8
7. Troubleshooting Guide
1. The unit does not build up pressure.
a) If the LED (5) lights up, than gas is leaking at one of the screw connections or out of the torch.
Solution: Check and tighten the generator tank screw cap (1c), the gas tube screw connection
(7), and the torch adjusting valve (10).
b) If the LED (5) does not light, then electric power for gas production has been interrupted.
Several faults are possible:
1. A defect of the pressure switch (18) has caused the safety pressure limiter (16) to trigger.
Solution: Replace the defective pressure switch and push down both pushbuttons (17) on
the safety pressure limiter.
2. The dropping resistor (21) has burned through.
Solution: Replace the dropping resistor.
3. The rectifier diodes on the diode plate (24) are defective.
Solution: Replace the diode plate.
4. The thermostat switch (30) has triggered because the generator is too hot.
Solution: Check that the cooling fan is working! When the fan is running, gas production
restarts automatically as soon as the generator cools to a temperature below
45°C.
2. The flame has normal color (
bright green
) but is not hot enough.
a) The fill level in the generator tank is too low.
Solution: Refill the generator with
distilled water
as described in Section 5, Step 1.
b) The electrolyte is contaminated or spent.
Solution: Renew the electrolyte as described in Section 6, Step 1.
c) The gas line is blocked either inside the unit, or in the flashback arresters of the torch or the gas
tube screw coupling.
Test:
Remove the nozzle from the torch, open the torch valve all the way open, and switch
the unit on. Normally, the LED should remain constantly lit to indicate that gas is
being produced, and the pressure indicator should stay at 0 because all of the gas is
being allowed to escape unhindered through the torch. However, if the pressure
increases and the LED goes off after a short period, then the gas is being blocked
somewhere. To find out where it is being blocked, start by pulling the torch out of the
tubing. If the pressure drops, then the flashback arrester of the torch is blocked. If the
pressure stays up, then the gas is blocked either in the flashback arrester of the gas
tube screw coupling or inside the unit. Unscrew the gas tube coupling. If the pressure
drops, then the flashback arrester of the gas tube screw coupling is blocked. If the
pressure stays up, then the gas is blocked inside the unit.
Solution: The flashback arresters can be cleaned with highly diluted sulfuric acid (density of
1.02). Fill roughly 4 to 5 cm of the diluted sulfuric acid into a glass. With the plunger
pushed in, connect the syringe to either the torch or the screw coupling, and dip the
torch or coupling into the acid. Now pull the plunger out to draw acid up into the
syringe while keeping the torch or coupling in the glass. Let the acid work for about 10
minutes. Occasionally move the plunger in and out a little to wash fresh acid into the
flashback arrester. When done, thoroughly rinse the flashback arrester with distilled
water, and dry it with compressed air.
If the gas is blocked inside the unit, call our customer service or send the unit to the
factory for repair.
3. The flame is red or pale, and not hot enough.
a) The fill level in the booster tank is too low.
Solution: Refill the booster with flux fluid as described in Section 5, Step 2.
b) The flux fluid is contaminated or old.
Solution: Empty and clean the booster tank as described in Section 6, Step 2. Refill the booster
tank with new flux fluid as described in Section 4, Step 2.
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