Installation & Operating Instructions

Installation & Operating Instructions

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Please find accompanying video demonstrations of Aquaflame machine setup here.

1. Filling the cell

Aquaflame Model 300 = 400 ml De-ionised to mix with the Koh Flakes – no second top up.

Aquaflame Model 500 = 800ml De-ionised to mix with the Koh Flakes first fill – 350ml second fill De-ionised water.

Aquaflame Model 800 = 1250ml De-ionised to mix with the Koh Flakes first fill – 1000ml second fill De-ionised water.

Aquaflame Model 1200 = 1250ml De-ionised to mix with the Koh Flakes first fill – 1250ml second fill De-ionised water – 100ml of De-ionised water.

ALWAYS WEAR ADEQUATE FACE & HAND PROTECTION – Using a clean polythene container, measure out the correct quantity of distilled water.
Pour in all the Electrolyte crystals supplied taking care not to splash the liquid. Slowly stir the mixture until the pellets have completely dissolved.

NOTE: The temperature of the mixture will rise and an acrid vapour will be given off.

Remove the top cap (or caps) on the machine. Insert the funnel into the cell filler tube. Pour ¾ of measured quantity of mixture slowly into the cell and check the liquid appears in the bottom of the sight tube on the front of the machine, if need be tip the machine forward through to 45 degrees to check. When the level is apparent in the sight tube, add mixture to bring the level up to the “Top Up” mark. Tip the machine backwards through to 45 degrees to clear any bubbles in the sight tube. Refit the Top Cap and tighten to hand tight.

2. Filling the gas booster

Remove the filler cap and, fill the gas booster with approximately 220 mls of Methyl – Ethyl – Ketone. Fill slowly allowing the level to stabilise in the sight tube. Fill only to lower level. The level will increase during use. Fit on the Top Cap making sure that the rubber washers is in place NOTE: a smear of grease, Vaseline or silicone will assist. Tighten to hand tight.

3. Connecting the torch

Connect the short length of rubber hose provided to the gas outlet on the machine. Connect the other end to the “Gas In” connection on the gas booster, and position the booster on the front of the machine locating the mounting clip into the rectangular hole provided in the front panel. Connect the long length of the rubber hose to the “Torch” connection on the Gas Booster, and the other end of the torch.

Fit the torch to the end of the torch using a screwdriver action clockwise for ¼ to ½ a turn, making sure it is fixed tight. The maximum correct size to use is indicated on the front of the machine, the smaller the number the larger the holes size.

4. Starting up the machine

DO NOT PLUG INTO THE MAINS YET. The machines have automatic gas regulation and an over pressure warning light. On the front are fitted two lights. The right hand of the two lights indicates that the gas is being produced, and will pulse on and off when the machine is operating correctly. The left hand light indicates only when overpressure conditions exists. At maximum pressure the right hand light will go out indicating production has ceased.

The understanding of paragraph 1 is of paramount importance since these lights are used to detect gas leaks. In operation, if the torch valve is closed and the machine is switched on then both lights should remain out because the gas system is sealed. I the torch valve is opened then gas will escape from the torch tip (gas leak) and the gas pressure in the system will fall. At a pre-set level the right hand light will come on indicating that gas is being produced. Pressure will again build up until the right hand light goes out once again.

This right hand light should pulsate all the time the machine is in use with gas coming from the torch tip. Now plug the machine into the mains and switch on at socket. Ensure the torch valve is closed, the press the on/off switch on the machine which will start up. The right hand light should also come “on” and then go out again after a few seconds. IT SHOULD REMAIN OUT AS LONG AS THE TORCH VALVE IS CLOSE (20 SECONDS IS LONG ENOUGH) No open the torch valve and place a finger over the end of the torch tip. The lights should operate as described on page 3. If the above function occurs “as stated” the machine is ready for use.

NOTE: The liquid level will rise in the sight tube on the gas booster. Leave the machine running for about two minutes before lighting the flame to allow any air to clear from the system, and then light the torch up.

5. Checking for gas leaks

This has been described in the previous paragraphs. A gas leak is described by the right hand light coming on when the gas system is sealed. The machine is designed to run with maximum size torch tip supplied without gas leaks. Running the machine with a gas leak or too large a torch tip will cause overheating and possible damage. This damage is not covered under guarantee as it constitutes misuse. If In doubt, ASK – check with the factory or your distributor.

6. Installation of the machine

The machine should be positioned near the work bench so that the rubber tubes to the torch are not tight. All sides of the machine must be free of obstruction so that a free flow of air throughout the machine can be achieved. The torch rubber tube can be extended to a maximum length of 2 metres.

7. Topping up the machine cell

Use only top quality distilled or demineralised water. DO NOT ATTEMPT TO SIPHON THE LIQUID FROM THE CELL BY MOUTH. IT IS HIGHLY CAUSTIC AND CAN CAUSE SERIOUS BURNS TO THE MOUTH. If the machine is overfilled, contact the factory before switching on the machine.

8. Topping up the gas booster

Generally the gas booster will require topping up when the machine requires distilled water. However, the liquids used in the bas booster are very volatile and more will be used when the ambient temperature is high. For the first week, check the level twice daily. Allowing the liquid level in the gas booster to fall below the “TOP UP” level mark in the sight tube can cause “blow back” which can damage the machine.

The repair would be chargeable. Close the torch valve thus extinguishing the flame, and then switch off the machine at the mains. Remove both the gas booster filler cap, and the cell filler cap, and allow a few seconds for the liquid level in the sight tube to drop. Refill to the FULL mark. DO NOT OVERFILL. Replace both filler caps and tighten hand tight.

9. Day to day use

The instructions for the daily checks are detailed on the label on the front of the machine. Strict adherence will give you long trouble-free use of the machine.

10. The machine operation

The machine consists of a power supply which supplies the high electric current to the Electrolyser cell. The passage of the high electric current through the cell breaks down the water to its constituent gases, hydrogen and oxygen. Since only water is converted into gas, the electrolyte put into the cell remains active for a very long time.

NOTE: The machine will not work without the electrolye. Periodic servicing of this machine is required 12-24 months depending on use.
MAIN CAUSES OF DIODE FAILURE ARE: Overfilling machine causing high current to flow through the cell. Running the machine with a gas leak or too large a torch tip.

NOTE: When returning machines for servicing to the factory or your distributor, siphon out main cell by using a plastic pump action siphon (note solution is caustic) and drain gas booster by removing both tubes and the cap and shaking out all the fluid. Seal gas outlet with a small piece of tube folded with wire or a suitable clamp. Pack carefully and keep upright. Return machine on a wooden pallet to prevent damage to the transformer.