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Maintenance and repair

28

BA/Elmaflame/GB/1107

© Elma GmbH & Co KG

8

Maintenance and repair

8.1 Maintenance

Caution!

For any maintenance or repair works related directly

or indirectly to electrolyte or vapourizer liquid carefully read and
observe the following safety warnings.

Caution when handling electrolytes!

Risk of causticization!

Strong acid alkaline!

Risk of causticization due to spilling alkaline or splashes of
alkaline from the filling duct during filling!

Always wear protective gloves and goggles when handling
hazardous substances!

WARNING!

Caution with open filling duct of the electrolyte reactor!

Risk of fire and explosion due to ignition sources!

Risk of ignition of the detonating gas in the electrolyte reactor
due to ignition sources!

Keep unit away from ignition sources! Do not light the filling
duct with the burner flame!

WARNING!

Caution with open filling duct of the electrolyte reactor!

Risk of fire and explosion due to electrostatic discharging!

Risk of ignition of the detonating gas in the electrolyte reactor
due to electrostatic discharging!

Touch the cap nuts on the holding angle pieces of the top part
with both hands for a short period of time before you open the
glass containers. This will branch off any possible electrostatic
charging of the operator without any risk!

WARNING!

Caution when handling vapourizer liquid!

Risk of fire and

explosion due to ignition sources!

Risk of ignition of the flammable liquids contained in the unit,
and of the flammable liquids used for filling, due to ignition
sources in the vicinity of the unit!

Keep the open vapourizer glass container and the vapourizer
liquid away from ignition sources!

WARNING!

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Summary of Contents for Elmaflame 140

Page 1: ...maflame units are fitted with a quick analogous pressure control device so that working on a number of different jobs and workplaces with one unit is no problem The operating pressure is variable and the set pressure keeps precisely at the required level even under changing ambient conditions Additional advantages High level safety standard in compliance with DIN 32508 Hydrogen oxygen mixture burn...

Page 2: ...er 1855 g solid KOH electrolyte solution 3600 g 3 6 litre distilled water 1855 g solid KOH electrolyte solution 3600 g 3 6 litre distilled water 3 How to procede 1 Fill the required quantity of distilled water into a temperature resistand and alkaline resistant container 2 Add the correctly measured quantity of potassium hydroxide carefully and slowly keep stirring the mixture Caution The liquid m...

Page 3: ...Operating Instructions Elmaflame 140 y 240 y 300 Hydrogen Soldering Units y English y Carefully read before operation ...

Page 4: ...ing of the vapourizer glass with vapourizer liquid 18 5 5 Connecting the unit to the mains 20 5 6 Setting of operating language in the display 21 6 Initial operation 22 6 1 Switch on the unit 22 6 2 Switch on the operating mode 22 6 3 Leack check 22 6 4 Selection of the burner nozzle 23 6 5 Adjustment of the gas pressure at the operating panel 24 6 6 Regulation of the burner flame at the burner ha...

Page 5: ...5 8 5 Repair 37 8 6 Transportation of the unit 37 8 7 Removal of electrolyte 38 8 8 Removal of vapourizer liquid 39 8 9 Spare Parts 40 9 Putting out of operation and waste disposal 41 9 1 Waste disposal of Elmaflame unit 41 9 2 Waste disposal of electrolyte 41 9 3 Waste disposal of vapourizer liquid 41 10 Manufacturer s contact address 42 ...

Page 6: ...nt operating instructions cannot take each and every specific regulation into consideration which might apply in various countries The operator of the unit must ensure that all relevant local regulations concerning the prevention of accidents and the use of hazardous substances are known and observed Elmaflame soldering and welding units are intended for soldering welding and melting of metals Ope...

Page 7: ...rities for information on the use and waste disposal of electrolytes Risk of fire and explosion The vapourizer liquid is a flammable substance Keep away from ignition sources while filling vapourizer liquid into the unit Risks caused by vapourizer liquid Avoid inhaling the vapours Do not eat drink or smoke while handling the vapourizer liquid Wear goggles and gloves The Elma vapourizer liquid elma...

Page 8: ...onating gas is then conducted through the gas hose to the burner hand piece via a backfire protection device If the detonating gas ignites it reacts releasing heat The remainder of the reaction is water H2O Temperature and energy of the burner flame can be adjusted to the soldering or welding job by the selection of a suitable nozzle size and the type of vapourizer liquid Adjustment of the microfl...

Page 9: ...cisely at a constant value even when the ambient conditions change Additional advantages Very high safety standard in compliance with DIN 32508 Hydrogen oxygen mixture burns without residues Easy operation microprocessor controlled with integrated leak detector check Quick regulation of the precise operating pressure with automatic adjustment LED indication for functional check and monitoring of v...

Page 10: ...eactor and of the transformer Flame stop backfire protection device made of sintered metal integrated in the burner hand piece Flame stop backfire protection device at gas outlet Reactor housing pressure vessel made of stainless steel EMC Mains fuse A high operating safety is guaranteed because gas is produced only when it is required i e when the valve at the burner hand piece is open 4 3 CE conf...

Page 11: ... burner nozzles depending on type of unit gas hose PVC 3 0 m long burner hand piece holder for burner hand piece filling funnel glass floating body for checking the electrolyte filling level 1 pair of disposable rubber gloves goggles Operating Instructions packing and transport box reusable please store for possible future transportation e g for service or repair return shipment ...

Page 12: ... and side view here Elmaflame 300 Unit top part with glasses for vapourizer liquid and condensate separator Moveable for an easy removal of the glasses Handles on both sides Operating panel with display and operating keys Ventilation openings on both sides Burner hand piece Holder for burner hand piece A B C D E F C D E F B ...

Page 13: ...op Screw cap on filling duct for vapourizer liquid Screw connection for the gas hose at the reactor outlet Screw cap of filling duct for electrolyte for initial filling or for distilled water for refilling in case of low reactor filling level Glass container for condensate separator also termed dryer glass with filter piece Glass container for vapourizer liquid also termed vapourizer glass with si...

Page 14: ...rating stops e g overnight over the weekend etc A Plug in mains cable connected with the mains socket B 4 8 Description of operating panel A Illustration 4 8 Operating panel with display and operating keys Display Top line section on the left indicates the actual value mbar inside the unit Top line section on the right indicates the actual reactor power which is required to produce the set gas pre...

Page 15: ...e following settings and display indications C Operating language The operating language can be selected available languages are German English or French Operating hour meter The operating hour meter counts and indicates the total number of operating hours of the unit operated with flame Display service mode The service mode of the display shows the actual service status of the unit The optimum on...

Page 16: ...mer Packing The unit must be operated under permanent supervision only Choice of workplace The workplace must allow free access to the unit The operator must be able to supervise the unit at all times Possible warning signals of the unit must be audible visible For operation place the unit on a dry and solid surface Ensure that the workplace is sufficiently ventilated The cooling air must circulat...

Page 17: ...top part to the 4 threaded bolts on the Elmaflame unit top fork wrench 10 mm How to proceed 2 Remove the yellow screw cap transport safety device on the reactor outlet B 3 Connect the gas hose to the reactor outlet by means of the union nut fork wrench 19 mm Caution Do not jam the connection nut Then tighten the connecting nut by means of the fork wrench For this hold the reactor at the filling du...

Page 18: ...tainers with electrolyte at a safe place and keep them out of reach of unauthorized persons in particular of children CAUTION Please note In order to avoid damages on the unit use suitable electrolyte and distilled water only If in doubt contact the manufacturer or your supplier for information NOTE Filling quantities Electrolyte solution Elmaflame 140 Elmaflame 240 Elmaflame 300 1 6 litre electro...

Page 19: ...ool down 1 Unscrew the closing cap from the filling duct see illustration 5 2 D at the electrolyte reactor How to fill electrolyte solution 2 Place the clean funnel included in the delivery volume onto the filling duct 3 Carefully pour approx 4 5 of the electrolyte total quantity see table in this section into the filling duct of the reactor 4 Carefully insert the glass floating body into the fill...

Page 20: ...e contained in other media borax In these cases the hand piece must be replaced Vapourizer liquids are flammable Therefore please observe the following safety instructions before filling Risk of fire and explosion due to ignition sources and electrostatic charging Risk of ignition of the flammable liquids used for filling due to ignition sources around the workplace Keep away from ignition sources...

Page 21: ...rgy density flame temperature With Redux the temperature of the falme is reduced to approx 1800 C In the same process the flame becomes coloured which is desirable with a view to labour protection For melting or soldering e g of platinum the flame does not have to be enriched by vapourizer liquid For these applications the vapourizer liquid can be removed from the vapourizer glass The high flame t...

Page 22: ...e nameplate of the unit correspond with the available local connection conditions Use the mains cable delivered with the unit Plug the cable into the mains socket at the Elmaflame unit as shown in illustration 4 7 Then plug the mains plug into a freely accessible mains socket Shockproof socket 2 phases 120 V 1 N 1 PE protective conductor Instructions for Elmaflame units EF 240 and EF 300 in 120 V ...

Page 23: ...er liquid is activated the display is lighted The programme offers to carry out a leak check Press the key Interrupt stop the leak check No at the operating panel to stop the check Select a display language at the operating panel twice Press the key Depending on the basic setting the display shows the following options Sprache Deutsch Language English Langue Français Select the requested operating...

Page 24: ...tion 4 6 H and the display is lighted 6 3 Leack check The programme offers to carry out a leak check You are asked to decide if you wish to have an automatic leak check carried out We recommend to carry out the leak check on a daily basis Leak check The leak check can only be carried out with cold electrolyte reactor below 45 C Check for leaks No Yes Confirm the request with the key Yes at the ope...

Page 25: ...tinue Confirm this programme step by pressing the key Continue at the operating panel The programme now carries out a signal buzzer test The signal buzzer is activated and the display shows Check signal buzzer On Press key Finish checks Press any operating key the signal buzzer is switched off and the unit is now ready for operation 6 4 Selection of the burner nozzle The Elmaflame units are delive...

Page 26: ...gas pressure is limited to 50 mbar Operating pressure range The display shows the actual operating pressure in the top line e g 120 mbar If the set pressure value is changed e g to 180 mbar the reactor starts operating at e g 75 power to reach the new set value The required reactor power depends on the size and number of nozzle s and on the preset pressure value Example 120 mbar 75 180 mbar set v ...

Page 27: ...kfire protection device is contaminated and the gas flow through capacity of the handle piece is reduced If this process is repeated several times the handle piece can be choked NOTE 6 6 Regulation of the burner flame at the burner hand piece Size and energy of the burner flame can be adjusted at the valve of the burner hand piece see illustration 6 6 or set at the operating panel by pre selecting...

Page 28: ...l system automatically switches off the ventilation device In stand by operating mode with cooled down unit the current consumption is reduced to a minimum The unit must be switched off at the mains switch only for prolonged operating stops overnight over the weekend over holiday periods Operating finished If the unit is switched off at the mains switch after a prolonged operating period damages t...

Page 29: ...aflame 240 Elmaflame 300 Mains voltage V 230 230 230 Power consumption W 900 1700 2000 Mains fuse A 10 16 16 Max gas production l h 140 240 300 Max nozzle size Ø mm 1 1 G19 1 5 G17 1 8 G15 Workplaces 1 3 1 8 1 8 Unit outer dimensions W D H mm 395 275 445 515 375 515 515 375 515 Weight kg 25 48 49 ...

Page 30: ... ignition sources Keep unit away from ignition sources Do not light the filling duct with the burner flame WARNING Caution with open filling duct of the electrolyte reactor Risk of fire and explosion due to electrostatic discharging Risk of ignition of the detonating gas in the electrolyte reactor due to electrostatic discharging Touch the cap nuts on the holding angle pieces of the top part with ...

Page 31: ...nside the filling duct for initial operation For this maintenance work read and observe the safety warnings given in section 8 1 e g protective goggles and gloves WARNING Check the filling level by means of the glass floating body only Do not light the filling duct with the burner flame for better vision Risk of explosion 1 Extinguish the flame at the burner hand piece Check of filling level of el...

Page 32: ... key 3 at the operating panel 4 Check the filling level again a If the floating body in the filling duct is still not visible repeat steps 1 to 3 b If the floating body in the filling duct is now visible refill only a small quantity of distilled water until the floating body is level with the filling duct edge 5 Screw the closing cap back onto the filling duct and tighten it 8 1 2 Refilling of vap...

Page 33: ...ng process is finished After prolonged idle periods of the unit the filling level of the vapourizer glass can only be determined exactly after the unit has been operated with correct operating pressure for a short period of time Ensure that the filling level of the vapourizer liquid in the vapourizer glass does exceed the level marked on the glass 8 1 3 Cleaning of the vapourizer glass NOTE Carefu...

Page 34: ...out this maintenance work During operation condensation water and entrained electrolyte are separated in the dryer glass see illustration 8 1 3 C If there is more than 1 cm of condensate in the glass remove the condensate and rinse the glass with hot water subsequently For the disposal of electrolyte see section 9 2 1 Switch off the gas production at the on off key at the operating panel 2 Unscrew...

Page 35: ...the filter cartridge remove and replace it 5 Remount the dryer glass by screwing the fastening ring back to the right see illustration 8 1 3 E 8 2 Service indications display During operation of a soldering unit the anodes and cathodes wear out Therefore the gas drawing hours are measured by the control of the unit to ensure safe operation The service level can be called by switching over the disp...

Page 36: ... temperature is exceeded the display shows the following malfunction Excess temp Let cool down Operation can be continued after the unit has cooled down For this change the set pressure value back to the required value In case of malfunctions due to overheating it is important not to switch off the unit at the mains switch as the ventilating device stops operating too If you feel uncomfortable due...

Page 37: ...sure is set at approx 150 mbar the valve at the burner hand piece is closed The actual gas pressure value does not correspond with the set value The hose system inside the unit is leaky Switch off the unit pull the mains plug open the unit check if the hose connections sit tightly retighten loose connections if necessary contact the Technical Support The unit does not produce any gas There is a si...

Page 38: ...ozzle and or filter cartridge illustration 8 1 3 B and or sintered cone in vapourizer glass illustration 5 4 C and or backfire protection illustration 4 6 B and or handle of burner hand piece Replace the choked components The nozzle is choked Clean or replace the nozzle The flame is instable The vapourizer liquid has been consumed Completely exchange the vapourizer liquid clean the glass The unit ...

Page 39: ... break down of the unit please contact your supplier or the manufacturer 8 6 Transportation of the unit For reasons of safety the unit must be shipped only when empty Electrolyte and vapourizer liquid are hazardous substances CAUTION 1 Remove the electrolyte see section 8 7 Prepare the unit for shipment 2 Remove the vapourizer liquid see section 8 8 3 To avoid transport damages a Remove the unit t...

Page 40: ...hose by mouth To prevent dangerous causticization when handling electrolyte always wear protective gloves and goggles WARNING 1 Switch off the Elmaflame at the mains switch at the back of the unit How to proceed 2 Open the screw cap of the filling duct for electrolyte 3 Remove the glass floating body Caution The glass floating body is covered with alkaline Rinse the floating body with water 4 Comp...

Page 41: ...s for a short period of time before you open the vapourizer glass container This will branch off any possible electrostatic charging of the operator without any risk WARNING How to proceed 1 Switch off the gas production at the on off key at the operating panel 2 Unscrew the fastening ring by turning it to the left see illustration 8 1 3 D 3 Remove the vapourizer glass Move the complete top part s...

Page 42: ......

Page 43: ...sposal companies Waste number 20 01 15 Alkalines Containers can also be returned free of charge when they are completely empty Rinse the containers with water before you return them for waste disposal Neutralization with acid e g acetic acid For this pour the acetic acid into a suitable tank first then add the electrolyte step by step Caution The liquid can heat up considerably 9 3 Waste disposal ...

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