Katanax K2 Prime User manual

®
Automatic fluxer
2

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Thank you for having chosen the K2 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 91 for contact
details).
© February 2015, Katanax inc. All rights reserved.

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Index
Index ...............................................................................................2
Installation......................................................................................5
Box contents............................................................................................ 5
Location ................................................................................................... 5
Leveling ................................................................................................... 7
Heating element protection....................................................................... 7
Hi-throughput “HX” version....................................................................... 8
Connection............................................................................................... 8
Questions ?.............................................................................................. 8
Introduction....................................................................................9
The fusion theory ..................................................................................... 9
Automatic fluxers ..................................................................................... 9
The K2 Prime fluxer................................................................................ 10
Main features of the Katanax K2 Prime.................................................... 12
Precautions ...................................................................................14
How the unit works ......................................................................15
Heating.................................................................................................. 15
Access to the furnace ............................................................................. 15
Agitation and pouring of the melt ............................................................ 15
Cooling .................................................................................................. 16
Solution agitation ................................................................................... 16
Using the K2 Prime (basic) ..........................................................17
Operation of the safety shield.................................................................. 17
The main running screen ........................................................................ 18
Electro-mechanical pushbuttons.............................................................. 20
Loading a program ................................................................................. 21
During a fusion....................................................................................... 22
The right ingredients .............................................................................. 23
Care of the elements .............................................................................. 26
Care of the platinumware ....................................................................... 27
Crucible installation ................................................................................ 27
Mold installation ..................................................................................... 29
A general fusion ..................................................................................... 29
Making solutions..................................................................................... 30
Description of the fusion steps ................................................................ 31
Programming the K2 Prime (advanced)......................................33
Viewing the fusion parameters ................................................................ 33
Unlocking the advanced mode ................................................................ 37
Managing fusion methods ....................................................................... 38
Preparing a fusion program..................................................................... 39
Heating steps......................................................................................... 39
Pouring step........................................................................................... 41

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Cooling steps ......................................................................................... 42
On-the-fly editing ................................................................................... 43
Global parameters ........................................................................44
Language............................................................................................... 44
Holding temperature offset ..................................................................... 44
Startup tolerance.................................................................................... 45
End beep ............................................................................................... 45
Automatic shut-off delay......................................................................... 45
Safety shield protection .......................................................................... 46
Fusion counter ....................................................................................... 46
Special parameters.......................................................................47
Accessing the Special parameters ........................................................... 47
Twisting correction ................................................................................. 47
Offsets................................................................................................... 48
Cam assisted.......................................................................................... 49
Movement testing................................................................................... 49
Fusion troubleshooting.................................................................51
Disk cracks............................................................................................. 51
Disk crystallizes...................................................................................... 51
Incomplete disk...................................................................................... 52
Non-homogenous disk............................................................................ 52
Bubbles in disk ....................................................................................... 52
Periodic inspection .......................................................................53
Warning................................................................................................. 53
Inspection schedule table........................................................................ 53
Flux spillage on holders........................................................................... 54
Holders alignment and functionality......................................................... 55
Visual integrity of heating elements......................................................... 56
Element terminal connections ................................................................. 56
Door springs tension check ..................................................................... 57
Furnace cleanliness ................................................................................ 57
Thermocouple junction ........................................................................... 58
Door Safety switch ................................................................................. 58
Linear motion system ............................................................................. 59
Service operations........................................................................60
Warning................................................................................................. 60
Platinumware holders service.................................................................. 60
Crucible holder removal .......................................................................... 60
Crucible holder assembly ........................................................................ 62
Crucible holder Installation...................................................................... 63
Mold holder removal............................................................................... 64
Mold holder assembly ............................................................................. 67
Mold holder installation ........................................................................... 68
Adjustment of holders ............................................................................ 68
Heating element replacement ................................................................. 77
Element tube replacement...................................................................... 79
Furnace top/back removal ...................................................................... 80
Spring position adjustment ..................................................................... 81
Furnace door removal............................................................................. 81

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Furnace backwards flipping..................................................................... 82
Blower box removal................................................................................ 83
Base compartment access ...................................................................... 84
Linear carriage lubrication....................................................................... 85
Firmware and program transfers.................................................86
Preset programs..................................................................................... 86
Backup or restore by USB....................................................................... 87
Technical specifications................................................................89
Electrical ................................................................................................ 89
Physical ................................................................................................. 89
Warranty .......................................................................................90
Contacting Katanax ......................................................................91

5
Installation
Congratulations on your acquisition of the K2 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 (K2 Prime main unit),#K2Pn-dd [n=5 or 6 positions, dd=mold diam.]
1 accessories box containing the parts to assemble the platinumware holders
1 instruction manual (this booklet) and other instructions
Additionally, if you have ordered a K2 Prime with solution-making capability, you
will find:
5 unbreakable PTFE beakers, 5x#KP0010A
5 magnetic stirring bars (included with KP0010A)
1 crucible holder middle section (to hold 5 crucibles)
Note that the rest of the solution-making devices are permanently installed into
the instrument, and are not packaged separately.
Location
Vent hood
Molten flux, additives and some samples may produce vapors and gases that
need to be extracted. In particular, the use of excessive amounts of halogen-
based non-wetting agent will potentially cause the deterioration of the fluxer if the
corrosive fumes are not properly vented out.
In order to minimize airflow around the unit, the hood shall ideally be of the
canopy type, i.e. with sides and front open. If the sides are closed or otherwise
occupied by other instruments, a clearance of 30 cm shall be maintained on either
sides and to the back of the instrument.
Sash-type hoods should preferably not be used; or if unavoidable, the sash shall
be kept open, so as not to create front-to-back air movements.
The funnel (intake section) of the hood shall be approximately equal (or slightly
larger than) the size of the instrument's footprint, and centered above it to avoid
sideways airflow around the fluxer.
The lowest part of the funnel shall sit 45 to 60 cm above the instrument (93 to
108 cm above the tabletop).

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Fume hood air speed, measured at the base of the intake funnel, shall be around
0.5 m/s.
Given the nature of the exhausted gases (halogen compounds), Katanax
recommends that the piping be internally coated with a corrosion-resistant finish,
PTFE-coated piping being the optimal. (Other corrosive-resistant coatings may be
allowed by your local fire codes.) The same applies to the fan / impeller and any
other part in contact with the gas flow.
Motor and fan / impeller sizing information can unfortunately not be provided by
Katanax, as those strongly depend on factors linked to each individual installation
(pipe diameter, pipe distance to the outside, exhaust baffle type, etc...). Those will
need to be calculated locally for each installation by HVAC engineers.
In all cases, the vent hood must be centered above the fluxer. Failure to comply
with this requirement could create temperature uniformity issues and/or
premature degradation of the platinumware holders.
Table
The counter on which the instrument is to be used must be able to withstand a
weight of 68 kg (150 lbs). It is recommended to use the instrument from a
standing position, and adjust table height accordingly.
The tabletop shall be made of a non-combustible material, horizontally flat, rigid,
and stable.
It is advisable that at least two persons carry the instrument to avoid back
injuries.
Safety clearance
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
from combustible materials. Similarly, a clearance of at least 45 cm (18’’) must be
provided above the top of the instrument.
93-108 cm
(37-43 in)
30 cm
(12 in)
30 cm
(12 in)
30 cm
(12 in)

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Leveling
In order to obtain glass beads with a regular thickness, it is important that the
molds be reasonably horizontal upon pouring. If in doubt, place a lightweight
bubble spirit level on the molds and adjust instrument’s feet to compensate for
possible slant. (See page 29 for mold installation details.)
Heating
element
protection
To protect the heating elements, especially during the initial fusion method
development phase, different protection devices are available. They represent a
simple way of shielding the elements from the sputtering that may occur during a
fusion that is not optimally set yet.
Katanax offers a protective plate, made of a dark-colored ceramic, and clear
tubes. The plate covers all bottom elements simultaneously, while tubes can be
installed over top elements and/or bottom elements (when no plate is installed).
The dark ceramic plates is very resistant to flux and chemicals, and can be used in
all types of sample preparation. This is the protection method that Katanax
recommends.
Alternatively, two clear tube material choices are available: Quartz and Sapphire.
The Quartz tubes (part number KP5010E, sold as a pack of 8) are inexpensive,
but while these tubes will normally last very long, they are not the best choice if
you plan on using Iodine-based releasing/non-wetting agent in your fusion
recipes. Indeed, those compounds (LiI, KI, NH4I…) will evaporate almost entirely
their iodine, which readily attacks quartz (SiO2).
Hence, if you are using (or plan on using) an Iodine-based releasing agent, we do
not recommend to install quartz tubes; rather, if you want a protection on the
elements, use Sapphire tubes or a protective plate.
In short:
1. If you do not use iodine-based non-wetting agent:
a. You can install optional Quartz tubes (p/n KP5010E) or Sapphire
tubes (p/n KP5011E) –or
b. You can install an optional protective plate (p/n KP1200A), with or
without tubes protecting the top elements –or
c. You can use the instrument without any optional protection
2. If you want to use iodine-based non-wetting agents:
a. You cannot use Quartz tubes.
b. You can order/install optional Sapphire tubes (p/n KP5011E) –or
c. You can install an optional protective plate (p/n KP1200A), with or
without Sapphire tubes protecting the top elements –or
d. You can use the instrument without this optional protection

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Please refer to page 79, Element tube replacement for additional instructions on
tube installation and replacement.
Hi-throughput
“HX” version
The K2 Prime is available at:
the original 15A, 3000W rating, or
at a boosted 20A, 4000W rating (with the addition of factory-installed
KP5201A or field-installed KP5200A).
We call this higher-power unit the “HX version”. This HX version allows not only a
faster heat-up rate, but also boasts a second mold cooling blower. The combined
effect of those two features can save up to 20% fusion cycle time.
Additionally, the HX version includes the protective plate for bottom elements.
However, the electrical current drawn by the HX version is higher than the regular
version, and so the power line, outlet and breaker must be chosen accordingly.
Connection
The K2 Prime works on 220-240 VAC, 50/60 Hz. Note that the in-wall power line
and corresponding wall breakers or fuses must be designed to carry at least 15 A
for the regular version(20 A for the HX version), with GFCI protection.
While it is technically workable to use the instrument at 208 VAC (standard in
some areas), heat-up times will be longer than in the recommended voltage
range. Katanax offers step-up transformers that can overcome such local
limitations.
IMPORTANT: This instrument is to be connected to a GFCI (Ground Fault
Circuit Interrupt) breaker, which provides necessary protection to the fluxer
installation.
Questions ?
Should you have any question regarding the proper installation and start-up of
your instrument, please contact Katanax directly (see information on page 91) for
assistance.