the risk of impairing work results or potential material damage to the equipment.
Symbol Meaning
Read the operating instructions!
Pull out the mains plug!
Wear eye protection!
Wear a mask!
Wear hand protection!
xFUME VAC ADVANCED 3 Product description
BAL.0731.0 • 2019-08-20 EN - 7
3 Product description
3.1 Technical data
WARNING
Hazards caused by improper use
If improperly used, the device can present risks to persons, animals and material property.
• Use the device according to its designated use only.
• Do not convert and modify the device to enhance its performance without authorization.
• Only qualified personnel are permitted to perform work on the device or system.
Connection voltage 115 V 230 V
Drive power 2 × 0.8 kW
Rated frequency 50 Hz/60 Hz
Filter surface 2 × 0.8m²
Connector diameter 60 mm
Max. air volume flow 340 m³/h
Sound pressure level LpA <68dB(A)
Max. inlet air pressure 5–6 bar
Weight 40 kg
Dimensions (LxWxH) 370×370×1050mm
Tab. 1 General information
Ambient temperature 0 °C to +40 °C
Relative humidity Up to 90 % at 20°C
Tab. 2 Ambient conditions during operation
Storage in a closed environment, ambient temperature 0°Cto+40°C
Ambient temperature for shipment −15 °C to +40 °C
Relative humidity Up to 90 % at 20°C
Tab. 3 Ambient conditions for transport and storage
EN - 8 BAL.0731.0 • 2019-08-20
3 Product description xFUME VAC ADVANCED
3.2 Nameplate
The extraction system is labelled by means of a nameplate. When making enquiries, please note the following information:
• Device type, device number, year of construction
3.3 Signs and symbols used
The following signs and symbols are used in the operating instructions:
Fig. 1 Nameplate
Symbol Description
• Bullet symbol for instructions and lists
Cross reference symbol refers to detailed, supplementary or further information
1Step(s) described in the text to be carried out in succession
xFUME VAC ADVANCED 4 Scope of delivery
BAL.0731.0 • 2019-08-20 EN - 9
4 Scope of delivery
Order the equipment parts and wear parts separately.
The order data and ID numbers for the equipment parts and wear parts can be found in the current product catalogue.
Contact details for advice and orders can be found online at www.binzel-abicor.com.
4.1 Transport
Although the items delivered are carefully checked and packaged, it is not possible to fully exclude the risk of transport
damage.
4.2 Storage
For ambient conditions for storage in a closed environment:
Tab. 3 Ambient conditions for transport and storage on page EN- 7
• xFUME VAC ADVANCED extraction system • Extraction hose (l=5.00 m) incl. 2× connectors
• 1 current clamp • Compressed air connector incl. seal ring
• Mains cable with safety plug • Operating instructions
Tab. 4 Scope of delivery
Goods inspection Use the delivery note to check that everything has been delivered.
Check the delivery for damage (visual inspection).
In case of
complaints
If the delivery has been damaged during transportation, contact the last carrier immediately.
Retain the packaging for potential inspection by the carrier.
Packaging for
returns
Where possible, use the original packaging and the original packaging material. If you have
questions concerning packaging and safety during shipment, please consult your supplier, carrier
or transporter.
Tab. 5 Transport
EN - 10 BAL.0731.0 • 2019-08-20
5 Functional description xFUME VAC ADVANCED
5 Functional description
The extraction system forms part of a welding system and is intended for use with manual and robot welding torches.
A maximum of two fume extraction torches can be connected. The filter medium corresponds to the welding fume separation
class H13. The extraction system is designed to separate fumes generated during welding or the thermal cutting of steels with
alloy constituents such as nickel or chrome < 30 % and high-quality steels.
Harmful fumes are produced during the welding process. Two powerful turbines (2) draw the polluted air into the middle
section of the extraction device via the air intake fittings (3). During this process, the air is pressed through the filter membrane
in the filter cartridges (5). The particles and dust from the welding process stick to the surface of the filter material. The filter
cartridges are automatically cleaned during operation. The cleaned air is then directed into the upper section of the
extraction system and returned to the environment through an exhaust air grille (1).
The extraction system can be connected to the following receptacles:
• Fume extraction torch
• Welding torch with external extraction systems
• Funnel-shaped nozzle with magnetic bracket
1Exhaust air grille 22 turbines 32 air intake fittings 44 castors 52 filter cartridges
Fig. 2 Functional description
1
3
2
5
4
xFUME VAC ADVANCED 6 Putting into operation
BAL.0731.0 • 2019-08-20 EN - 11
6 Putting into operation
6.1 Transport and installation
DANGER
Risk of injury due to unexpected start
The following instructions must be adhered to during all maintenance, servicing, assembly, disassembly and repair work:
• Switch off the extraction system.
• Disconnect all electrical connections.
DANGER
Risk of fire
Before installing and operating the extraction system, please observe the following:
• The extraction of welding fumes while welding oil-wetted parts is prohibited.
• The system must not be installed in areas that are subject to dust or gas explosion hazards.
• Before putting the system into operation, check whether the operating voltage specified on the nameplate corresponds
to the mains voltage.
• The operating, maintenance and servicing conditions must be observed.
NOTICE
• Only use the extraction system in sufficiently ventilated rooms.
• The extraction system is equipped with a safety device to monitor the minimum air volume flow to be extracted.
Monitoring occurs using a differential pressure switch (ON/OFF). If a filter change is required, the service light (1)
lights up, Fig. 5 on page EN-15.
• The extraction system must be positioned on a flat surface near the work area.
• Only qualified personnel are permitted to perform work on the device or system.
CAUTION
Risk of injury
Injuries may be caused by improper handling:
• Use an appropriate lifting tool with load securing devices for transport and installation of the device.
• Only transport the device over even ground.
• Watch out for obstacles.
• Avoid lifting and setting down the device abruptly.
• If passing over an edge, ensure that the filter housing is not in position on the system as this can damage the filter
housing.
• Do not lift the components over persons or other devices.
• Check and wear your personal protective equipment.
• Send bystanders out of the danger zone.
• Note the weight of the extraction system when lifting it.
3.1 Technical data on page EN- 7
CAUTION
Risk of toppling
Physical injury or damage to the extraction system can result from its improper transportation and positioning.
• Place the extraction system on a suitable surface (flat, solid, dry) on which it will not topple over.
EN - 12 BAL.0731.0 • 2019-08-20
6 Putting into operation xFUME VAC ADVANCED
Fig. 2 Functional description on page EN- 10
1Position the extraction system appropriately and lock the castors (4).
6.2 Attaching the welding torch’s extraction hose
1Connect the extraction hose (4) to the air intake fittings (1) on the extraction system (2).
6.3 Attaching the compressed air hose
Fig. 5 Control elements/ports on page EN- 15
1Screw in the compressed air connector, including the seal (included in the scope of delivery).
2Attach the compressed air hose to the compressed air connector (8).
NOTICE
• The extraction system must be at least 1.0 m away from the wall.
• Select a location that enables a short and straight extraction hose feed and prevents it from entering the employee’s
space of movement.
• Protect the components from rain and direct sunlight.
• Only use the device in dry, clean and well-ventilated rooms.
NOTICE
• A maximum of two fume extraction torches (1) can be connected.
1Air intake fittings 2Extraction system 3Fume extraction torch 4Extraction hose
Fig. 3 Attaching the welding torch’s extraction hose
1
3
4
2
xFUME VAC ADVANCED 6 Putting into operation
BAL.0731.0 • 2019-08-20 EN - 13
6.4 Establishing an electrical connection
For the mains voltage and the fuse protection, please refer to:
3.1 Technical data on page EN- 7
3.2 Nameplate on page EN- 8
13 Appendix
6.4.1 Version 115V
The mains plug is not pre-attached.
1Attach and plug in an appropriate mains plug (customer-specific).
6.5 Version 230 V
Mains cable and mains plug are pre-mounted.
1Plug in the mains plug.
6.6 Automatic starting
The automatic starting function enables the extraction system to be switched on automatically when the welding process
starts. When the welding process starts, the extraction system receives a signal from the current clamp and automatically
starts the extraction process.
WARNING
Electric shock
Dangerous voltage due to defective cables.
• Check all live cables and connections for proper installation and damage.
• Replace any damaged, deformed or worn parts.
NOTICE
• Before establishing an electrical connection between the product and the mains, check whether the operating voltage
indicated on the nameplate corresponds to the mains voltage.
NOTICE
• The automatic function increases the extraction system’s service life.
EN - 14 BAL.0731.0 • 2019-08-20
7Operation xFUME VAC ADVANCED
6.6.1 Mounting the current clamp
The extraction system comes with a current clamp. A second current clamp is optionally available for the connection of
a second fume extraction torch.
1Attach the current clamp to the connector (10).
Fig. 5 Control elements/ports on page EN- 15
2Place the current clamp (1) over the cable assembly (3).
3On the control panel, set the Auto On/Off switch (3) to “On”, Fig. 5.
7Operation
Fig. 5 Control elements/ports on page EN- 15
1Set the Device On/Off switch (4) on the extraction system to the “On” position.
NOTICE
• Ensure that the red dot on the current clamp is always pointing in the direction of the current flow.
1Current clamp 2Red dot 3Cable assembly
Fig. 4 Mounting the current clamp
12
3
WARNING
Health risk due to harmful dust
Before and during operation, please observe the following:
• During operation, the complete extraction system must be kept closed.
• After switching off the extraction system, wait at least one minute before opening the dust collecting drawer.
CAUTION
Risk of injury
Injuries may be caused by improper handling.
• Do not draw in any flammable substances or liquids.
• Ensure sufficient ventilation while operating the extraction system.
6.1 Transport and installation on page EN- 11
NOTICE
• Only qualified personnel are permitted to perform work on the device or system.
• Consult the documentation for the welding components.
6 Putting into operation on page EN- 11 Cleaning and maintenance
xFUME VAC ADVANCED 8 Putting out of operation
BAL.0731.0 • 2019-08-20 EN - 15
7.1 Control elements/ports
8 Putting out of operation
Fig. 5 Control elements/ports on page EN- 15
1Use the Device On/Off switch (4) on the control panel to switch off the extraction system.
2Disconnect the extraction system from the power supply.
3Disconnect the compressed air supply and, if applicable, the current clamp.
1Service LED
2Power LED
3Auto/Manual switch
4Device On/Off
5Fuse
6Power cable
7Hour meter
8Compressed air connector
9Current clamp port 1
10 Current clamp port 2
Fig. 5 Control elements/ports
7
8
10
9
6
5
4
3
2
1
EN - 16 BAL.0731.0 • 2019-08-20
9 Maintenance and cleaning xFUME VAC ADVANCED
9 Maintenance and cleaning
Regular ongoing maintenance and cleaning are prerequisites for a long service life and trouble-free operation.
9.1 Inspection intervals
We recommend splitting cleaning into two parts. The first part involves emptying the dust from the collecting drawer.
Regularly emptying out the dust can extend the service life of the filter cartridge. The second part involves the electrical and
mechanical maintenance of the filter system. The maintenance cycle is determined by the work environment and by the length
of the scheduled intervals between maintenance of the devices. The maintenance cycle is usually three months.
If the device is operated for more than 8 hours a day, the maintenance intervals should be changed as needed. Regular
maintenance keeps the device in good visual condition and good working order.
DANGER
Risk of injury due to unexpected start
The following instructions must be adhered to during all maintenance, servicing, assembly, disassembly and repair work:
• Switch off the extraction system.
• Close off the compressed air supply.
• Disconnect all electrical connections.
WARNING
Electric shock
Dangerous voltage due to defective cables.
• Check all live cables and connections for proper installation and damage.
• Replace any damaged, deformed or worn parts.
WARNING
Risk of crushing
Limbs may be drawn into the device and crushed.
• Keep your hands out of the danger zone.
NOTICE
• Take appropriate precautions before conducting maintenance and cleaning work.
• Maintenance and cleaning work must only be carried out on the extraction system in areas with locally filtered forced
ventilation.
• Only qualified personnel are permitted to perform work on the device or system.
• Check and wear your personal protective equipment.
NOTICE
• The specified maintenance intervals are standard values and refer to single-shift operation.
• We recommend recording the inspections. The date of the inspection, the detected defects and the name of the inspec-
tor must be recorded.
xFUME VAC ADVANCED 9 Maintenance and cleaning
BAL.0731.0 • 2019-08-20 EN - 17
9.2 Replacing the turbines
1Turn off the extraction system by setting the Device On/Off switch (4) to “Off”, Fig. 5.
2Pull out the mains plug (no Fig.).
3Open the clamps on the sides and use the handle to lift off the upper section of the extraction system.
4Undo the screws and remove the cover.
9.3 Replacing the carbon brushes (for the 230 V version only) on page EN- 17
5Loosen the turbine clamps and electrical connection, then remove the turbines.
6Dispose of the turbines in accordance with local regulations (no Fig.).
12 Disposal on page EN- 21
7Insert the new turbines, attach the turbine clamps and establish an electrical connection (no Fig.).
8Reverse the steps above to reassemble the system (no Fig.).
9.3 Replacing the carbon brushes (for the 230 V version only)
The carbon brushes have a service life of approx. 800 hours. The service life is reduced by 30% each time a carbon brush
is replaced. The carbon brushes can be replaced twice in total. After two replacements, the motor must then be replaced.
Step 1 to step 4 on page EN-17
1Loosen the clamps on the sides and remove the turbine cover.
2Remove the carbon brush cover and replace the carbon brushes.
3Dispose of the brushes in accordance with local regulations (no Fig.).
12 Disposal on page EN- 21
4Reverse the steps above to reassemble the system (no Fig.).
Fig. 6 Replacing the turbines
3)
4)
5)
Fig. 7 Replacing the carbon brushes
1)
2)
EN - 18 BAL.0731.0 • 2019-08-20
9 Maintenance and cleaning xFUME VAC ADVANCED
9.4 Replacing the filter cartridges
1Turn off the extraction system by setting the Device On/Off switch (4) to “Off”, Fig. 5.
2Pull out the mains plug (no Fig.).
3Loosen the lower clamps and remove the housing.
4Unscrew the filter cartridges and replace with new ones.
5Dispose of the dust collecting bag in accordance with local regulations (no Fig.).
12 Disposal on page EN- 21
6Reverse the steps above to reassemble the system (no Fig.).
9.5 Emptying the dust collecting drawer
1Turn off the extraction system by setting the Device On/Off switch (4) to “Off”, Fig. 5.
2Pull out the mains plug.
3Loosen the screws (3) and pull out the dust collecting drawer (2).
4Empty the dust collecting drawer (2).
5Dispose of the dust collecting bag in accordance with local regulations (no Fig.).
12 Disposal on page EN- 21
6Reverse the steps above to reassemble the system.
Fig. 8 Replacing the filter cartridges
3)
4)
1Extraction system 2Dust collecting drawer 32 screws
Fig. 9 Emptying the dust collecting drawer
1
24
xFUME VAC ADVANCED 10 Troubleshooting
BAL.0731.0 • 2019-08-20 EN - 19
10 Troubleshooting
Please observe the attached ‘Warranty’ document. In the event of any doubts and/or problems, please contact your retailer
or ABICOR BINZEL.
DANGER
Risk of injury and device damage when handled by unauthorised persons
Improper repair work and modifications to the product may lead to serious injuries and damage to the device. The
product warranty will be rendered invalid if work is carried out on the product by unauthorised persons.
• Only qualified personnel are permitted to perform work on the device or system.
CAUTION
• Suitable safety measures must be taken before performing maintenance and cleaning work.
• Maintenance and cleaning work must only be carried out on the extraction system in areas with locally filtered forced
ventilation.
• Always wear your personal protective equipment when performing maintenance and cleaning work.
• Personal protective equipment consists of protective clothing, safety goggles, a class P3 respiratory mask, protective
gloves and safety shoes.
NOTICE
• Please also consult the operating instructions for the welding components, such as the power source, welding torch
system, re-circulating cooling unit etc.
Fault Cause Troubleshooting
No complete fume detection. • Clean air outlet covered. • Keep the clean air outlet clear.
Extraction volume too low.
• Filter elements saturated. • Replace the filter elements.
• Extraction hose blocked. • Clean the extraction hose.
• Extraction hose defective. • Replace the extraction hose.
External extraction system does not start.
• Power supply defective. • Check and replace if necessary.
• Electrical components defective.
• Carbon brushes defective
Dust escapes from the dust collecting
drawer.
• Dust collecting drawer not properly
sealed.
• Check and install correctly.
• Dust collecting drawer full. • Empty the dust collecting drawer.
Filter cleaning does not work. • Compressed air supply faulty. • Check and replace if necessary.
Tab. 6 Troubleshooting
EN - 20 BAL.0731.0 • 2019-08-20
11 Disassembly xFUME VAC ADVANCED
11 Disassembly
To disassemble and dispose of the device, follow the steps in sections 6 and 7 in reverse order.
6 Putting into operation on page EN- 11
7 Operation on page EN- 14
Dispose of the components in accordance with legal regulations.
12 Disposal on page EN- 21
DANGER
Risk of injury due to unexpected start
The following instructions must be adhered to during all maintenance, servicing, assembly, disassembly and repair work:
• Switch off the extraction system.
• Close off the compressed air supply.
• Disconnect all electrical connections.
NOTICE
• Only qualified personnel are permitted to perform work on the device or system.
• Check and wear your personal protective equipment.
• Persons without personal protective equipment must not remain near the extraction system when it is being
disassembled.
• The extraction system must not be cleaned using compressed air or a hammer.
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