TIP HydroFlame Torch Manual de usuario
CONTENTS
Introduction 2
How The HydroFlame Torch Works 3
The principles of operation behind the HydroFlame Torch
Setting-up Your Unit 4
How to properly install the HydroFlame Torch
Using the HydroFlame Torch 8
Recommendations on using the HydroFlame Torch
Maintenance 9
Guidelines for proper maintenance of the unit
Changing the Electrolyte 10
Step-by-step instructions on changing the electrolyte
Troubleshooting 12
Answers to common questions
Material Safety Data Sheets 16
Health and Safety information on the chemicals used with the HydroFlame Torch
1-800-40-FLAME
INTRODUCTION
Brazing and soldering are some of the oldest methods for joining two metals. As early as 1475
B.C. soldering was being used to join gold and silver. The heat source for these early operations
was usually a wood or charcoal fire fanned by the solderer's breath. Thankfully, the art of
soldering has evolved since then.
For many years standard soldering torches operated on a variety of combustible gasses. Natural
gas, acetylene, methane, propane, and air/gas combinations were widely used throughout many
industries. However, these gasses have drawbacks. They are usually bought in pressurized
bottles that can be costly, dangerous and are prohibited in increasing numbers of municipalities
and states. In addition, these gasses generally do not burn cleanly and can leave excessive
oxidation and "fire scale" on articles. What the jewelry industry needed was a torch that could
solder cleanly, effectively and safely.
The HydroFlame Torch answers all these needs and more. The HydroFlame is an oxyhydrogen
generator that operates by converting distilled water into an oxygen/hydrogen fuel gas. The
HydroFlame Torch creates gas on a demand basis. This means that there is no potentially
dangerous stored gas.
Because the HydroFlame Torch burns a gas that has a high hydrogen content, it produces what is
referred to as a "reducing" flame. What this means is that the flame of the HydroFlame Torch
will actually eliminate oxides to some extent. Because it reduces or eliminates oxidation,
soldering with the HydroFlame Torch is much cleaner than what can be achieved with traditional
torches. However, the reducing flame of the HydroFlame is only effective where the flame is
actually in contact with the piece. Because of this, it is always advisable to use a flux dip prior to
soldering, and to use a suitable flux when soldering to ensure clean, perfect joints.
HOW THE HYDROFLAME TORCH WORKS
The HydroFlame Torch generates fuel gas by passing an electrical current through distilled
water. To improve the electrical conductivity of the water, an electrolyte is added. The name of
the electrolyte used in the HydroFlame Torch is Potassium Hydroxide.
As the electrical current passes through the
electrolyte solution, it breaks the bonds
between the oxygen and hydrogen atoms of the
water molecule and releases them as a mixed
gas. The HydroFlame never separates the
oxygen and hydrogen gasses. The torch flame
burns a mixture of 1 part oxygen and 2 parts
hydrogen. The temperature of this flame,
without flux, is approximately 5600oF.
After generation, the gas is passed through a filter that removes any residual moisture from it.
Then it is "bubbled" through a flux solution. The flux solution contains methol alcohol and boric
acid. As the gas passes through this solution, it picks up some of the alcohol and some of the
boric acid in the gas. These chemicals are burned in the flame at the torch tip. The flux serves
two purposes. It lowers the temperature of the flame to approximately 4850oF while increasing
the BTU value of the flame. The boric acid is carried in the flame to the article being soldered.
This helps protect the parts being soldered from excessive fire-scale. However, it is very
important to note that the fluxing effect of the HydroFlame Torch is usually not sufficient to
solder pieces without additional flux. It is always recommended that you use additional flux
when soldering to obtain best results.
The HydroFlame Torch works with many different needle tips. By changing the tip size, you can
work on a wide variety of pieces and precisely control how much heat is applied to your work.
SETTING-UP THE HYDROFLAME TORCH
1. Location
The HydroFlame Torch must be placed on a level surface with adequate ventilation. We
recommend a minimum of 4 inches of clearance on each side. Using the HydroFlame Torch on a
closed shelf or in a drawer will void all warranties. The HydroFlame requires cooling at all
times.
2. Electrical
The HydroFlame operates optimally on a grounded 110 volt, 60 Hz electrical line. It is advisable
to check the building fuse or circuit breaker to ensure that there is sufficient current to operate
the Welder (10 amps maximum). We recommend that you operate the unit on a dedicated power
line in order to avoid power surges or dips which can be caused by other equipment in use. These
fluctuations can affect the performance of your unit. Do not plug in your unit until after step 5.
3. Connecting the Handpiece
A piece of clear tubing is already connected to the unit. A plastic and metallic filter is connected
to the end of this tubing. The clear tubing of the handpiece will fit snugly on the free end of this
tubing. Press the tubing firmly over the filter. Check that the tubing is secure on both ends of the
metallic filter and on the handpiece. Check that the screw cap on the bottom of the handpiece is
snug.
4. Adding the Electrolyte Solution
**CAUTION** The electrolyte is highly caustic and should always be handled using
protective equipment such as rubber gloves and safety glasses or goggles, and protective
clothing. When handling the electrolyte solution, be careful not to spill any. The electrolyte
may damage any finished surfaces, clothing, etc. Electrolyte is highly corrosive to many
metals, including copper, brass, zinc and aluminum, and reacts violently with acids.
Electrolyte destroys human tissue on contact. It is odorless and colorless. Please refer to the
Material Safety Data Sheet at the end of this manual for more specific health and safety
information.
1. Put on safety glasses, gloves and protective clothing.
2. Move, or cover up anything that may be damaged by spilled electrolyte.
3. Check the drain plug in the side of the unit to make sure the plug is tight.
4. Unscrew the cap from the electrolyte chamber (the small cap).
5. Using a plastic funnel, slowly pour the solution into the DISTILLED WATER CHAMBER.
6. Carefully wipe up any electrolyte spills with a clean paper towel.
7. Pour the entire bottle of electrolyte into the DISTILLED WATER CHAMBER.
8. After filling the chamber, rinse the funnel with clean water and dry.
9. Do not use the funnel for any other application. Store the funnel for future use.
10. Rinse the electrolyte bottle in clean water. Replace cap and dispose in garbage. DO NOT REUSE ELECTROLYTE
BOTTLE!
11. Replace the stainless steel cap on the DISTILLED WATER CHAMBER. Tighten until snug. Do not overtighten.
5. Adding the Flux Solution
**CAUTION** Flux solution is very flammable. Keep the GREEN flux solution
away from open flames or sources of ignition at all times. Do not smoke or have
open flames near the unit when filling the flux chamber.
•Put on safety glasses, gloves and protective clothing.
•Unscrew the cap from the FLUX CHAMBER. (the large cap at the front of the unit)
•Slowly pour the GREEN flux solution into the FLUX CHAMBER.
•If you use the funnel from the electrolyte, make sure the funnel has been thoroughly
rinsed with clean water and dried. Electrolyte contaminates the flux solution and makes it
unusable.
•Fill the FLUX CHAMBER up to the MINIMUM level. DO NOT OVERFILL!
•Carefully wipe up any flux spills with a clean paper towel.
•Rinse the funnel with clean water and dry with a paper towel.
•Recap the flux bottle and store in a cool, dry place; away from open flames.
•Replace the stainless steel cap on the flux. Tighten until snug. Do not overtighten.
6. Adding the Filter Material
The filter is designed to remove any moisture and impurities from the incoming
oxyhydrogen gas. The result is a clean, moisture-free flame with minimal contamination
of the flux solution. The filter material is a micro-fiber that resembles cotton.
Take a small handful of the filter material and gently tamp it into the inner cylinder of the
FILTER CHAMBER. Do not pack the filter too tightly. The entire inner chamber does not
need to be filled with material.
7. Plug the unit into a grounded standard outlet (115-volt, 60 hz).
For best results, the outlet should be on a dedicated circuit. When possible, avoid
plugging your HydroFlame Torch into circuits that also power other machinery or
equipment. The power drains caused by the other equipment could cause your
HydroFlame Torch to run slightly hotter than normal and may cause condensation in the
tubing leading to the torch handpiece.
8. Installing the Torch Stand (optional)
On either side of the HydroFlame Torch, you will find
four screws holding the black cover in place.
Determine which location is most convenient for you
to mount your torch holder. Unscrew that screw and
set aside. Locate the black torch holder in the
accessory bag. Insert the screw through the hole in the
torch holder, and screw it back in to the hole in the
torch cover. Orient the torch holder so it is pointing
straight up, and tighten the screw firmly.
Using The HydroFlame Torch
1. Make sure the valve on the handpiece is turned completely off.
2. Choose a needle tip. The larger the tip, the greater the heat applied to the article being
soldered.
3. To attach a tip, firmly press the tip onto the end of the torch handpiece and give a half
turn. The friction will hold the tip firmly in place.
4. Make sure that all the caps are snug.
5. Check the level gauges on the front of the unit. Both levels should be between the
minimum and maximum marks. *IMPORTANT* DO NOT RUN THE UNIT IF THERE
IS INSUFFICIENT DISTILLED WATER!! SERIOUS DAMAGE TO THE
HYDROFLAME TORCH WILL RESULT AND ALL WARRANTIES WILL BE
VOID.
6. Turn the unit on. The power switch is on the upper left side of the front of the unit. The
light should go on indicating that the unit is producing gas. After a few seconds, when the
unit has built pressure, the light should go off.
7. Open the valve on the handpiece one full turn. Run without a flame for 30 seconds to
bleed any entrapped air. Close the valve, wait 30 seconds and repeat. *CAUTION* do
not bleed lines near an open flame - gas is present.
8. Open the valve one full turn. Using a "sparker" or other lighting device, carefully light
the torch, making sure that it is facing away from you or any flammable surfaces. Never
light the torch without aneedle tip in place!!! If the torch does not light right away, try
decreasing or increasing the pressure by closing or opening the valve on the handpiece.
The flame should be bright green. Note: using a cigarette lighter to light the torch can be
dangerous. There is a possibility that the lighter could explode if the flame from the torch
comes too close to it. A sparker or other torch-lighting device is the safest means of
lighting the HydroFlame .
9. Try changing tips. Turn the valve on the handpiece off using a smooth consistent
motion. Do not close the valve slowly, as the flame may burn back into the tip.
Occassionally, the torch may make a popping or snapping noise when it is extinquished.
This is normal. Once the flame has shut off, remove the needle tip by twisting and gently
pulling. Put on a new needle and light it as shown above. Notice that when a small tip
(larger gauge) is on, the generator light cycles on and off much faster than when a large
tip (smaller gauge) is on. This is because the large tips use more gas and the HydroFlame
has to keep up with it.
10. When shutting the machine off, always extinguish the flame first by closing the valve
on the handpiece, then turn off the power switch. When the machine is off, open the
handpiece to bleed any residual pressure from the system. Be sure to close the handpiece
when finished.
Maintenance
Daily
1. Close the valve on the handpiece and turn the unit on. Let the unit run for 20 seconds.
You do not need to light the flame. Turn the machine off and open the valve on the
handpiece to release pressure. Check the flux level gauge. The level should be between
the minimum and maximum mark.
2. If necessary, add flux. Unscrew the cap on the flux chamber. For best results, add flux
in small amounts (approximately 1 ounce at a time) until the gauge reads between the
minimum and maximum mark. Be careful not to overfill. This can lead to moisture in the
line and flooding of the system.
3. Check the distilled water level. Add distilled water if the level is below the minimum
mark. Add distilled water slowly and watch the level gauge. Use distilled water only. Tap
water contains impurities that can affect the performance of your unit.
4. Check the clear hose for any condensation that may have occurred. If condensation is
present, turn the unit off and disconnect the hose at the rear check valve. Drain all fluid
out of the hose. If possible, dry the hose using compressed air. Thoroughly dry the
handpiece.
Weekly
1. Clean tips by placing them in an ultrasonic cleaner for a few minutes. For better
results, clean tips using a steam cleaner.
2. Check the filter material in the dryer chamber for contaminants or moisture. If the filter
shows signs of moisture or contaminants, remove it. Wear rubber gloves when doing this
since the filter may contain traces of the caustic electrolyte. Replace the filter material
taking care not to pack it too tightly. For best results, the filter should be changed after
every 30 operating hours, regardless of appearance.
3. Check the flux in the chamber. If the flux shows signs of contaminants, or if the flame
color has changed or weakened during the week, change the flux. Suction out old flux
using a turkey baster. Wipe the inside of the chamber dry with a towel or rag. Refill the
chamber with fresh flux.
Monthly
1. Clean the sintered metal check-valve in the torch handpiece. Unscrew the handpiece at
the base near the black "O" ring. If the cylindrical check-valve does not come right out,
tap the open of the torch into the palm of your hand. The filter will dislodge and fall out.
Clean this under a steam cleaner for 1 minute or in an ultrasonic cleaner for 5 minutes.
2. Check the gaskets on the inside of the caps for any wear and tear.
CHANGING THE ELECTROLYTE SOLUTION
Depending on your use, the electrolyte may last for up to 1 year. We recommend
changing the electrolyte at least each year to keep the unit operating at peak performance.
When changing the electrolyte, the flux solution and filter material also must be changed.
You will know the electrolyte needs to be changed when:
1. The flame becomes weaker
2. The pressure drops
3. The unit does not generate any gas
You will need:
Rubber gloves Turkey baster or large syringe
Eye protection 1 quart of electrolyte*
Protection for your clothing Clean filter material*
Drop cloth or safe work area Fresh flux*
Plastic bucket Replacement rear check valve*
Plastic funnel Warm distilled water
*All replacement parts are available through the distributor from whom you purchased
your HydroFlame Torch.
To change the electrolyte:
**CAUTION** The electrolyte is highly caustic and should always be handled using
protective equipment such as rubber gloves and safety glasses or goggles. When handling
the electrolyte solution, be careful not to spill any. The electrolyte may damage any
finished surfaces, clothing, etc. Electrolyte is highly corrosive to many metals, including
copper, brass, zinc and aluminum, and reacts violently with acids. Electrolyte destroys
human tissue on contact. It is odorless and colorless.
1. Unplug the unit. Put on protective equipment.
2. Remove all caps.
3. Use the turkey baster to remove all flux and discard in accordance with all applicable
regulations. Wipe the inside of the chamber dry.
4. Remove all dryer filter material and discard. If there is any moisture in the dryer
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