Installation & Operating Instructions

FILLING MACHINE FLUIDS

Aquaflame Model 500 requires approx. 1kg of electrolyte flake and 1.5 litres of de-ionised water.

Aquaflame Model 800 requires approx. 2.2kg of electrolyte flake and 3.5 litres of de-ionised water.

Aquaflame Model 1200 requires approx. 2.2kg of electrolyte flake and 3.5 litres of de-ionised water.

ALWAYS WEAR GOGGLES AND RUBBER GLOVES!
Using an empty bucket mix the electrolyte flake and deionised water as above.
STIR CAREFULLY. DO NOT USE METAL FOR STIRRING.
NOTE: This process will produce heat - allow the electrolyte solution to cool before pouring into the machine.

FILLING THE MACHINE CELL
Remove the filler cap on the top of the machine cell using the spanner provided. Place a funnel in the cell orifice and slowly pour the electrolyte mix into the cell. View the cell sight glass located at the front of the machine. Fill until the electrolyte level reaches the upper limit level line as indicated next to the cell sight glass. Replace the filler cap onto the cell and gently tighten with the spanner over tightened cap may be difficult to remove next time! Remove any electrolyte fluid from the top of the machine using a clean damp cloth.

Remove the filler cap on the gas booster and using a different funnel simply fill the gas booster half full with MEK (Methyl Ethyl Ketone). NEVER USE THIS SAME FUNNEL FOR ELECTROLYTE FLUID. The exact fluid level is not critical. The fluid level can be viewed through the side of the booster. Refit the gas booster filler cap and tighten.

Connect the shorter length of rubber hose to the gas outlet on the gas booster. Connect the other end of this hose to the gas outlet on the gas booster. It is important to push the hose firmly onto both connectors to ensure no gas leaks. Never twist the hose or torch connect the torch to the rubber hose. Connect the selected torch nozzle securely to the torch. DO NOT OVER-TIGHTEN AS THIS MAY DAMAGE THE NOZZLE SEAL AND THUS CAUSE A GAS LEAK.

Connect the mains plug and switch on the electrical supply. Ensure the red power switch on the machine front panel is in the ON position.
The machine cooling fan will operate. Depending on the machine model you will see the gas pressure rise on the pressure gauge and the gas production light will illuminate. Leave the machine running for 2 – 3 minutes before opening the torch valve.
Open the torch valve to allow the gas to purge from the system. Ignite the gas at the torch nozzle using a piezo lighter. The flame will be yellow initially. As the gas flows through the gas booster and MEK fluid, the flame colour will change from yellow to blue indicating that the MEK fluid is vaporizing into the gas stream. The correct flame is blue in colour and approx. 10 – 15mm long. If the flame goes out, simply relight the gas. Adjust the flame size and length using the torch valve.
When shutting down the machine, CLOSE the torch valve first. This will extinguish the flame. Then switch off the main switch on the machine front panel. This sequence prevents backfiring down the hose.

Before using the machine it is highly recommended to perform a gas leak test. An internal gas leak could cause gas pressure not to reach the preset limit or the machine to keep running even when the torch valve is closed. Close the torch valve and switch on the machine. Wait for the pressure to reach maximum (approx 1 – 2 mins depending on model). The pump switch will cut out, and the pressure on the gauge should remain steady. If the pressure drops, investigate and rectify any leaks around the gas booster filler cap or torch/hose connections.

The machine should be positioned on a firm workbench that is capable of supporting the machine's weight. All sides of the machine must be free of obstruction to allow free airflow of the cooling fan. It must be protected from direct heat sources. Ensure that the torch hose is not snagged or kinked.

The fluid level in the machine cell drops as gas is produced. ALWAYS TOP UP WITH DE-IONISED WATER ONLY! ONLY ADD ELECTROLYTE CRYSTALS WHEN THE MACHINE HAS BEEN COMPLETELY DRAINED AND CLEANED AFTER 6 TO 12 MONTHS OF USE.

During use, the MEK fluid level within the gas booster will drop and therefore must be topped up. Switch off the machine and permit the gas pressure to release. Remove the filler cap and top up the MEK fluid to approx. half full. Avoid spilling MEK over the machine cases. Refit the gas booster filler cap.
To completely empty and clean the gas booster, remove the gas booster from its bracket, remove the booster filler cap and discard the old MEK correctly. Wash the booster internal thoroughly with warm soapy water to dissolve any accumulated debris. Rinse thoroughly with clean warm water, dry inside and refill with new MEK fluid.

The true cost of using the Aquaflame system is lower than traditional bottled gas models. Daily visual checks of the cell and booster fluid levels are essential.

The maximum capacity limits the machine output of gas. If the torch tip is too large for the machine's capability, gas pressure will drop and the flame will become soft - potentially causing a 'pop or bang'.
NOTE: TO PREVENT A POTENTIAL 'FLASHBACK' (LOUD BANG OR POP) ARISING FROM A LARGE NOZZLE SIZE BEING USED ON A SMALL MACHINE, A 0.8MM RESTRICTOR IS FITTED WITHIN THE TORCH HANDLE. IF YOU INTEND TO USE A NOZZLE LARGER THAN 0.8MM THE RESTRICTOR MUST BE REMOVED.
NOTE: When using Aquaflame machines for acrylic polishing or soldering, always use a single torch with a single tip. Using multiple torches or a burner head will rapidly deplete the gas pressure leaving the torches susceptible to flashbacks. A flashback will not normally damage the machine, but can startle the operator or bystanders and cause safety concerns if protective equipment is not worn.