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Summary of Contents for MIG-O-MAT Lötstar 141
- Page 1 Operating Instructions MIG-O-MAT Lötstar 141 175 241 301 Hydrogen Soldering Units English MIG·O·MAT Mikrofügetechnik GmbH • Werksstrasse 20 • DE-57299 Burbach • Fon +49 (0) 2736 4154 0 • Fax +49 (0) 2736 4154 99 info@mig-o-mat.com · www.mig-o-mat.com...
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Page 2: Table Of Contents
General............... 4 Important safety warnings .......... 4 Description of operational process ......7 Product description ............. 8 Product features MIG-O-MAT Lötstar units ....8 Safety devices ............9 CE conformity ............9 Delivery volume ............10 Description of unit components .......11 Description of unit top part ........12... - Page 3 Contents 8.1.1 Check and refill demineralized water in the reactor 8.1.2 Refilling of vaporizer liquid ........35 8.1.3 Cleaning of the vaporizer glass ......36 8.1.4 Cleaning of the dryer glass ........37 8.1.5 Exchange of the filter cartridge in the dryer glass 37 Service indications (display) ........38 Malfunctions and warnings ........38 Trouble shooting .............40...
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Page 4: General
Intended use MIG-O-MAT Lötstar soldering and welding units are intended for soldering, welding and melting of metals. Operation is allowed by industrial and commercial businesses only. - Page 5 Avoid inhaling the vapors! Do not eat, drink or smoke while handling the vaporizer liquid! Wear goggles and gloves! MIG-O-MAT vaporizer liquid BLQ 1800 is not toxic. When using other, methanol-containing vaporizer liquids, take into consideration that these substances may be highly toxic! Read and observe the relevant instructions on the labels of the products used.
- Page 6 Risk of burns and fire! Hang the torch hand piece with burning flame onto the soldering stand for short operating stops. Ensure that there is a sufficient distance between the flame and any flammable items. Ensure that there is sufficient ventilation for all soldering and welding operations! Exclusion of liability The manufacturer cannot be held liable for damages on...
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Page 7: Description Of Operational Process
Description of operational process Description of operational process Operational principle Lötstar units produce a hydrogen flame with very high temperatures of up to approx. 2850° C. In the integrated reactor, detonating gas is produced through electrolysis from demineralized water. The detonating gas is guided from the reactor to a condensate separator to dry. -
Page 8: Product Description
This increases both reliability and service life of the units. The MIG-O-MAT Lötstar units are equipped with a quick analogous pressure control to allow operation of the units on changing jobs or on more than one workplace. The operating pressure is variable and is automatically kept precisely at a constant value even when the ambient conditions change. -
Page 9: Safety Devices
(i.e. when the valve at the burner hand piece is open). CE conformity The present MIG-O-MAT Lötstar hydrogen soldering unit is in compliance with all relevant CE marking criteria. The declaration of conformity can be obtained from the manufacturer. -
Page 10: Delivery Volume
Delivery volume The delivery volume of the Lötstar units comprises: Lötstar soldering and welding unit • Electrolyte, ready for use • vaporizer liquid BLQ1800 • 5 pieces of burner nozzles depending on type of unit • gas hose 3.0 m long •... -
Page 11: Description Of Unit Components
Product description Description of unit components Illustration 4.5. Unit front and side view (here Lötstar 300) Unit top part with glasses for vaporizer liquid and condensate separator. Moveable for an easy removal of the glasses. Handles (on both sides) Operating panel with display and operating keys Ventilation openings (on both sides) Burner hand piece Holder for burner hand piece... -
Page 12: Description Of Unit Top Part
Description of unit top part Illustration 4.6. Unit top part of Lötstar Gas hose (PVC) to burner hand piece with connection to gas outlet on the unit top part. Check valve as protection against the flame backfiring into the unit (flame barrier and temperature-sensitive gas cut-off). Screw cap on filling duct for vaporizer liquid. -
Page 13: Description Of Unit Back
Product description Description of unit back Illustration 4.7. Mains socket with mains switch Mains switch as main switch for switching off the unit during longer operating stops, e.g. overnight, over the weekend, etc. Plug-in mains cable connected with the mains socket. ©... -
Page 14: Description Of Operating Panel
Description of operating panel Illustration 4.8. Operating panel with display and operating keys Display Top line – section on the left: indicates the actual value (mbar) inside the unit. Top line – section on the right: indicates the actual reactor power which is required to produce the set gas pressure. -
Page 15: Preparatory Measures For Initial Operation
Preparatory measures for initial operation Preparatory measures for initial operation Unpacking and placement of unit Check for transport The unit is shipped in a suitable packing. Check the MIG-O- damages MAT Lötstar unit for possible transport damages before initial operation. In case of visible damages do not operate the unit and contact your supplier and the forwarding agent immediately. -
Page 16: Mounting Of The Unit Top Part
Mounting of the unit top part The preassembled unit top part is packed separately and must be mounted onto the Lötstar base unit. The protecting foil remain around the glass containers (serves as fracture protection). Risk of injury splintering glass! Combustion of gas inside the glasses due to gross disregard of WARNING the safety instructions can cause the glasses to burst. - Page 17 Preparatory measures for initial operation the screw connection fast to avoid leaks in the pressure system. 4. Connect the gas hose of the burner hand piece to the outlet on the top part (C). The unit top part is movable to facilitate the removal of the glass containers.
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Page 18: Filling Of The Reactor With Electrolyte
Filling of the reactor with electrolyte For the production of gas a certain amount of electrolyte solution is required. When delivered, the unit is not filled with electrolyte for reasons of safety. The electrolyte is included in the delivery volume Electrolyte is a strong caustic solution! Risk of severe chemical burns on skin, mucous membranes and eyes! - Page 19 Preparatory measures for initial operation The glass float remains in the filling duct for future filling level checks. 6. Screw the closing cap back onto the filling duct and tighten 7. The filling process is now finished. Illustration 5.3. Filling duct with glass float at maximum filling level ©...
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Page 20: Filling Of The Vaporizer Glass With Vaporizer Liquid
(except platinum). The flowing gas is enriched and thereby produces a flame which is adjusted to the individual properties of the metal. We recommend the use of MIG-O-MAT vaporizer liquid BLQ 1800 (MIG-O-MAT Order No. 50.2501631, 1 litre). Unlike other methanol-containing liquids MIG-O-MAT BLQ 1800 is not toxic. - Page 21 Preparatory measures for initial operation The maximum temperature of the hydrogen-oxygen flame is ° approx. 2850 C. It is typical that the pure detonating gas flame is almost invisible and the flame temperature is too high for many applications. Therefore, the gas is guided through a vaporizer liquid to reduce the energy density (flame temperature).
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Page 22: Connecting The Unit To The Mains
2 phases (120 V); 1 N; 1 PE protective conductor EF 240 and EF 300 in 120 V mains Illustration 5.5. Mains requirements for MIG-O-MAT Lötstar units EF 240 and EF 300 in 120 V mains. BA_Lötstar_EN_Vers.07.2016 © MIG·O·MAT GmbH... -
Page 23: Setting Of Operating Language In The Display
Switch on the Lötstar unit at the mains switch on the back of the unit (see illustration 4.7.). The display is activated and shows the following indication: MIG-O-MAT Lötstar Switch the unit into Switch the unit into operating mode by pressing the on/off key operating mode at the operating panel for a short period. -
Page 24: Initial Operation
The electrolysis process reduces the quantity of electrolyte solution in the reactor. When using a nozzle of size 0.9, at a gas pressure of approx. 100mbar a MIG-O-MAT Lötstar 140 for example consumes about 55 ml/h of water. A correct filling level is indispensable for proper functioning and a long service life of the unit. -
Page 25: Leak Check
Initial operation Follow the instructions given in Section 8.1.1. Check and refill demineralized water in the reactor. When the glass floating body in the filling duct (see illustration 8.1.1.A.) goes down by more than 1 cm, refill demineralized water. Switch the unit back into operating mode at the on/on key in the operating panel. -
Page 26: Select The Burner Nozzle
If the unit is If there is no leak, the display shows: leakproof No leak Continue Confirm this programme step by pressing the key (Continue) at the operating panel. The unit is now ready for operation. Select the burner nozzle The Lötstar units are delivered with a selection of nozzles of different sizes. -
Page 27: Adjustment Of The Gas Pressure At The Operating Panel
Initial operation Adjustment of the gas pressure at the operating panel Size and energy of the burner flame can be adjusted at the valve of the burner hand piece or set at the operating panel by pre-selecting the gas pressure. When the unit is ready for operation the display shows 2 different operating pressure values (see illustration 4.8) Display... -
Page 28: Regulation Of The Burner Flame At The Burner Hand
Please note! If the set gas pressure value is too low for the selected nozzle size, so that the gas burning speed is higher than the gas escaping speed, the flame backfires into the NOTE nozzle. In most cases, this will destroy the nozzle. The backfire of the flame is stopped by the backfire protection device inside the handle. - Page 29 Initial operation only at the operating panel. When the ventilator for cooling the reactor has stopped running (delayed shut-off) switch off the unit at the mains switch on the back of the unit. If the unit is switched off at the mains switch after a prolonged operating period, damages to the unit due to overheating are possible.
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Page 30: Extinction Of The Flame At The Burner Hand Piece
6.10 Extinction of the flame at the burner hand piece When the gas pressure is adjusted correctly, the burner flame does not touch the nozzle, there is a distance of several tenths of millimetres between nozzle and flame. The nozzle tip remains cold and in perfect condition. -
Page 31: Technical Details
Technical details Technical details MIG-O-MAT MIG-O-MAT MIG-O-MAT MIG-O-MAT Lötstar 141 Lötstar 175 Lötstar 241 Lötstar 301 Mains voltage (V) Power consumption (W) 1200 1800 2000 Mains fuse (A) Max. gas production (l/h) Max. nozzle size 1.0 (G19) 1,2 (G18) 1.5 (G17) 1.8 (G15) -
Page 32: Maintenance And Repair
Maintenance and repair Maintenance Caution! For any maintenance or repair works related directly or indirectly to electrolyte or vaporizer liquid carefully read and observe the following safety warnings. Caution when handling electrolytes! Risk of chemical burns! Strong acid alkaline! Risk of chemical burns due to spilling alkaline or splashes of WARNING! alkaline from the filling duct during filling! Always wear protective gloves and goggles when handling... -
Page 33: Check And Refill Demineralized Water In The Reactor
Maintenance and repair Caution when handling vaporizer liquid! Risk of explosion due to electrostatic discharging! WARNING! Risk of ignition of the flammable liquids contained in the unit top part, and of the flammable liquids used for filling, due to electrostatic discharging! Touch the cap nuts on the holding angle pieces of the top part with both hands for a short period of time before you open the glass containers. - Page 34 Please note! When a large quantity of demineralized water is refilled, the floating body does not immediately indicate the correct filling level as the specific density of demineralized NOTE water is lower than that of the electrolyte. Immediately after filling of a large quantity of demineralized water the floating body indicates a filling level which is lower than the actual level.
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Page 35: Refilling Of Vaporizer Liquid
Maintenance and repair 8.1.2 Refilling of vaporizer liquid During operation of the unit, the vaporizer liquid is consumed. It may be necessary to refill the vaporizer liquid. Check of filling level of When the level of the liquid in the vaporizer glass has gone vaporizer liquid down to the sintered gas distributor (see illustration 5.1.3.F) refill vaporizer liquid. -
Page 36: Cleaning Of The Vaporizer Glass
8.1.3 Cleaning of the vaporizer glass Carefully read and observe the safety instructions in section 8.1. before you carry out this maintenance work! WARNING! We recommend to empty the vaporizer glass regularly (approx. once per month, depending on the operating hours) (see illustration 8.1.3.A.) and to clean it with hot water before you refill it again. -
Page 37: Cleaning Of The Dryer Glass
Maintenance and repair 8.1.4 Cleaning of the dryer glass Carefully read and observe the safety instructions in section 8.1. (e.g. protection goggles and gloves) before you carry out this maintenance work! WARNING! During operation, condensation water and entrained electrolyte are separated in the dryer glass (see illustration 8.1.3.C.). If there is more than 1 cm of condensate in the glass, remove the condensate and rinse the glass with hot water subsequently. -
Page 38: Service Indications (Display)
Service indications (display) During operation of a soldering unit the anodes and cathodes wear out. Therefore, the gas drawing hours are measured by the control of the unit to ensure safe operation. Show service level The service level can be called by switching over the display. Press the key at the operating panel to indicate the gas drawing hours and the service level:... - Page 39 Maintenance and repair If the allowed reactor temperature is exceeded, the display shows the following malfunction: Excess temp.! Let cool down! Operation can be continued after the unit has cooled down. For this, change the set pressure value back to the required value. In case of malfunctions due to overheating it is important not to switch off the unit at the mains switch, as the ventilating device stops operating, too.
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Page 40: Trouble Shooting
Trouble shooting Malfunction / Fault Possible cause Remedy The unit does not produce The unit is not connected to the Plug the mains cable into a any gas, mains. suitable socket. the display shows no The unit has not been switched Switch on the unit at the mains malfunction. - Page 41 Maintenance and repair Malfunction / Fault Possible cause Remedy The unit produces too little The gas route is leaky Find the leaks at the connections gas, the actual value goes (carry out a leak check as (daub with foam-building media) described in section 6.3.).
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Page 42: Repair
Repair Repair and maintenance works that require the unit to be Opening of the unit connected and opened must be carried out by authorized by authorized specialized staff only. specialized staff only Risk of electrocution due to live parts inside the unit! Pull the mains plug before you open the unit! WARNING! The manufacturer cannot be held liable for any damage caused... -
Page 43: Removal Of Electrolyte
Maintenance and repair Removal of electrolyte For shipment of the Lötstar unit, and for particular maintenance works, remove all electrolyte from the unit. For emptying the electrolyte reactor use a suitable alkaline- resistant suction device. If in doubt please contact your supplier or the manufacturer of the unit. -
Page 44: Removal Of Vaporizer Liquid
Removal of vaporizer liquid For shipment of the Lötstar unit, and for particular maintenance works, remove all vaporizer liquid from the unit. Dispose of the residual vaporizer liquid as described in section 9.3. Caution when handling vaporizer liquid! Risk of fire and explosion due to ignition sources and electrostatic charging! WARNING! When handling vaporizer liquid keep away from any ignition... -
Page 45: Spare Parts & Accessoires
Maintenance and repair Spare Parts & accessoires Extra charge for platinum outlet in 50.2515799 the upper part (ex works) cpl. Including micro torch, cranced type (50.2502410) and 3 m gas tube Extension of work station Lötstar 50.2517901 141, consists of: - Micro torch with control valve, cranked type, with exchangeable flame barrier - T-part... - Page 46 (0,7 | 0,8 | 0,9 |1,0 | 1,2) x 10 mm, for Lötstar Nozzle set (5 St.): 50.25019002 (0,8 | 0,9 |1,0 |1,2 | 1,5) x 10 mm, for Lötstar 241/301 Evaporating liquid type MIG-O-MAT 50.2501631 BLQ 1800 (1-litre-bottle) Methanol (1-litre-bottle) 50.2501609 MIG-O-MAT Flux (1-litre-bottle) 50.2501614...
- Page 47 Maintenance and repair Elektrolyte, ready for use, for Lötstar 50.2501600 80 and Lötstar 141 2 bottles with total 1.8 liter electrolyte, ready to use Elektrolyte, ready for use, for Lötstar 50.4030100 175 / 241 / 301 1 canister with 4.1 liter electrolyte, ready to Micro torch with control valve, 50.2502410 cranked type...
- Page 48 Glass float 50.2520820 Gas distributor / sinter cone (for 50.2520211 vapourizer glass) Filter piece (for gas dryer) 50.2520208 External booster for individual 50.2504020 workstations As standard-booster for Lötstar 80 (supplied with the unit) or as additional booster in case of using flux (e.g. for Lötstar 141-301). Delivery incl.
- Page 49 Maintenance and repair Torch stand with holder for nozzles 50.2630002 for Lötstar 80-301 Ignition unit for manual working 50.2630002 places Ensures reliable ignition of the flame by placing the micro torch Trolley for Lötstar 141 30.900001 with 4 swivel rolls, 2 lockable. The trolley can be connected additionally without tools to the device Trolley for Lötstar 141...
- Page 50 Glass cylinder for gas dryer, with 50.25164165 drain cock kpl. for retrofitting (emptying the glass without disassembly) Glass cylinder for gas dryer, with 50.25164160 drain cock Additional cost for new Lötstar, with shut-off valve and glass protector (emptying the glass without disassembly) Micro torch with control valve, 50.2504200 straight type...
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Page 51: Putting Out Of Operation And Waste Disposal
Putting out of operation and waste disposal Putting out of operation and waste disposal Waste disposal of Lötstar unit After removal of the operating substances (see sections 8.7 and 8.8.) the components of the Lötstar can be taken to electronics and metal recycling stations. -
Page 52: Manufacturer's Contact Address
Manufacturer’s contact address MIG·O·MAT Mikrofügetechnik GmbH Werksstrasse 20, DE-57299 Burbach Telefon: +49 (0) 2736 4154 0 Telefax: +49 (0) 2736 4154 99 info@mig-o-mat.com www.mig-o-mat.com BA_Lötstar_EN_Vers.07.2016 © MIG·O·MAT GmbH...
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