MIG-O-MAT Lötstar 141, Lötstar 241, Lötstar 301, Lötstar 175 Operating Instructions Manual

MIG·O· MAT Mikrofügetechnik GmbH • W erksstrasse 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

Operating Instructions

MIG-O-MAT Lötstar 141  175  241  301

Hydrogen Soldering Units

 English 

Contents

BA_Lötstar_EN_Vers.07.2016

Contents

Contents ........................................................................... 2

1 General....................................................................... 4

2 Important safety warnings .......................................... 4

3 Description of operational process ............................. 7

4 Product description ..................................................... 8

4.1 Product features MIG-O-MAT Lötstar units .............. 8

4.2 Safety devices ......................................................... 9

4.3 CE conformity .......................................................... 9

4.4 Delivery volume ......................................................10

4.5 Description of unit components ...............................11

4.6 Description of unit top part ......................................12

4.7 Description of unit back ...........................................13

4.8 Description of operating panel ................................14

5 Preparatory measures for initial operation ................ 15

5.1 Unpacking and placement of unit ............................15

5.2 Mounting of the unit top part ...................................16

5.3 Filling of the reactor with electrolyte ........................18

5.4 Filling of the vaporizer glass with vaporizer liquid ....20

5.5 Connecting the unit to the mains .............................22

5.6 Setting of operating language in the display ............23

6 Initial operation ......................................................... 24

6.1 Switch on the unit ...................................................24

6.2 Switch on the operating mode .................................24

6.3 Electrolyte filling level check ...................................24

6.4 Leak check .............................................................25

6.5 Select the burner nozzle .........................................26

6.6 Adjustment of the gas pressure at the operating panel 27

6.7 Regulation of the burner flame at the burner hand piece 28

6.8 Operating stops ......................................................28

6.9 After operation ........................................................28

6.10 Extinction of the flame at the burner hand piece .....30

7 Technical details ....................................................... 31

8 Maintenance and repair ............................................ 32

8.1 Maintenance ...........................................................32

Contents

8.1.1 Check and refill demineralized water in the reactor 33

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

8.2 Service indications (display) ....................................38

8.3 Malfunctions and warnings ......................................38

8.4 Trouble shooting .....................................................40

8.5 Repair .....................................................................42

8.6 Transportation of the unit ........................................42

8.7 Removal of electrolyte ............................................43

8.8 Removal of vaporizer liquid .....................................44

8.9 Spare Parts & accessoires ......................................45

9 Putting out of operation and waste disposal ............. 51

9.1 Waste disposal of Lötstar unit .................................51

9.2 Waste disposal of electrolyte ..................................51

9.3 Waste disposal of vaporizer liquid ...........................51

10 Manufacturer’s contact address ............................... 52

BA_Lötstar_EN_Vers.07.2016 © MIG·O·MAT GmbH

1 General

The present Operating Instructions are part of the delivered equipment. They must be ready for use at any time and remain with the unit in case of resale.

We reserve the right to carry out technical modifications on the unit due to advanced development.

An operating manual cannot take account of every conceivable use. Contact your dealer or the manufacturer for further information or in the event of problems which are not covered or not sufficiently covered in this operating manual

2 Important safety warnings

Carefully read and observe before putting into operation!

The present unit operates with acid, flammable and – depending on the type of vaporizer liquid – toxic substances. Therefore, a predetermined operating sequence and strict observance of the safety and protection measures described below are prerequisite.

The present operating instructions cannot take each and every specific regulation into consideration which might apply in various countries. The operator of the unit must ensure that all relevant local regulations concerning the prevention of accidents and the use of hazardous substances are known and observed.

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.

The unit must be operated by specialized, trained staff only. The operating instructions must be strictly observed. The unit must not be operated by unauthorized persons or by children.

For reasons of safety, the unit must be connected to a shockproof socket only. The technical data indicated on the nameplate must correspond with the available local connection conditions, particularly with regard to mains voltage and current consumption values.

For maintenance and service works, in case of liquid inside the unit and malfunctions, and when you have finished working with the unit pull the main plug. In case of a malfunctioning please contact your supplier or the manufacturer.

The unit must be opened by authorized and specialized staff only!

Instructions for the

operator

Intended use

Operating staff

Mains connection

Risks due to electric

current

Important safety warnings

Electrolyte solution can cause severe chemical burns!

Always wear alkaline-resistant gloves and goggles when you work with electrolyte solution! Do not eat or drink while filling electrolyte solution into the unit!

Wash your hands after filling the reactor! Avoid contact with eyes and skin! In case of contact with the eyes rinse the open eye(s) under running water for several minutes and seek medical advice. In case of contact with the skin wash immediately with soap and rinse thoroughly.

If you have overfilled the unit, do not remove any excess electrolyte by sucking it through a hose by mouth. There is a risk of severe chemical burns! If you have overfilled the unit by mistake, use a suitable alkaline-resistant suction device which is not operated by mouth.

Electrolyte containers which are not completely empty must be kept tightly closed and stored out of reach of unauthorized persons, in particular of children. Thoroughly rinse empty electrolyte containers with water. Then the container can be disposed of into the ordinary waste. We recommend to contact the local authorities for information on the use and waste disposal of electrolytes.

Risk of fire and explosion! The vaporizer liquid is a flammable substance! Keep away from ignition sources while filling vaporizer liquid into the unit!

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.

Risk of fire and explosion! Do not leave the unit switched on unsupervised. The gas escaping from the unit is highly flammable and explosive. The switched-on unit must be operated with opened valve only until the flame ignites. Any escaping gas which does not burn in a flame causes a high risk of fire and explosion! For refilling the reactor keep away from ignition sources! Even the open pressure-less reactor contains highly explosive burnable gases.

To prevent the creation of electrostatic sparks immediately before opening the reactor (e.g. for checking the filling level or for refilling demineralized water), touch the cap nuts on the top part of the unit or the metal screws on the housing with both hands.

Risks caused by

electrolyte

Risks caused by

vaporizer liquid

Risks caused by

burnable gas and gas

flame

BA_Lötstar_EN_Vers.07.2016 © MIG·O·MAT GmbH

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!

The manufacturer cannot be held liable for damages on persons, equipment or work pieces caused by improper use. The operator is responsible for the correct instruction of the operating staff.

Exclusion of liability

Description of operational process

3 Description of operational process

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. Then, the gas is enriched with solvent vapours in a vaporizer tank. The processed detonating gas is then conducted through the gas hose to the burner hand piece via a backfire protection device.

If the detonating gas ignites, it reacts releasing heat. The remainder of the reaction is water (H2O).

Temperature and energy of the burner flame can be adjusted to the soldering or welding job by the selection of a suitable nozzle size and the type of vaporizer liquid.

The fine adjustment of the quantity of delivered gas is carried out by the regulating wheel on the burner hand piece. The operating pressure can also be set at the operating panel depending on the required energy of the flame.

As soon as the valve at the burner hand piece is closed the gas production is automatically interrupted.

Depending on the temperature of the electrolyte reactor the ventilation device keeps on operating for a certain period of time until the reactor has cooled down to 45°C. The ventilation device is fitted with 3 speed ranges which are controlled electronically.

The extremely low energy consumption and the low cost of consumption goods (demineralized water, vaporizer liquid) ensure extraordinarily low operating costs compared to other procedures.

Operational principle

Adjustment of the

Lötstar

Stand

by mode

Economic efficiency

BA_Lötstar_EN_Vers.07.2016 © MIG·O·MAT GmbH

4 Product description

4.1 Product features MIG-O-MAT Lötstar units

The MIG-O-MAT Lötstar units comprise the latest soldering and welding technology.

The special top part makes operation, maintenance and functional checks particularly easy. There is almost no condensation inside the unit due to the special gas guiding device. 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. Additional advantages:

• Very high safety standard in compliance with DIN 32508

• Hydrogen-oxygen mixture burns without residues

• Easy operation

• Integrated leak detector check

• Microprocessor-controlled regulation of the operating

pressure

• Almost noiseless operation with temperature-controlled ventilation device („whisper cooling“)

• Single or multi-workplace operation possible

• Low operating costs:

Any losses of liquid due to operational processes are compensated by refilling demineralized water. Exchange of the electrolyte is not required before approx. 1000-1500 operating hours.

No mineral wool padding necessary for drying the gas.

Product description

4.2 Safety devices

Lötstar units are designed and manufactured in compliance with the latest technology standards. Operation is safe provided that the safety and operating instructions are observed and provided that the units are used only for applications for which they are intended.

Safe operation of the units is ensured by means of the following safety devices.

• Gas pressure monitoring by means of safety pressure switch

• Temperature monitoring of the reactor and of the transformer

• Flame barrier (backfire protection device) integrated in burner hand piece

• Flame barrier (backfire protection device) and temperature activated cut off valve at the gas outlet

• Main filters (EMC)

• Mains fuse

A high operating safety is guaranteed because gas is produced only when it is required (i.e. when the valve at the burner hand piece is open).

4.3 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.

BA_Lötstar_EN_Vers.07.2016 © MIG·O·MAT GmbH

4.4 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

• burner hand piece

• Torch stand with holder for nozzles

• filling funnel

• glass floating body for checking the electrolyte filling level

• 1 pair of disposable rubber gloves

• goggles

• Operating Instructions

The units are supplied in special packing (reusable, please store for possible future transportation, e.g. for service or repair return shipment)

Product description

4.5 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

4.6 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.

Screw connection for the gas hose at the reactor outlet.

Screw cap of filling duct

for electrolyte (for initial filling) or for demineralized water (for refilling in case of low reactor filling level).

Glass container for condensate separator (also termed dryer glass) with filter piece.

Glass container for vaporizer liquid (also termed vaporizer glass) with gas distributor (sintered cone).

Product description

4.7 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.

4.8 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. Indication range between 10% and 100% depending on the actual state of the unit.

Bottom line: indicates the set pressure value (mbar) inside the unit.

The display also shows service indications, operating hours, display language, etc.

Key on/off for switching the gas reactor on and off.

Menu selector key to call the following settings and display

indications:

Operating language: The operating language can be selected, available languages are German, English or French.

Operating hour meter: The operating hour meter shows the hours during which the unit has produced gas.

Display service mode: The service mode of the display shows the actual service status of the unit. The optimum on new or newly serviced units is 100%. At 0% the Lötstar must be serviced by an authorized service company.

Selector keys for changing and indicating the unit settings.

D / E

C D

Preparatory measures for initial operation

5 Preparatory measures for initial operation

5.1 Unpacking and placement of unit

The unit is shipped in a suitable packing. Check the MIG-OMAT 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.

If possible, keep the original transport packing in store for possible later shipment for maintenance or repair purposes. Or dispose of the packing material according to the relevant local regulations on waste disposal. You can also return the packing material to the manufacturer for disposal (shipment charges to be paid by the customer).

The unit must be operated under permanent supervision only.

The workplace must allow free access to the unit. The operator must be able to supervise the unit at all times. Possible warning signals of the unit must be audible/visible.

For operation, place the unit on a dry and solid surface. Ensure that the workplace is sufficiently ventilated! The cooling air must circulate through the cooling openings on both sides of the unit.

Risk of electrocution due to humidity inside the unit!

Protect the unit from entering humidity!

Keep workplace and housing dry in order to prevent electrical accidents and damages from the unit.

• Allowed ambient temperature during operation: +5°C up to +40°C

• Allowed relative humidity of air during operation: max. 80 %

• Indoor operation only (no operation in the open)

• Protect the unit from direct or indirect heat sources (e.g.

heating elements, direct sunlight) to avoid overheating.

Check for transport

damages

Packing

Choice of w

orkplace

Placement

WARNING

Ambient conditions

5.2 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 the safety instructions can cause the glasses to burst.

Do not operate the unit without protective the hood (illustration

5.2.E.) over the glasses.

After replacing either one or both of the glasses, pull the protective hood(s) over the new glass(es).

• 1 fork wrench size 10 mm (or comparable, suitable tool).

• 1 fork wrench size 19 mm (or comparable, suitable tool).

Illustration 5.2. Correctly mounted and connected unit top part

1. Use the 4 cap nuts (A) to screw the unit top part to the 4 threaded bolts on the Lötstar unit top (fork wrench 10 mm).

2. Remove the yellow screw cap (transport safety device) on the reactor outlet (B). Please keep the yellow screw cap for possible future service purposes.

3. Connect the gas hose to the reactor outlet by means of the union nut (fork wrench 19 mm). Caution! Do not jam the connection nut. Then tighten the connecting nut by means of the fork wrench. For this, hold the reactor at the filling duct with one hand. A slight movement of the reactor is possible and harmless because the reactor connection is elastic. Tighten

WARNING

Required tools

How to proceed

+ 36 hidden pages

MIG-O-MAT Lötstar 141, Lötstar 241, Lötstar 301, Lötstar 175 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual