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6. Maintenance
1. Renewing the Electrolyte:
Caution:
When working with electrolyte , always wear protective gloves and safety goggles to
prevent acid burns (see Section 2. Safety Instructions)!
The electrolyte should be renewed about every 8 to 12 months, depending on how often the unit is
used. An indication that it is time to renew the electrolyte is when the gas yield starts to drop, i.e., the
gas pressure is too low for large nozzles (the nozzle burns) or the flame is not hot enough. The
generator should be emptied while it is still warm from being operated to allow the sediment that
collects at the bottom to be removed.
Before changing the electrolyte, always remove the gas
tube screw coupling (7) from the booster tank and screw on and hand tighten the booster tank
screw cap (2c).
After removing the generator screw cap (1c) and the level indicator float (1b), tilt the
unit toward the front side (power switch side) until the electrolyte starts to pour out in a steady stream,
but not too far so that air can still get back in. The unit must be tilted toward the front (power switch
side) so that electrolyte does not flow into the tubing inside the unit. As electrolyte pours out, continue
tilting the unit slowly until it is upside down and completely empty. Before filling new electrolyte (see
Section 4, Step 1), rinse the generator once or twice with distilled water. To do this, slowly pour in
about ½ l of distilled water, shake the unit lightly, and then empty it by tilting it as described above.
Make sure to dispose of the old electrolyte properly (it is a caustic substance).
2. Replacing Old or Contaminated Flux Fluid:
If the booster fill level is OK, but the flame is pale or reddish instead of bright green, or if electrolyte or
distilled water has been filled into the booster tank by mistake, then the flux fluid must be replaced.
Switch the unit on for a short period to allow fluid to be pumped from the runback reservoir back into
the booster tank, then use the syringe (12) to suck the old fluid out of the booster tank. If the old fluid
is contaminated, e.g., with electrolyte or distilled water, then rinse the empty tank with about 100 ml of
flux fluid and then empty the tank again. Dispose of the old flux fluid properly.
Never rinse the
booster tank with water, because the flux fluid saponifies (becomes soapy) when combined
with water, which can stop up the gas lines.
Refill the booster tank with new flux fluid as described
in Section 4, Step 2.
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