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.