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MIG-O-MAT microflame 140 Service Instructions Manual

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CAUTION! Operate the unit only when you have read and understood the
Hausanschrift:
Telefon:
MIG
•
O
•
MAT
Telefax:
Mikrofügetechnik GmbH
Werksstrasse 20
E-Mail:
DE-57299 Burbach
Internet:
Service Instructions
MIG-O-MAT microflame 140  170  240  300
Hydrogen Soldering Units
present Operating Instruction!
++ 49 (0)2736 - 41 54 - 0
Bank:
Sparkasse Burbach
++ 49 (0)2736 - 41 54 - 99
Kto. 2568 (BLZ: 460 512 40)
info@mig-o-mat.com
IBAN:
DE 36 4605 1240 0000 0025 68
www.mig-o-mat.com
SWIFT-BIC:
 english 
04/2023
USt.IdNr.:
DE 811249554
Amtsgericht
Siegen, HRB 4718
WELADED1BUB
Geschäftsführer:
Dipl. Ing. Thomas Schumacher

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  • Page 1 Service Instructions MIG-O-MAT microflame 140  170  240  300 Hydrogen Soldering Units  english  04/2023 CAUTION! Operate the unit only when you have read and understood the present Operating Instruction! Hausanschrift: Telefon: ++ 49 (0)2736 - 41 54 - 0...
  • Page 3 MIG-O-MAT Mikrofügetechnik GmbH Service manual microflame 140-300...

  • Page 4: Table Of Contents

    Gas flow reduced, flame too weak ......26 Unit overfilled – damage by overfilling .....28 Foaming of electrolyte in gas hose ......31 Defect of pressure sensor ........32 Exchange the circuit board ........32 Exchange the safety pressure switch ......34 Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 5 Spare parts ............... 53 Putting out of operation and waste disposal ..... 56 Waste disposal of microflame unit ......56 Waste disposal of electrolyte ........56 Waste disposal of vaporizer liquid ......56 Manufacturer’s contact address ......57 MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 6: General

    Repair and service Instructions on trouble shooting, repair and service of the unit. Spare parts list The major spare parts are listed. If a more detailed list of spare parts is required please contact the manufacturer. Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 7: Important Safety Warnings

    MIG-O-MAT soldering and welding units are intended for Intended use soldering, welding and melting of metals. Operation is allowed by industrial and commercial businesses only.
  • Page 8 Avoid inhaling the vapours! Do not eat, drink or smoke while handling the vaporizer liquid! Wear goggles and gloves! The MIG-O-MAT vaporizer liquid BLQ1800 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 9: Repair And Service

    Goggles, rubber gloves, smock Software Software and adapter cable for diagnosis purposes and for resetting the service intervals, depends of production year (available from MIG-O-MAT) Vacuum pump For taking the electrolyte liquid out of the reactor Current probe D.C. current probe / clamp-on ampere meter (measuring range >...

  • Page 10: Safety Instructions

    Risk of ignition of the flammable liquids contained in the unit, WARNING! and of the flammable liquids used for filling, due to ignition sources in the vicinity of the unit! Keep the open vaporizer glass container and the vaporizer liquid away from any ignition sources! Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 11 This will branch off any possible electrostatic charging of the operator without any risk (mains cable must be connected to the mains)! MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 12: Malfunction And Service Indications In The Display

    If the main transformer is overloaded, the display shows the following malfunction message: Transf. overload! Let cool down! Operation can be continued only after the transformer has cooled down. For this change the set value back to the required value. Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 13: Excess Temperature

    Faulty pressure control! Switch off the unit at the mains switch and restart it (reset the unit). If the malfunction continues, the pressure sensor is probably Cause faulty or damaged (see Section 6.6). MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 14: Excess Pressure - Safety Pressure Switch Broken

    Excess pressure! Safety pressure switch faulty! A signal tone indicates the malfunction. The reactor is switched off automatically and the gas production is stopped. Replace the safety pressure switch as described in Section 6.8. Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 15: Trouble Shooting

    Section 6.1. Check filling level, refill distilled Electrolyte filling level too low. water if required. Gas route is partly obstructed. Check gas route for obstructions as described in Section 6.2. MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...
  • Page 16 Section 5.1) and clean the reactor (see Section 7.5). The display is dark, unit is Faulty fuse(s) on circuit board or Check fuses and replace if dead. main switch. necessary (Section 5.4 / 12.4.1). Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 17 (Section 6.7). The display shows the The safety pressure switch is Replace the safety pressure following malfunction faulty. switch (Section 6.8). message: Excess pressure! Faulty safety pressure switch! MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 18: Preparatory Measures

    3. Take out the glass floating body. Caution! The glass floating body is covered with base! Rinse the floating body with water. 4. Remove all electrolyte from the reactor by means of a suitable suction device. Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 19: Remove The Vaporizer Liquid From The Vaporizer Glass

    Or dispose of the electrolyte as described in Section 9.3. 6. Remount the vaporizer glass by screwing the fastening ring back to the right (see fig. 7.2.E). MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 20: Open The Unit

    3. Carefully tip the operating panel to the front. 4. Pull the electric contact of the LED connection (fig. 5.4.A) off the circuit board. 5. Cut the cable clip (fig. 5.4.B) to allow some space to remove the operating panel from the unit. Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 21: Description Of Circuit Board

    Connection for LED vaporizer glass lighting Fastening screws (4 pcs) Pressure sensor with gas hose Connection for temperature sensor Connection for excess pressure switch Connection for transformer Time-lag fuse 10A Time-lag fuse 500mA Connection for mains supply MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 22: Open The Casing Top For Repair And Service Purposes

    4. Unscrew the 4 cap nuts (B) that fasten the top part with the glasses and put the top part at a safe place. 5. Unscrew the 4 screws that hold the casing cover 6. Remove the cover. D(4x) Fig. 5.5 Top part complete with glasses Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 23: Description Of Internal Components

    Preparatory measures 5.5.1 Description of internal components Fig. 5.5.1 Opened unit with top part mounted Safety pressure switch Rectifier Transformer Ventilator Reactor MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 24: Troubleshooting

    Tighten the screws Fig. 7.2. A – B – C – D – E hand-tight. Attention! Do not use a pipe wrench! Repeat the leak check. If the display still indicates a leak retighten the lock nut (F): Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 25 1. If the leak check is not OK, check the reactor following the instructions below. 2. If the leak check is OK (which is not very probable, as all sections where a leak is possible have been checked) start the leak detection process again. MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...
  • Page 26 The measuring range should be up to approx. 200 mbar. Remove the gas hose from the reactor outlet and mount the manometer to the outlet. Fig. 6.1.3 Manometer mounted to gas outlet duct Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 27: Gas Route Obstructed, No Flame

    Filter candle 5. If the pressure does not go down with unscrewed and removed dryer glass the filter candle (F) is obstructed and must be replaced. Fig. 6.2 Top part with nozzle MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 28: Gas Flow Reduced, Flame Too Weak

    Microflame Microflame Microflame 70 A 100 A 140 A 170 A If the electrolysis current is considerably lower than the indicated values, clean the reactor and exchange the electrolyte (provided the filling level is correct). Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 29 0.1V DC. If the difference of the measured values is larger than that, unscrew and clean the contacts. Fig. 6.3.1 Electric measuring points overview Fig. 6.3.2 Electric measuring points rectifier MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 30: Unit Overfilled - Damage By Overfilling

    Check filling level At first, check the reactor filling level: An overfilling is indicated by the position of the glass floating body (fig. 6.4.1.B) in the filling duct (A). Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 31 Replace the circuit board as described in Section 6.7. 5. Remove any residues from the hose (e.g. by rinsing) or replace the hose. Check pressure Switch on the unit: No malfunction message must be indicated. sensor MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...
  • Page 32 Troubleshooting Fig. 6.4.2 Gas hose with pressure sensor Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 33: Foaming Of Electrolyte In Gas Hose

    (see Sections 7.4 and 7.5). 3. Replace the reactor sealing and remount the reactor. Check the gas hose to the pressure sensor visually, replace the pressure sensor if necessary (see Section 6.4/6.6). MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 34: Defect Of Pressure Sensor

    3. Use a 7 mm fork wrench to unscrew the 4 fastening screws (see fig. 6.7.A). 4. Mount the new circuit board in reverse order. Ensure that there is a minimum distance of 6 mm between the circuit board and the operating panel. Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 35 Troubleshooting Fig. 6.7 Control board mounted MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 36: Exchange The Safety Pressure Switch

    6. Check again if all electric connections are positioned correctly (see fig. 6.8.C). The safety pressure switch is set to the correct releasing pressure by the manufacturer. For reasons of safety the settings must not be modified at any later time. NOTE Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 37 Troubleshooting Fig. 6.8 Safety pressure switch mounted MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 38: Ventilator Out Of Operation / Display Indicates Excess Temperature

    At a reactor temperature of approx. 20°C/room temperature the voltage is approx. 230 V. If the measured value deviates considerably, or if it is 0 V exchange the circuit board as described in Section.7. Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 39: Replace The Ventilator

    4. Insert and mount the new ventilator in reverse order. Ensure that no cables touch the ventilator blades and that the blades can rotate easily. Fig. 6.10 Ventilator correctly mounted MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 40: Replace The Temperature Sensor

    6.11.B) that fasten the temperature sensor to the reactor, take out the temperature sensor. 4. Mount the new temperature sensor in reverse order. Ensure that no cables touch the ventilator blades. Fig. 6.11 Temperature sensor mounted to the reactor Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 41: Unit Service At Service Status 0

    Replace o-rings of glasses (2 pcs). • Replace any contaminated hoses. • Fill new electrolyte, check unit for leaks, carry out a trial run. • Reset maintenance counter. Fig. 7 Standard replacement kit for unit service MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 42: Reset Maintenance Counter

    Unit service at service status 0 % Reset maintenance counter At microflame machines up to production date 2012 you have to use the MIG-O-MAT service software to read out any malfunction messages and to set the service status back to 100%.
  • Page 43 Unit service at service status 0 % After replacing either one or both of the glasses, pull the protective hood(s) over the new glass(es). Fig. 7.2 Vaporizer glass (A) with sinter piece (B) and dryer glass (D) with filter candle (C) MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 44: Replace The Check Valve

    Remove the gas tube on left side by unscrewing the nut and pulling of the gas tube MIG-O-MAT flame barrier 50.2504210 loosen the nut with the 19 mm or a 20mm wrench (depends on the model) Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 45 It is a right-hand thread. It could be helpful to remove the glasses before. Remove the old copper seal and place a new copper seal into the threaded hole MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 46: Dismount The Reactor

    3. Unscrew the temperature sensor from the cooling body of the reactor (see Section 6.11). 4. Unscrew the electric cables from the reactor (see fig. 7.4.1.B); pull off the gas hose (C). Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 47 5. Place the (emptied) unit on its side or rear and unscrew the 4 fastening screws holding the reactor bottom (see fig. 7.2.2.C) e.g. with a 10 mm fork wrench. 6. Take the reactor out of the unit. Fig. 7.4.2 Unit bottom with 4 reactor screws MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 48: Clean Reactor And Electrodes

    (C) and spacers (D). Anodes and cathodes (E/F) are now separated. Clean electrodes 6. Clean the anodes and cathodes by the same method, or use an ultrasonic cleaning unit (use distilled water only). Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 49 (risk of short circuit and risk of combustion of gas inside the reactor). Replace worn and/or damaged electrodes with new electrodes (available from the supplier and manufacturer of the unit). MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...
  • Page 50 7.5.4 damaged electrodes Mount intact/new Screw anode and cathode together with the plastic nuts, thread electrodes after cleaning rods and spacers. Ensure that there is no electrically conductive connection between the electrodes (see fig. 7.5.5 and 7.5.6). Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 51 Screw the preassembled electrodes to the reactor cover. Ensure that there is no electrically conductive connection reactor cover between the electrodes (metal thread rod) and the reactor cover! Carefully insert the insulation rings, observe the correct order and positioning (see fig. 7.5.7). MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...
  • Page 52 Fig. 7.5.7 Electrodes screwed to the reactor cover Mount the new reactor cover with using a new reactor sealing. Mount reactor cover Tighten the screws (fig. 7.5.8.A) equally. Fig. 7.5.8 Reactor cover correctly and completely mounted (microflame 140) Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 53: Replace Electrodes Inside The Reactor

    19mm open-end wrench. Check hose nozzle for blockages and clean if necessary (e.g. with a small file or drill) or replace it (order number: 50.2501143) Remove any existing hose View of the interior of the device clamp with elbow fitting MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 54: Fill Unit And Put Into Operation

    Carry out leak check Switch on the unit and carry out a leak check. If the test is not passed and a leak is indicated follow the instructions given in Section 6.1 to find the leak. Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 55: Spare Parts

    Nozzle set 1,8 x 10 50.25019180 consisting of 5 pcs nozzles 1,8 x 10 (G15) Nozzle set (5 St.) for microflame 140 50.2501803 (0,6 | 0,7 | 0,8 | 0,9 |1,0) x 10 mm Nozzle set (5 St.) for microflame 170 50.25019001...
  • Page 56 (price per meter) Glass cylinder for gas dryer, including sealing 50.25164140 Vaporizer glass (with filling mark), including 50.25164200 sealing Glass protection tube 50.2516415 For microflame 140-300, fits to glass cylinder for gas dryer and vaporizer Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...
  • Page 57 50.2520207 from the year 2017 onwards. manufactured 2017- Tube filter (for gas dryer) 50.2520208 Safety valve 50.2504210 flame barrier with integrated flame stop for microflame 140-300 Torch stand with holder for nozzles for 50.2630009 microflame MIG-O-MAT Mikrofügetechnik GmbH Service manual_microflame_EN...

  • Page 58: Putting Out Of Operation And Waste Disposal

    Do not let escape into the sewerage system / surface water / groundwater. Do not let escape into the soil. Do not let escape into the environment uncontrolled. Containers can also be returned free of charge when they are completely empty. Service manual_microflame_EN MIG-O-MAT Mikrofügetechnik GmbH...

  • Page 59: Manufacturer's Contact Address

    Manufacturer’s contact address Manufacturer’s contact address MIG-O-MAT Mikrofügetechnik GmbH Werksstrasse 20 57299 Burbach Germany Phone: +49 2736 4154-0 Fax: +49 2736 4154-99 Email: info@mig-o-mat.com Internet: www.mig-o-mat.com Do you have any queries or suggestions concerning the present unit, its operation or the Operating Instructions? Please contact us, we will be glad to assist.

This manual is also suitable for:

Microflame 170Microflame 240Microflame 300

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