Welding fume extraction system xFUME® PRIME
Powerful high-vacuum system for manual and automated welding
If you use automated welding, robot welding, or your welding workstations are located further apart, you need very powerful high-vacuum extraction systems – such as the xFUME® PRIME from ABICOR BINZEL. Up to 4 extraction torches can be connected.
Advantages of the xFUME® PRIME
The xFUME® PRIME high-vacuum extraction system combines the following advantages:
- Robust and durable construction
- High performance guaranteed even in continuous operation
- Can be used for manual welding, automatic welding, and robotic welding
- Up to 4 extraction torches can be connected as an option
- Equipped with HEPA filter (filter class H14) as standard
- Automatic filter cleaning increases filter service life and reduces operating costs
- Intuitive operation via 7" touch display
- Start-stop function – also for welding robots – increases the service life of the motor and filter
A few features in detail:
Up to 4 fume extraction torches can be connected to an xFUME® PRIME extraction system. For both manual and robotic welding. This allows you to bridge distances of up to 30 meters between the extraction system and the welding workstation.
Do you frequently change welding workstations and want to ensure reliable fume extraction everywhere? In this case, you can move the xFUME® PRIME extraction system to its new position using a forklift truck or indoor crane. It requires the same amount of space as a Euro pallet.
The HEPA filter of the xFUME® PRIME with filter class H14 allows you to recirculate the air directly into the work area. If regional exhaust air regulations require that the purified air be discharged to the outside, simply connect the xFUME® PRIME to your exhaust air system.
Extraction at source is the most efficient method for capturing the maximum amount of welding fumes and providing your employees with the best possible protection against harmful fumes. If you mainly use manual welding, mobile extraction systems with the appropriate extraction torches are the best choice.
How the welding fume extraction system works
Setting up at the application site
Use a forklift or cargo crane to position your xFUME® PRIME in your production facility so that you can connect up to four welding workstations. Up to two extraction torches can be connected to each extraction nozzle. To do this, remove the cap from the extraction nozzle. Instead of the adapter ring, use a Y-connector.
In the event of extremely heavy fume generation or if you are welding in forced positions, such as overhead, you have the option of connecting the extraction hose to an additional extraction funnel. You can place the extraction funnel directly above the area to be welded, for example using a magnet. In this case, use the Y-connector for an intake socket. Then connect the extraction torch and the additional extraction funnel to this.
If the regulations for handling exhaust air at your location permit, you can recirculate the purified air directly back into the ambient air. If recirculation is not permitted, simply connect your fume extraction system to your piping system, which will direct the purified air to the outside. The necessary accessories are available on request.
Intuitive operation
The xFUME® PRIME is easy to operate and self-explanatory thanks to the 7" touch display, which you activate when you switch on the extraction device.
The following operating functions are available:
- General system information
- System status information
- Filter pressure during operation
- Start manual cleaning process
- Set automatic frequency control for cleaning
- Switch to external control
- Service menu for setting individual parameters such as cleaning cycle, maximum vacuum, vacuum tolerance, warning times, etc.
- A help menu provides support if required
You can individually set the display to English, German, or Chinese.
Start-stop function
The xFUME® PRIME extraction system actively reduces operating costs. The start-stop function ensures that welding fume extraction is only active during welding. This not only reduces your energy costs but also extends the service life of the motor and filter. In addition, all employees in the vicinity benefit from lower noise levels.
The start-stop function can be activated for both manual and robotic welding.
Technical data
| Type | xFUME® PRIME |
| Weight: |
330 kg |
| Max. air flow: |
550 m3/h |
| Connection diameter: | 2 x 86 mm/60 mm (expandable to 4 torches with a Y-piece) |
| Max. negative pressure: | 19.000 Pa |
| Noise level: | 72 dB (A) |
| Voltage: | 380–400 V 50 Hz |
| Protection class: | IP 20 |
| Motor power: | 5,5 kW |
| Air requirement: | 120 l/min (hose inner diameter ≥ 13 mm), min. 6 bar |
| Filter: | Cartridge filter filter class E11, 10 m², HEPA filter H14, 2.6 m² |
| Dust capacity: | 40 liters |
| Dimensions: | Length 1,350 mm; width 750 mm; height 1,700 mm |
Integrated filter technology
The xFUME® PRIME is equipped with filter technology that has already proven itself in large central systems. The advantage of this system is that larger dust particles or foreign objects that are extracted are directed onto an impact plate immediately after extraction and fall into the dust collection container. These particles do not get in contact with the filter at all. This means:
- You need to run cleaning intervals less often
- Your filter lasts longer
- Work interruptions are reduced
Filter cleaning instead of disposable filters
The pressure-monitored cartridge filter offers you a major advantage. If the contamination level becomes too high, the negative pressure increases and activates the automatic filter cleaning system. It only takes a few seconds for the integrated rotary nozzle to loosen all particles. These then fall into the dust collection container.
With automated filter cleaning, you can be sure that the extraction performance remains consistently high. Compared to systems with disposable filters, the system included in the xFUME® PRIME also reduces operating costs.
W3 classification
Do you weld materials such as chrome-nickel alloys, which release hexavalent chromium that is highly harmful to health? Or do you work with galvanized steel, which releases zinc oxide during welding? With the xFUME® PRIME extraction system, you can safely weld these and other hazardous materials, as its filter system is tested in accordance with DIN EN ISO 21904 Part 1 and Part 2 and classified as W3. In any case, always familiarize yourself with your regional regulations for the extraction of welding fumes.
Suitable extraction torches
All fume extraction torches from the xFUME® range can be connected to the xFUME® PRIME extraction system::
- The powerful extraction torches of the xFUME® PRO series for tough everyday industrial use are a technical advancement of the proven RAB GRIP and RAB GRIP HE 2, which feel like you are holding a standard MIG/MAG torch in your hand
- The heavy-duty extraction torches of the xFUME® PRO HD series are specially designed for welding thick sheets with even better heat absorption and dissipation, higher temperature resistance, and longer service life compared to the xFUME® PRO extraction torches
- The lightest MIG/MAG extraction torch in its class, the gas cooled xFUME® COMPACT, for thin sheet metal welding up to 250 amps CO2
- The gas cooled and liquid cooled TIG extraction torches of the xFUME® TIG series for welding stainless steel, aluminum alloys, and high-alloy materials to absorb even invisible, highly harmful fumes
- The xFUME® AUT fume extraction torch, specially designed for automated welding, e. g., on welding machines, welding gantries, welding tractors, etc., to provide optimum protection against fumes for people working on or near the machines
- The xFUME® ABIROB® robot extraction torch, whose welding torch is based on the proven, highly reliable ABIROB® series and can be used with welding robots with external cable assemblies and welding cobots
Why is extraction at source necessary on a welding robot?
Welding robots are in an enclosure, but harmful fumes still escape during welding. Even if the welding cell has its own extraction system, particles still escape to the outside. People working in the vicinity of the welding robots are exposed to these fumes, for example when loading the robots. Extraction at source absorbs the welding fumes at the point of origin and is therefore considered the most efficient method of fume extraction.
Is fume extraction necessary for TIG welding?
With TIG welding, it appears that no fumes are produced. However, TIG welding produces fumes that are invisible to the human eye but very dangerous to humans. The best protection is to capture and extract these fumes directly at their source.
What are the advantages of extraction at source over hall exhaust systems?
Firstly, there is no other welding method that captures fumes more efficiently and precisely than extraction at source. The reason: the welding fumes are extracted directly where they are generated. This is also confirmed by the Federal Institute for Occupational Safety and Health. On the other hand, a fume extraction system for extraction at source requires considerably less energy than a system with hall ventilation. More and more companies with welding production are now converting their fume extraction systems to extraction at source.