▶ Introduction
▶ Setting Up The HydroFlux
▶ Using The HydroFlux
▶ Maintenance
▶ Changing Electrolyte
▶ Troubleshooting
▶ MSDS-Flux Solution
▶ MSDS-Electrolyte Solution
HydroFlux Welder Support
Troubleshooting the HydroFlux Welder
Below are some common support questions regarding the HydroFlux. Please click on each topic to view our suggestions. We're working to update this section, so if you don't see an answer to your question, please call us at 1-800-223-0025 or email us at techsupport@okai.com. We'll do our best to answer your question -and- we'll get those answers posted up here for future reference. Thank you!
This is normal for a new unit or one that has not been used in some time. The components of the unit are going through a 'breaking in' period that should not affect the performance of the unit. If this condition persists for more than two weeks of normal use, please contact our technical sales department.
This is normal for a new unit or one that has not been used in some time. The components of the unit are going through a 'breaking in' period that should not affect the performance of the unit. If this condition persists for more than two weeks of normal use, please contact our technical sales department.

If the electrolyte chamber should accidentally be overfilled with distilled water, it will be necessary to completely flush the HydroFlux Welder. Follow the directions given under Changing The Electrolyte.

Do not siphon excess liquid from the machine. Do not attempt to partially drain the machine. Go immediately to the flushing procedure.


The most obvious symptom of this is liquid in the hose line that connects to the handpiece.

1. Remove excess flux from the chamber using the turkey baster. Bring the level to the halfway mark.
2. Disconnect the hose from the rear filter assembly and shake it vigorously. If possible, dry the hose and handpiece by blowing compressed air through both.
3. Repeat step 2 as many times as necessary to completely clear the line.

When the needle tips begin to blacken or turn cherry red at the hot end it is because the flame is beginning to burn back up into the tip. This will happen for several reasons:

1. There is excessive flux liquid in the hose and it has entered the handpiece. It catches fire as it comes through the tip.

Disconnect the hose from the rear check valve and the handpiece. Drain any fluid from the hose. Dry the hose by blowing compressed air through it. Remove the filter from the back of the handpiece and air dry. Also thoroughly dry the handpiece and the tip. Reconnect everything and turn the unit on. Open the valve on the handpiece and let the gas free-flow for 15 seconds before lighting.

2. The torch is shut off before the flame is extinguished at the handpiece.

The gas must first be shut off at the handpiece, before turning the unit off. If the gas is left on while the unit is turned off, the flame will try to burn back into the tip. This will singe the end of the tip and can melt the plastic casing on the tip.


The electrolyte is contaminated or needs to be changed.

When there is a problem with the electrolyte, gas generation is impaired. The lack of sufficient pressure causes the flame to draw into the tip, burning the tip. Follow the instructions for changing the electrolyte.


An orange flame develops generally from one or more of the following causes:

1. Insufficient gas pressure causes the flame to burn backward into the torch tip and burn the tip. Causes are:
a. Gas leaks or blockages; check all hoses and connections.
b. Dirty filter element; replace filter.
c. Low water level in gas generator; add distilled water.
d. Low voltage; check line voltage and/or change lines.
e. Deformed torch tip; replace torch tip.
f. Corroded electrical connections; clean connections.
g. Electrical failure; check incoming power source.
2. Flux level low, or chamber empty; Add Flux.
3. Torch tip dirty;Clean tips in an ultrasonic or steam cleaner. Replace if necessary.
4. Gas generator overheated and delivering water vapor to the torch tip.
Turn unit off for a few minutes to allow it to cool. Check that the ventilation slots are not blocked. Check that the fan is still running.



Spitting of liquid from a torch tip during operation is often, but not always, associated with overheating of the gas generator. Possible causes of such overheating are:

1. Gas generator tank overfilled with distilled water;
2. Too high a line voltage;
3. Contaminated electrolyte;
4. Corroded electrical connections inside the gas generating chamber;
5. High resistance short circuit inside gas generating chamber;
6. Operating environment too hot;
7. Fan failure;
8. Gas generator excessively dirty; and/or
9. Power setting too high.

The first thing to check is the filter chamber. Spitting indicates that excess liquid is in the line. Check the filter to see if it has become moist and replace if necessary. The gas generator will generally run pretty hot and a temperature of 160oF on the chamber surface is not unusual. This temperature can be achieved when the gas generator runs continuously at or near full load conditions. At this temperature the gas generator can be expected to deliver some water vapor into the lines along with the oxyhydrogen gas. However, the filter and flux booster will tend to trap this water vapor before it reaches the torch tip. If the filter is wet and is unable to trap all the moisture, it will pass into the flux chamber. The blue flux supplied by the factory will change in color from blue to pink when it has trapped significant quantities of water vapor. The change in color indicates that the flux has become excessively contaminated and that the solution should be cleaned out and replenished with new, clean flux.

When electrolyte in the gas generator becomes even slightly contaminated, especially with flux solution, significant quantities of liquid and water vapor will be emitted from the gas generator at chamber temperatures even lower than 160oF, and the flux chamber will require more frequent cleaning in order to serve effectively as a contaminant trap. Under certain conditions of electrolyte contamination, the chamber temperature can also rise above 160oF, giving a doubly severe boiling condition inside the gas generator cell and the gas generator should then have its electrolyte changed or be returned to the factory for servicing and generator tank clean-out.

Once spitting has occurred, all gas lines and filter elements become wet and will continue to emit liquid through the system until they run themselves dry or until they are dried out by being removed and cleaned. Such removal and cleaning is only a temporary corrective measure unless the cause of the vapor emission from the generator tank is also eliminated.

Corrective measures for each of the above are described elsewhere in this manual under appropriate headings. A thorough study of the manual should be made to gain an overall understanding of the various causes and their respective corrective measures.


First, remove each cap. The gasket under the cap should be intact and seated in the top of each cap. If the gasket is bent, disfigured or has any tearsin it you must order a new gasket from your supplier. If the gasket is in good shape, replace each cap and screw down tightly. Try the unitagain.

If theunit still does not generate any pressure at the handpiece, there may bea gas leak somewhere in the system. Turn the unit on. Open the cap onthe flux chamber. There should be vigorous bubbling activity in the fluxwhere the gas is being mixed. If there is no bubbling activity, thenthere is a leak prior to the flux chamber. Call the factory forassistance on checking internal components.

If thereis bubbling activity in the flux, and there is still no pressure at thehandpiece, then there is probably a leak between the flux chamber andthe handpiece. Recap the chamber and hold portions of the clear hoseunder soapy water. Look for bubbles from the hose. These will indicatewhere a leak is. Check the entire hose this way.

If, afterchecking all tubing and connections, the same conditions occur there maybe a problem with a diode. Contact the factory for assistance.


Incorrectflame size and color can be attributed to any of the following:

1. Dirty or clogged tips. Clean tips in an ultrasonic or steam cleaner regularly.
2. The flux level is too low. Check the level and fill as necessary.
3. The check valve filters are dirty or clogged. Clean filters in an ultrasonic or steam cleaner regularly.
4. The water level in the gas generating cell is too low. Fill if necessary.
5. The power line voltage is too low to produce sufficient gas. Check the line voltage and relocate the unit if necessary.
6. The gas generating cell has overheated. See above section.
7. Electrolyte is old, or its effectiveness has been reduced by many hours of use and dilution. Flush the machine and replace the electrolyte.

The flame is the most reliable indicator of performance on the HydroFlux Welder. If any part of the unit is not performing up to standard, symptoms will appear in the flame. The color of the flame may change, the size of the flame may change, spitting may occur, or the flame may not generate at all. By keeping a close eye on the flame, you will be able to monitor the performance of the unit and spot any potential problems before they occur.