Elettronica Todescato L/160 Operating Instructions And Maintenance

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INDEX

SECTION 1: Description and main features of the welder

1.1 Presentation 4

1.2 Warranty 4

1.2.1 Exclusion from warranty 5

1.3 Machine identification 6

1.4 Equipment 7

1.5 Machine description and use limitation 7

1.5.1 Description 7

1.5.2 Use limitation 7

1.6 Noise 8

1.7 Technical features 9
SECTION 2: Safety and prevention

2.1 Safety 10

2.1.1 General safety regulations 10

2.2 Safety signs (Symbols) 11

2.3 Safe use and maintenance 12
SECTION 3: Transport and installation

3.1 Packaging 12

3.2 Shipping 12

3.3 Un-packaging 13

3.4 Positioning 13

3.5 Storing 13
SECTION 4: Use

4.1 Connection to the electric circuit 14

4.2 Preparing the electrolyte 14

4.3 Tank filling 15

4.4 Booster tank filling 15

4.5 Preparing deoxidizer liquid 15

4.6 Hazardous operations 16

4.7 Starting the machine 16

4.8 Stopping the machine 17

4.9 Backfire 17

4.10 Safety device 18

4.11 Refilling deoxidizer liquid 18

4.12 Refilling distilled or demineralized water 18
SECTION 5: Maintenance

5.1 Generalities 19

5.2 Every six months 19

5.3 Once per year 19

5.4 Every four years 20

5.5 Putting the machine out of service 20

5.6 Scrapping 20

5.7 Disposing of the electrolyte 20

5.8 Disposing of the liquid deoxidizer 20

5.9 Trouble shooting 21

5.10 Interventions 25

5.10.1 What to do in order to see if the tank is short- circuit 25

5.10.2 Controlling pressure, adjustment valve 25

5.10.3 Checking valve tightness 26

5.10.4 Replacing the valve 26

5.10.5 Replacing the electrolyte 27
SECTION 6: Spare parts

6.1 Spare parts 27
FIGURE LIST
Fig.1 Welding and components 6
Fig.2 Machine layout 9
Fig.3 Safety signs 11
Fig.4 Valve replacement 27
Fig.5 Spare parts 29
Fig.6 Wiring diagram 31
Fig.7 Gas circuit 32

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SECTION 1

Description and main features of the welder

1.1 PRESENTATION

This manual gives information regarded as necessary to know, use correctly and carry out normal
maintenance operations on this welder « L/160 » (hereinafter referred to as machine) fabricated by
«Elettronica Todescato S.r.l.» in Arcugnano (Vicenza) Italy (hereinafter referred to as Manufacturer).
The material in this manual is not intended to be a complete description of the parts nor a detailed
explanation of their option. The user, however, will find the kind of Information normally required to
operate the machine correctly and safely and also to keep in good working condition.

Compliance with and observance of what is described in the manual is an essential condition for the
trouble-free operation, long life and cost effective performance of the machine.

ATTENTION
Failure to observe the instructions in this manual, negligence, incorrect or improper use of the
machine can be cause of machine warranty coverage cancellation by manufacturer.
Manufacturer therefore declines any and all liability for injury to persons or damage to
property caused by failure to follow the instructions given in this Manual.

Service work or overhauls involving complex operations must be entrusted to an authorized Technical
Service Center which have the necessary specialized personnel. Or directly to the Manufacturer who
is at your complete disposal to ensure fast and complete technical assistance and anything else that
can promote improved operation and optimum performance by the machine.

DANGER

This Manual must be kept in a safe place at the disposal of the operator and service engineer,

for consultation at any time during the machine’s entire working life. It should be delivered with

the machine if this latter is sold.
The manual must be kept in a safe place that is familiar to the assigned personnel. It is the
responsibility of the personnel to keep the manual complete to allow for a consultation for the
entire life of the machine. If the manual is damaged or lost, a copy must be immediately
requested from the Manufacturer.

1.2 WARRANTY

Elettronica Todescato S.r.l. ensures that the machine referred to in this manual has been tested in

its own premises. The machine is guaranteed for 1 year (12 months) from the date of purchase. Should
the machine be tampered with or improperly used, particularly concerning the safety devices, the
warranty will be voided and the manufacturer will be discharged from any liability whatsoever. Upon
delivery, make sure that the machine has not suffered damage during transportation and that it is
complete with all standard accessories and any optional equipment specifically ordered. Complaints
must be made in writing and be submitted to your reseller within and not later than 8 (eight) days.

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1.2.1 EXCLUSIONS FROM WARRANTY

This warranty shall be null and void (apart from the causes given in the Purchase Contract):

- If the machine is used with incorrect voltage.

- If the damage is due to insufficient maintenance or lack of proper service.

- If, following repairs carried out by the owner without manufacturers consent due to installation
of non-original spare parts, the machine has been changed and the damage was caused by
this changes.

- If the instructions given in this manual were not followed correctly. - Exceptional events.

Damage caused by negligence, lack of care, improper and bad use of the machine or incorrect
maneuvering by the operator shall also cause this warranty coverage to be null and void.

ATTENTION

Removal of safety devices installed on the machine will automatically make this warranty null
and void of the Manufacturer.

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1.3 MACHINE IDENTIFICATION

Each machine is equipped of identification plate (fig.1 # 21), giving the following Information:

- Name and address of Manufacturer;

- «CE» Mark;

- A) Machine type;

- B) Year of fabrication;

- C) Serial number;

- D) Voltage;

- E) Ampere;

- F) Watt;

- G) Frequency;

- H) Pressure.

The data given on the identification plate should be written in the spaces provided on the back cover
of this manual and should always be specified when ordering spare parts or requesting Technical
Assistance.

FIG. 1- WELDER AND COMPONENTS

Legend Fig.1

1. Three-position switch

2. Safety cap

3. Filling neck

4. Power control knob

5. Minimum level indicator light (yellow)

6. Maximum level indicator light (red)

7. Booster tank

8. Handle knob

9. Booster holder

10. Torch

11. Burner tip/nozzle

12. ON indicator light (green)

13. Check valve cap

14. Torch holder (optional)

15. Torch hose

16. Torch hose fitting

17. Booster holder hose fitting

18. Flame arrester cap

21. Identification plate

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1.4 EQUIPMENT

Standard equipment

- Burner tip (Fig. 1 # 11).

- User Manuals and DVD. -

- Spare fuse (Fig. 5 # 37).

- Plastic funnel.

- Torch (es).

- Fire proof rubber hose.

- Power cord.

Optionals:

- Container with distilled / demineralized water.

- Container with liquid flux (deoxidizer).

- Torch holder (14 Fig. 1). -

- 2.5 Bar pressure gauge.

- Electrolyte solution.

- One year maintenance kit.

- Igniter.

1.5 MACHINE DESCRIPTION AND USE LIMITATION

The «ET Hydrogen Welder L/160» is a machine marked with «CE» symbol in compliance with
European Union regulations pursuant to EEC

Directiv

e 2014/35/UE and 2014/30/CE

as detailed

in the UE

Declaration

of

Conformity annexed to

each

machine.

1.5.1 DESCRIPTION

The «ET Hydrogen Welder L/160» can be used in craftwork or industrial workshop with a minimum
volume of 30 m³ and provided with natural ventilation by means of suitable openings to the outside in
compliance with the regulations in force in the user’s country. This machine is mainly used for soft
and hard brazing applications in the fields of jewelry, goldsmith, costume jewelry, dental mechanics,
micromechanics, and for welding materials such as platinum, beryl, nickel, thermocouples, enamel
copper, glass, quartz.

1.5.2 USE LIMITATIONS

The hydrogen and oxygen mixture produced by this welder must be solely used to produce one flame
for braze welding or thermal treatments of metal parts in general, or for working quartz glass.

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DANGER
Any use whatsoever different from those quoted here within and not included or not directly

inferred from this instructions’ manual, will be regarded as «NOT ALLOWED».

It is not permitted to operate the machine when the flame is out. This would result in,
accumulation of explosive mixture in the surrounding environment and pollution caused by
the methyl alcohol.
The machine has been designed for professional use. The operator must be of proven ability
and capable of reading and understanding the instructions given in this manual.
The operator must also use the machine in accordance with the ruling accident prevention
standards, operating conditions and characteristics of the machine.

DANGER
THE USE OF THE MACHINE FOR ANY OTHER PURPOSE THAN THAT DESCRIBED IN THIS
MANUAL RELIEVES THE MANUFACTURER ANY RESPONSIBILITY FOR DAMAGES TO
PERSONS, ANIMALS OR THINGS RESULTING FROM INAPPROPRIATE USE.

1.6 NOISE

The noise level (acoustic pressure) was determined with the machine running under no load
conditions with the readings of the 70 dB(A) inferior.

1.7 TECHNICAL FEATURES

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FIG. 2– MACHINE LAYOUT

H2/O2 Gas production

It/h

160

Water consumption

cc/h

82

Alcohol consumption

cc/h

30

Booster tank capacity

cc

282

Maximum power

Watt

100

Electrolyte

It

3

Weight

Kg

45

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SECTION 2

Safety and Prevention

2.1 SAFETY

The owner of the machine must instruct personnel about the risk of industrial accident, the safety
device installed for operator safety and on general industrial accident prevention regulations applied
by law in the country where the machine is to be operated.
Operator safety is a matter of considerable importance for machine design and fabrication. When
designing a new machine, every effort is made to foresee every possible dangerous situation and,
naturally, adopt suitable safety devices to counter them. Therefore, a careful reading of this manual
and special care and attention whenever any intrinsically dangerous operations have to be carried
out, they are obligatory.

DANGER

Manufacturer declines any and all liability for injury to persons or damage to things caused by failure
to follow this safety regulation and accident prevention recommendations detailed here.

Pay special attention when you see this symbol in the manual.

2.1.1 GENERAL SAFETY REGULATIONS

ATTENTION
The failure to comply with the information described in «Section 2 – Safety and Prevention»
and the mishandling of the safety devices relieves the Manufacturer from any responsibility in
the event of accidents, damage or machine malfunctions.

General rules:

- The user undertakes to entrust the machine to a qualified and trained personnel only.

- The user is bound to take all the necessary measures for preventing unauthorized personnel
from accessing the machine.

- The user undertakes to provide its personnel with adequate information regarding the
application and observance of the safety regulations. To this end, the user undertakes to
ensure that all the personnel understand the machine operating instructions and the safety
regulations relative to their particular responsibility.

- The user must inform the Manufacturer of any defects or malfunctions in the accident
prevention system and any situations of potential danger.

- The personnel must use the personal protection items provided for by law and respect
instructions given in this manual.

- The personnel must respect the danger and caution symbols on the machine.

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- The personnel must not perform under their own initiative operations or interventions that lie
outside their competence.

- The personnel are obliged to notify their superiors of any problem or dangerous situation that
may arise.

- The machine has been commissioned and tested with all the parts included within the
standard equipment. The installation of parts or other makes or modifications to the machine
may vary its characteristics and compromise its operating safety.

- The machine must only be used for the purpose for which it was constructed.

2.2 SAFETY SIGNS (Symbols)

During construction of the machine, all the possible solutions for safeguarding the operator have
been adopted. The machine may nevertheless present ulterior residual risks which it has not been
possible to eliminate completely under certain operating conditions. This risks have been highlighted
on the machine with adhesive warning symbols that indicate the various situations if reduced safety
or danger.

ATTENTION

Keep the safety stickers clean and replace them immediately if they are peeling away or
damaged.

The following warnings refer to Figure 3. Read them carefully and learn their meaning.

1. Excessive voltage. Before interventions, disconnect power.

2. Toxic substance, if swallowed. Do not inhale the vapors.

3. Easily flammable.

4. Corrosive liquid when in touch with body members.

5. Attention, electrostatic discharge sensitive device.

6. Flammable. Do not approach free flames.

7. Use protection glass.

8. Use protection mask for respiratory tract.

9. Use protection gloves.

10. Before using the machine, read the operating instructions carefully.

11. Attention, do not turn the handle knob while the flames are lit.

FIG. 3

–

SAFETY SIGNS

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2.3 SAFE USE AND MAINTENANCE

ATTENTION

- It is prohibited for the machine to be used by:

o Persons who have not read and understood the instructions given in this manual;
o Inexperienced persons; o Persons not in good physical/mental health.

- Periodically check that the machine and its protection devices are in perfect working order.

- Before maintenance operations or repairs on the machine, disconnect power.

- Maintenance operations and repairs must only be carried out by personnel trained to perform
these special functions.

- At the end of the maintenance operations and repairs, before restarting the machine, the
technical foreman must check that the work has been finished, the safety device reactivated
and the protections reassembled.

- The spare parts must correspond with those stipulated by the Manufacturer. Use only original
spare parts.

- During maintenance operations and repairs, protective clothing must be worn, i.e. protective
eyewear, gloves for preventing cuts and mask for respiratory tract protection.

- Do not use water jets to dean the machine.

SECTION 3

Transport and Installation

3.1 PACKAGING

The welder is wrapped up in a polythene film and subsequently packed in a three-layer waterproof
cardboard box sealed with adhesive tape and secured by means of a double strap.

3.2 SHIPPING

Whatever transportation method is used, either by (plane, sea or land) continental or intercontinental,
the machine tanks will be empty.

If REQUESTED or where PERMITTED:

The packaged electrolyte salts and/or bottled demineralized water, will be shipped according to the
rules, law and regulations of each host country destination.