INSTRUCTION MANUAL FOR

FWW-Series
WATER WELDER

PLEASE READ THIS MANUAL CAREFULLY BEFORE OPERATION

3, Hagavish st. Israel 58817 Tel: 972 3 5595252, Fax: 972 3 5594529 mrc@mrclab.com

MRC.VER.02-11.10
Operation Instructions

Assembly Procedures
A. Move all parts out of carton box.

B. Connect the gas pipe between machine gas out (G) and booster (K).

C. Connect the pipe between booster (K) and torch diffusion stone pipe (L).

D. Open the cap of booster (K), then fill in Methyl Alcohol I or IPA (note: the
percentage of Alcohol should be higher than 95%) to 1/3 ~ 1/2 level of the booster sight glass
(P).
E. Ensure the electrolyte tank sight glass (I) that is between HI & LO. If not, please open
the DI water add port then fill in distilled water between "HI & LO" level.
F. Adjust the output Adj. (H) to "O".

G. Take a piece of torch tip (N) then set it on torch diffusion stone pipe (L).

H. Make sure the right voltage of the machine as showing on the name plate 220V or 110V
before plugging in.

Clean Electrolytic Tank Procedures:

A. Turn off the power at first. Open the flame Adj. valve (M), to release the pressure
from the electrolytic tank. As the pressure gauge (C) turns to "O", then close the
valve (M).
B. Open the DI water add port (J), and siphon out the used electrolyte. Then pour DI water
inside until half of sight glass (I), then siphon out the water again. Repeat the action 4 -5
times in order to clean up the used electrolyte.
C. After the finishing above procedures, then continue the next steps for mixing the new
electrolyte.
Mix Electrolyte Procedures:
A. After cleaning the electrolytic tank, you need to add the new electrolyte. Please pre
mix the electrolyte and the rate is 15g KOH with 100c.c. DI water.

B. At first, fill the DI water into the machine from the DI water add port (J).
Approx. 20mm below the LO level and leave the cap open .(use funnel to avoid spills
of water to the machine)

C. Turn the output Adj. knob (H) to "7", turn on the power switch (F) In the meantime,
please pay attention to the indicator of the input A meter (B), and it should be maximum
2A. If the indicator point up to 2A, you should clean the electrolytic tank once again.

D. For this moment, please prepare the electrolyte (or electrolytic powder or grain).

E. As filling the electrolyte into the electrolyte tank, the indicator will be showed slowly
up of input A meter (B).Especially, please do not fill too much for one time in order to
avoid over amperage above 4A.

F. If the indicator is nearly the red line on the input A meter (B), and you need to stop
adding the electrolyte, then add DI water to indicate between HI and LO of the sight glass
(I).
G. Turn off the power, and lock the DI water add port (J) tighten. Re-power on the machine, it
should be o.k. as the pressure gauge will be up slowly to approx. 0.6kg/cm2 then cut off
automatically.
Points for Attention:
A. Place the booster at a lower position than the main unit to prevent the Alcohol from back
flowing.

B. Check the electrolyte and Alcohol level every eight hours. Pour out used Alcohol and refill
with new Alcohol every week.

C. It's very important to turn off the power and release the gas to "O" before refilling the DI water and
Alcohol. Do not to drop the water into the internal of the machine.

D. Please replace the electrolyte that is valid for a year in order to extend the machine life.

E Please wears a pair of rubber gloves when you replace or refill the electrolyte. Avoid
getting in eyes or mouth. In case of eyes or skin contact, flush with water and soap. If
swallowed, go to hospital immediately.

F. Do not use excess amperage for long time operation. Pay attention to the input A meter (B)
all the time.

G. After finishing your current job and just take a break, no need to turn off the power. Keep
the fan working to cool the machine.

H. Ventilate the working room. Keep the environment temperature under 30°C while on
operating. As if the temperature becomes higher than 30°C , the Alcohol and DI water maybe
evaporated in the tube, booster and torch.

I. Keep the machine distance from the wall about over 20cm to ensure the cooling fan is
efficient. The machine must be earthed with power cord for safety reason.

J. Please contact us promptly when the machine breakdown.

Please do not disassemble by yourselves in order to protect you from danger and ensure the
life of machine. (Except the skilled engineers)

K. When start cold the production speed of the gas will be slowly, you must adjust higher of the
output Adj. knob (H) or have enough time to warm up the machine, when warming pay
attention to the input A meter (B), do not let it excess the red line.
L. After 30 minutes working, the input A meter (B) will be up more and more, by then, you can
turn the output Adj. knob (H) to normal, do not excess the red line.

M. The electrolyte and Alcohol will become concentrated after using some time (8 hrs).At this
time, you can add some DI water and Alcohol to recover it.

N. If A meter (B) is normal but the pressure gauge (C) do not raise up, it means the inner
machine or pipe are may be leak. Please check whether locked tighten or change electrolyte
tank packing, tighten the clamps of pipe, connector, o-rings and other leakage possible parts.

O. It is possible, that sometimes, once changing the position of the output Adj (H) ,especially
on the high position #6 or #7 , the circuit breaker on the electrical panel will activated. It is
recommend to change the position of the output Adj (H) first & then to turn on the power
switch (F) to avoid spike of current.

Power-On Procedures:
A. Ensure the electrolyte tank sight glass (I) is between the position of "HI" and "LO".

B. Adjust the output Adj. Knob to "7'', then turn on power switch (F), then watch the input A
meter (B) and set it close to the red sign till the gas pressure gauge (C) turns to 0.3kg/cm2
,then open the gas out valve (G) and the flame Adj. Valve (M).

C. Light up the torch: use the output Adj. Knob (H) and flame Adj. Valve (M) to adjust the

flame while operating the water welder, keep the pressure stably between 0.3 0.5kg/cm2 on
pressure gauge (C) in order to have a longer working time.

D. To get better flame shape, use a diagonal pliers to cut the torch tip (N), and sandpaper to
grind the nozzle edge of tip (N)

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Power-Off Procedures:
A. Extinguish the flame, and then turn off the power switch (F).

B. Directly extinguish the flame by the flame Adj. Valve (M), or fully open the valve (M)
till it is extinguished by itself. Fully open the valve again to release the gas until the
pressure gauge (C) turns to "O".
C. Close the gas out valve (G).

Flame Nozzle:

(Ref.I ) (Ref.2) (Ref.3) (Ref.4)

CUT HERE

A. Nozzle size applicable to: FWW- 270 (#22 ~ #23), FFW-640 (#21 ~ #23) , FFW-1200 (#20 ~
#23) , FFW-1600 (#18 ~ #23)

B. Use diagonal pliers to cut lightly the part of nozzle tip that would be cut. (Ref.1) To turn
round the pliers then press lightly to cause a dent on the nozzle tip. Now you can bend and
cut off from this dent part. (Ref.2) The nozzle tip must be like the (Ref.3), it is the prefect for
using. If not, please use the sandpaper to grind the edge to make a perfect round shape.

C. Please do not put excess strength to bend and cut off the nozzle tip, otherwise the nozzle
head will be squelched. (Ref.4)

Prohibition of Power-On Machine:

A. Do not open the DI water add port (J) or booster cap (K) to fill in distilled water or
alcohol. Before the above mentioned actions, you have to extinguish the torch and power
off the machine, then release the gas until the pressure gauge (C) showed "O" to avoid
causing dangerous.
B. Do not exchange the torch tip (N) or unfasten the connect pipe or power off the machine
while flaming.
C. If power failure suddenly, please extinguishes the fire immediately. Do not keep the fire on
burning, otherwise it will fire back.
D. Do not put any metals on the machine especially keep away from the area between handle and
DI water add port (J) as there will be easy to occur a short circuit. Then the power fuses maybe
burn out.

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