▶ Introduction
▶ Setting Up The HydroFlux
▶ Using The HydroFlux
▶ Maintenance
▶ Changing Electrolyte
▶ Troubleshooting
▶ MSDS-Flux Solution
▶ MSDS-Electrolyte Solution
HydroFlux Welder - Introduction
  The HydroFlux Welder must be placed on a level surface with adequate ventilation. We recommend a minimum of 4 inches of clearance on each side. Using the HydroFlux Welder on a closed shelf or in a drawer will void all warranties. The HydroFlux requires cooling at all times.
  The HydroFlux operates optimally on a grounded 110 volt, 60 Hz electrical line. It is advisable to check the building fuse or circuit breaker to ensure that there is sufficient current to operate the Welder (10 amps maximum). We recommend that you operate the unit on a dedicated power line in order to avoid power surges or dips which can be caused by other equipment in use. These fluctuations can affect the performance of your unit. Do not plug in your unit until after step 5.
A piece of clear tubing is already connected to the unit. A plastic and metallic filter is connected to the end of this tubing. the clear tubing of the handpiece will fit snugly on the free end of this tubing. Press the tubing firmly over the filter. Check that the tubing is secure on both ends of the metallic filter and on the handpiece. Check that the screw cap on the bottom of the handpiece is snug.  Click on the thumbnails below for photos of this step.  
The electrolyte is highly caustic and should always be handled using protective equipment such as rubber gloves and safety glasses or goggles, and protective clothing. 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. Please refer to the Material Safety Data Sheet at the end of this manual for more specific health and safety information.
A. Put on safety glasses, gloves and protective clothing.
B. Move, or cover up anything that may be damaged by spilled electrolyte.
C. Check the drain plug in the side of the unit to make sure the plug is tight.
D. Unscrew the cap from the electrolyte chamber (the small cap).
E. Using a plastic funnel, slowly pour the solution into the electrolyte chamber.
F. Carefully wipe up any electrolyte spills with a clean paper towel.
G. Pour the entire bottle of electrolyte into the DISTILLED WATER chamber.
H. After filling the chamber, rinse the funnel with clean water and dry.
I. Do not use the funnel for any other application. Store the funnel for future use.
J. Rinse the electrolyte bottle in clean water. Replace cap and dispose in garbage. DO NOT REUSE ELECTROLYTE BOTTLE!
K. Replace the stainless steel cap on the electrolyte chamber. Tighten until snug. Do not overtighten.
Click on a thumbnail below to see a larger image...
Flux solution is very flammable. Keep the blue flux solution away from open flames or sources of ignition at all times. Do not smoke or have open flames near the unit when filling the flux chamber.
A. Put on safety glasses, gloves and protective clothing.
B. Unscrew the cap from the flux chamber. (the large cap at the front of the unit)
C. Slowly pour the BLUE flux solution into the flux chamber.
D. If you use the funnel from the electrolyte, make sure the funnel has been thoroughly rinsed with clean water and dried. Electrolyte contaminates the flux solution and makes it unusable.
E. Fill the flux chamber up to the MINIMUM level. DO NOT OVERFILL!
F. Carefully wipe up any flux spills with a clean paper towel.
G. Rinse the funnel with clean water and dry with a paper towel.
H. Recap the flux bottle and store in a cool, dry place; away from open flames.
The filter is designed to remove any moisture and impurities from the incoming oxyhydrogen gas. The result is a clean, moisture-free flame with minimal contamination of the flux solution. The filter material is a micro-fiber that resembles cotton.  Take a small handful of the filter material and gently tamp it into the inner cylinder of the filter chamber. Do not pack the filter too tightly. The entire inner chamber does not need to be filled with material.  
  Standard HydroFlux Welders should be plugged in to a grounded standard 115-volt, 60hz outlet.  For best results, the outlet should be on a dedicated circuit. When possible, avoid plugging your HydroFlux Welder into circuits that also power other machinery or equipment. The power drains caused by the other equipment could cause your HydroFlux Welder to run slightly hotter than normal and may cause condensation in the tubing leading to the torch handpiece.
On either side of the HydroFlux Welder, you will find four screws holding the black cover in place. Determine which location is most convenient for you to mount your torch holder. Unscrew that screw and set aside. Locate the black torch holder in the accessory bag. Insert the screw through the hole in the torch holder, and screw it back in to the hole in the torch cover. Orient the torch holder so it is pointing straight up, and tighten the screw firmly.