6
5. Daily Operation
Before beginning work, you should check the fill levels of the generator and booster tanks. Depending
on how often you use the unit, you may not necessarily have to do this every day. When it is in its
ready state (power switch on, torch valve closed) the unit does not consume fluids. When gas is being
produced, the approximate consumption rates are as follows:
Consumption of distilled water: 25 ml / hour
Consumption of flux fluid: 7 ml / hour
Note: Before opening the generator tank screw cap (1c) or the gas tube screw coupling (7), you must
open the torch valve with power switched off to release the pressure. Caution: Keep open flames
away!
1. Checking the Fill Level of the Generator Tank (black filler opening):
With the unit switched off, remove the screw cap (1c) of the generator tank, and check the depth of
the level indicator float (1b). If the float is down too far, then use the large funnel (3a) to slowly pour
in distilled water until the top of the float is level with the top edge of the filler opening (1a). Because
there are several cells in the generator and it takes time for the water to flow into them, check the float
again after about 1 minute and add more distilled water as needed. Screw on and hand tighten the
screw cap.
Important: Never add more electrolyte solution after filling for the first time or renewing (see
Step 1 in Section 6)! The electrolyte is not consumed, it just gets old or spent.
The electrolyte consists of potassium hydroxide dissolved in distilled water, and has a concentration
that ensures an ideal electrical conductivity. During electrolysis (gas production), only the distilled
water is consumed while the amount of potassium hydroxide in the generator stays the same. If you
were to keep adding electrolyte, its concentration would increase, initially causing a loss in
performance and later, a crystallization that would damage the generator.
2. Checking the Fill Level of the Booster Tank (red filler opening):
With the unit switched off, remove the screw coupling of the gas tube (7) from the filler opening of the
booster tank (2a), or if the coupling is not connected, remove the screw cap. Switch the unit on for a
short period until you hear gas escaping from the filler opening in order to allow flux fluid to be
pumped from the runback reservoir back into the booster tank. (There is runback reservoir inside the
unit between the gas generator and booster that prevents flux fluid from being sucked into the
generator by the partial vacuum that is created when the warm generator cools down after being in
operation. When the unit is switched on again, the gas pressure pumps the flux from the reservoir
back into the booster tank, so that the fill level of the booster tank increases although no fluid was
added.) Switch the unit off again. Only after this has been done, can the true fill level of the
booster tank be reliably determined by checking the booster float (2c). The top of the float should
be about 2 to 3 cm below the top edge of the filler opening. Using the small funnel (3b), fill flux fluid
(2d) as required until the float indicates that the tank is full. If you have put in too much fluid, you can
use the syringe (12) to suck some of it back out. Replace the gas tube screw coupling (7) and screw it
down hand tight, or if you are not going to use the unit, put the booster screw cap (2c) on and screw it
down hand tight.
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