Katanax K1 PRIME User manual

®
Automatic fluxer
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Thank you for having chosen the K1 Prime fusion machine from Katanax. To enjoy
years of reliable, efficient and safe use of this time-saving instrument, please read
this manual thoroughly and keep it in a safe and handy place for future reference.
Should you have any question regarding the use, maintenance or repair of your
instrument, kindly contact Katanax directly for assistance (see page 55 for contact
details).
© 2018, Katanax inc. All rights reserved.

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Index
Index ...............................................................................................2
Installation......................................................................................4
Box contents ............................................................................................ 4
Location................................................................................................... 4
Leveling ................................................................................................... 5
Connection............................................................................................... 5
Compatibility with the older K1 model ....................................................... 5
Questions ?.............................................................................................. 5
Introduction....................................................................................6
The fusion theory ..................................................................................... 6
Automatic fluxers ..................................................................................... 6
The K1 Prime fluxer.................................................................................. 7
Main features of the Katanax K1 Prime.................................................... 10
Precautions ...................................................................................12
High temperature................................................................................... 12
High voltage........................................................................................... 12
Acid spills............................................................................................... 12
Heavy instrument................................................................................... 12
Crucible locking ...................................................................................... 12
How the unit works ......................................................................13
Heating.................................................................................................. 13
Agitation and pouring of the melt ............................................................ 13
Cooling .................................................................................................. 13
Solution agitation ................................................................................... 13
Using the K1 Prime (basic) ..........................................................15
The main running screen ........................................................................ 15
During a fusion....................................................................................... 17
The right ingredients .............................................................................. 18
Care of the elements .............................................................................. 21
Crucible installation ................................................................................ 22
Mold installation ..................................................................................... 22
A general fusion ..................................................................................... 22
Making solutions..................................................................................... 23
Description of the fusion steps ................................................................ 24
Programming the K1 Prime (advanced)......................................27
Viewing the fusion parameters ................................................................ 27
Unlocking the advanced mode ................................................................ 31
Managing fusion methods ....................................................................... 31
Preparing a fusion program..................................................................... 32
Heating steps ......................................................................................... 32
Pouring step........................................................................................... 33
Cooling steps ......................................................................................... 34

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Solution programs.................................................................................. 35
On-the-fly editing ................................................................................... 35
Global parameters ........................................................................36
Language............................................................................................... 36
Automatic shut-off delay......................................................................... 36
Fusion counter ....................................................................................... 36
Fusion troubleshooting.................................................................37
Disk cracks............................................................................................. 37
Disk crystallizes...................................................................................... 37
Incomplete disk...................................................................................... 38
Non-homogenous disk............................................................................ 38
Bubbles in disk ....................................................................................... 38
Periodic inspection .......................................................................39
Warning................................................................................................. 39
Inspection schedule table........................................................................ 39
Flux spillages.......................................................................................... 39
Visual integrity of heating elements......................................................... 40
Element terminal connections ................................................................. 41
Thermocouple junction ........................................................................... 41
Service operations ........................................................................43
Warning................................................................................................. 43
Crucible heating element replacement..................................................... 43
Mold heating element replacement.......................................................... 47
Firmware and program transfers.................................................50
Preset programs..................................................................................... 50
Backup or restore by USB....................................................................... 51
Technical specifications................................................................53
Electrical ................................................................................................ 53
Physical ................................................................................................. 53
Warranty .......................................................................................54
Contacting Katanax ......................................................................55

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Installation
Congratulations on your acquisition of the K1 Prime fluxer, from Katanax. Please
read the following section for proper commissioning of your instrument. Do not
hesitate to contact Katanax with any question you might have with this crucial
step.
IMPORTANT: It is advisable that at least two persons carry this instrument to
avoid injuries. Do not drop instrument.
Box contents
The instrument comes with its essential accessories. In addition to optional items
you might have ordered, the box should contain:
1 fluxer (K1 Prime main unit)
1 mold heating/cooling unit
1 mold holder to fit your mold size
1 power cord
1 tool kit (hex keys, spare fuses...)
1 instruction manual (this booklet)

Additionally, if you have ordered a K1 Prime with solution-making capability, you
will find:
1 solution agitation module
1 unbreakable Teflon beaker
1 magnetic stirring bars
Location
Vent hood
Molten flux, additives and some samples may produce vapors and gases that
need to be extracted, but since this instrument does not produce post-combustion
hot gases, only a small hood is required. A wide, funnel-ended, flexible suction
duct may be the most practical and economical solution.
Table
The counter on which the instrument is to be used must be made of non-
combustible material and must be able to withstand a weight of 30 kg (66 lbs). It
is recommended to use the instrument from a standing position, and adjust table
height accordingly.
It is advisable that at two persons carry the instrument to avoid back injuries.
Clearances
Because your new fluxer will produce heat, a minimal safety clearance must be
provided to prevent surrounding material from heating and potentially catching
fire. All around the instrument, a minimum distance of 30 cm (12’’) must be free

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from combustible materials. Similarly, a clearance of at least 45 cm (18’’) must be
provided above the top of the instrument.
Leveling
In order to obtain glass beads with a regular thickness, it is important that the
mold be reasonably horizontal upon pouring. If in doubt, place a lightweight
bubble spirit level on the mold and adjust instrument’s feet to compensate for
possible slant. (See page 22 for mold installation details.)
Connection
The K1 Prime works on 117-127 or 220-240 VAC, 50/60 Hz.
When used at 117-127 VAC, the power line must be able to provide
12 A.
When used at 220-240 VAC, the power line must be able to provide
10 A.
While it is technically workable to use the instrument in the lower range of
voltages, heat-up times will be longer than in the recommended voltage range. It
is possible that the instrument show heating errors due to this, because the
microprocessor monitors temperature increase vs. time.
In areas where the voltage during operation is likely to fall below the lower
recommended limit, the use of a 1500 W step-up transformer is required.
Compatibility
with the older
K1 model
If you own an older-generation K1 unit, please note that the mold heating module
and the solution agitation module, while being physically very similar to their new
versions, are NOT compatible.
IMPORTANT: Damage to the instrument will occur if an older module is
connected to the K1 Prime.
Questions ?
Should you have any question regarding the proper installation and start-up of
your instrument, please contact Katanax directly (see information on page 55) for
assistance.

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Introduction
This section intends to introduce the reader to the fusion technique and to
familiarize him or her to the K1 Prime.
The fusion
theory
Fusion is a technique used to prepare inorganic samples, with a view to analyze
them by x-ray fluorescence (XRF), inductively coupled plasma (ICP) atomic
absorption (AA) or any traditional wet chemistry method. Typical samples include:
cements, ores, slag, sediments, soils, rocks, ceramics, pigments, glasses and
even metals.
A fusion can produce either a small, homogenous solid glass disk (or “bead”) for
XRF, or an acid solution for other analytical methods.
The process of fusion as a sample preparation method exhibits many advantages
over other methods, as it does not produce mineralogy, grain size or orientation
effects and the result is perfectly homogenous.
In sample preparation by fusion, the sample never actually melts. It is merely
dissolved into a solvent. This solvent, generally a lithium borate flux, is solid at
room temperature and must be molten to dissolve anything. This is the only
reason the process requires heat.
Therefore, the peak temperature of a sample preparation by fusion is
determined only by the type of flux, not the type of sample.
A fusion temperature of 1100°C should be considered as a maximum.
Heating above that temperature could cause flux evaporation that could bias the
subsequent analysis.
Automatic
fluxers
Because of the potential risk of manipulating red-hot samples and to increase
repeatability of temperature, mixing and duration, the industry has now adopted
the automated fusion machine as the standard equipment to prepare samples by
fusion.

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The K1 Prime
fluxer
General view
Enter the K1 Prime, the fusion machine that is the evolution of the original K1,
which was the first and only fully automated electric resistance fluxer. Based on
this success, Katanax has updated the concept, making it sturdier and easier-to-
use than ever.
The K1 Prime comes pre-loaded with various fusion methods that can be used as
is, or can be customized. All fusion methods can be saved, renamed, deleted or
copied, just like computer files. Only the preset methods are protected to avoid
accidental overwriting.
Crucible
heater
Mold heater
LCD
interface
Safety shield

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Crucible heater
A straight-walled platinum crucible is loaded with a few grams of powdered
sample, an appropriate flux and often other agents. The crucible is inserted into
the crucible heater, and locked by the locking bar’s crucible lid.
A removable spill protector is provided, so that any pouring residue can easily be
cleaned.
Crucible
Locking bar
Crucible
heater
Crucible lid
Spill protector