▶ Introduction
▶ Setting Up The HydroFlux
▶ Using The HydroFlux
▶ Maintenance
▶ Changing Electrolyte
▶ Troubleshooting
▶ MSDS-Flux Solution
▶ MSDS-Electrolyte Solution
HydroFlux Maintenance
1. Close the valve on the handpiece and turn the unit on. Let the unit run for 20 seconds. You do not need to light the flame. Turn the machine off and open the valve on the handpiece to release pressure. Check the flux level gauge. The level should be between the minimum and maximum mark.
2. If necessary, add flux. Unscrew the cap on the flux chamber. For best results, add flux in small amounts (approximately 1 ounce at a time) until the gauge reads between the minimum and maximum mark. Be careful not to overfill. This can lead to moisture in the line and flooding of the system.
3. Check the distilled water level. Add distilled water if the level is below the minimum mark. Add distilled water slowly and watch the level gauge. Use distilled water only. Tap water contains impurities that can affect the performance of your unit.
4. Check the clear hose for any condensation that may have occurred. If condensation is present, turn the unit off and disconnect the hose at the rear check valve. Drain all fluid out of the hose. If possible, dry the hose using compressed air. Thoroughly dry the handpiece.


1. Clean tips by placing them in an ultrasonic cleaner for a few minutes. For better results, clean tips using a steam cleaner.
2. Check the filter material in the dryer chamber for contaminants or moisture. If the filter shows signs of moisture or contaminants, remove it. Wear rubber gloves when doing this since the filter may contain traces of the caustic electrolyte. Replace the filter material taking care not to pack it too tightly. For best results, the filter should be changed after every 30 operating hours, regardless of appearance.
3. Check the flux in the chamber. If the flux shows signs of contaminants, or if the flame color has changed or weakened during the week, change the flux. Suction out old flux using a turkey baster. Wipe the inside of the chamber dry with a towel or rag. Refill the chamber with fresh flux.


1. Clean the sintered metal check-valve in the torch handpiece. Unscrew the handpiece at the base near the black "O" ring. If the cylindrical check-valve does not come right out, tap the open of the torch into the palm of your hand. The filter will dislodge and fall out. Clean this under a steam cleaner for 1 minute or in an ultrasonic cleaner for 5 minutes.
2. Check the gaskets on the inside of the caps for any wear and tear.



Depending on your use, the electrolyte may last for up to 1 year. We recommend changing the electrolyte at least each year to keep the unit operating at peak performance. When changing the electrolyte, the flux solution and filter material also must be changed. You will know the electrolyte needs to be changed when:

  • The flame becomes weaker
  • The pressure drops
  • The unit does not generate any gas


Rubber gloves Turkey baster or large syringe
Eye protection 1 quart of electrolyte*
Protection for your clothing Clean filter material*
Drop cloth or safe work area Fresh flux*
Plastic bucket Replacement rear check valve*
Plastic funnel Warm distilled water

*All replacement parts are available through the distributor from whom you purchased your HydroFlux Welder.


The electrolyte is highly caustic and should always be handled using protective equipment such as rubber gloves and safety glasses or goggles. When handling the electrolyte solution, be careful not to spill any. The electrolyte may damage any finished surfaces, clothing, etc. Electrolyte is highly corrosive to many metals, including copper, brass, zinc and aluminum, and reacts violently with acids. Electrolyte destroys human tissue on contact. It is odorless and colorless.


Unplug the unit. Put on protective equipment.
2. Remove all caps.
3. Use the turkey baster to remove all flux and discard in accordance with all applicable regulations. Wipe the inside of the chamber dry.
4. Remove all dryer filter material and discard. If there is any moisture in the dryer chamber suction it out and wipe dry.
5. Place the plastic bucket under the drain plug. If possible, place the bucket close enough to avoid splashing. The electrolyte is a highly caustic material. See the MSDS at the end of this manual for safety and health precautions.
6. Open the drain plug with the wrench or pliers. Take care that the plug does not fall into the bucket. After a few turns with the wrench it should be only finger-tight. Remove the plug. It is EXTREMELY IMPORTANT THAT YOU WEAR SAFETY GLASSES, GLOVES AND PROTECTION FOR YOUR CLOTING DURING THIS STEP! ELECTROLYTE IS CAUSTIC AND WILL IMMEDIATELY DAMAGE YOU SKIN.
7. Allow the chamber to drain. The electrolyte should be a muddy-brown to black color. Tip the unit slightly to facilitate draining.
8. With the drain still open, slowly pour approximately one quart of warm distilled water through the electrolyte chamber. Allow it to run through the unit and into the bucket. Repeat until the water is reasonably clear.
9. Replace the drain plug and tighten. The plug should be tightened to finger tight plus an additional 1/4 turn. The drain plug "O" ring can be damaged easily if the plug is too tight.
10. Remove the cover of the unit.
11. Carefully disconnect the clear tube that connects the flux chamber to the outside wall of the overflow reservoir. Drain any remaining flux from this tube. Replace the cover.
12. Replace the rear check valve filter by disconnecting the tubing from both ends and inserting a new filter.
13. Disconnect the tubing from the base of the handpiece. Unscrew the base of the handpiece at the black "O" ring. Tap out the gray sintered metal check valve filter and clean in an ultrasonic or steam cleaner.
14. Replace dryer filter material, taking care to pack it firmly, but not tightly. Check the inside gasket on the cap for cracks or tears. Replace if necessary.
15. Refill flux chamber to the halfway mark between minimum and maximum. Check the inside gasket on the cap for cracks or tears. Replace if necessary.
16. Using the plastic funnel, slowly fill the distilled water chamber with electrolyte. Check the inside gasket on the cap for cracks or tears. Replace if necessary.
17. Refer back to the sections on Setting-up Your Unit and Using the HydroFlux Welder to resume use.