MIG-O-MAT microflame 140 Operating instructions

Hausanschrift:
Telefon: ++ 49 (0)2736 - 41 54 - 0
Bank: Sparkasse Burbach
USt.IdNr.:
Geschäftsführer:
MIG•O•MAT
Telefax: ++ 49 (0)2736 - 41 54 - 99
Kto. 2568 (BLZ: 460 512 40)
DE 811249554
Dipl. Ing. Thomas Schumacher
Mikrofügetechnik GmbH
Werksstrasse 20
E-Mail: [e-mail]
IBAN: DE 36 4605 1240 0000 0025 68
Amtsgericht
DE-57299 Burbach
Internet: www.mig-o-mat.com
SWIFT-BIC: WELADED1BUB
Siegen, HRB 4718
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!

MIG-O-MAT Mikrofügetechnik GmbH
Service manual microflame 140-300
1

Contents
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MIG-O-MAT Mikrofügetechnik GmbH
Contents
Contents........................................................................... 2
1General....................................................................... 4
1.1 Structure of the present service instructions............ 4
2Important safety warnings .......................................... 5
Repair and service ........................................................... 7
2.1 Demands on service staff......................................... 7
2.2 Liability..................................................................... 7
2.3 Testing aids, tools and inspection equipment........... 7
2.4 Safety instructions.................................................... 8
3Malfunction and service indications in the display... 10
3.1 Service interval has run down.................................10
3.2 Excess temperature................................................11
3.3 Faulty pressure control ...........................................11
3.4 Excess pressure –safety pressure switch broken...12
4Trouble shooting....................................................... 13
5Preparatory measures.............................................. 16
5.1 Remove the electrolyte from the reactor .................16
5.2 Remove the vaporizer liquid from the vaporizer glass
17
5.3 Open the unit..........................................................18
5.4 Open the operating panel for detail repair on
electronics ...........................................................................18
5.4.1 Description of circuit board ..................................19
5.5 Open the casing top for repair and service purposes
20
5.5.1 Description of internal components......................21
6Troubleshooting........................................................ 22
6.1 Leak check indicates malfunction –unit leaky.........22
6.2 Gas route obstructed, no flame...............................25
6.3 Gas flow reduced, flame too weak..........................26
6.4 Unit overfilled –damage by overfilling.....................28
6.5 Foaming of electrolyte in gas hose..........................31
6.6 Defect of pressure sensor.......................................32
6.7 Exchange the circuit board......................................32
6.8 Exchange the safety pressure switch......................34

Contents
MIG-O-MAT Mikrofügetechnik GmbH
Service manual_microflame_EN
3
6.9 Ventilator out of operation / Display indicates excess
temperature.........................................................................36
6.10 Replace the ventilator.............................................37
6.11 Replace the temperature sensor.............................38
7Unit service at service status 0 %............................. 39
7.1 Reset maintenance counter....................................40
7.2 Replace sinter piece and filter candle......................40
7.3 Replace the check valve.........................................42
7.4 Dismount the reactor...............................................44
7.5 Clean reactor and electrodes..................................46
7.6 Replace electrodes inside the reactor.....................51
7.7 Check elbow fitting of the test line...........................51
7.8 Fill unit and put into operation.................................52
8Spare parts............................................................... 53
9Putting out of operation and waste disposal............. 56
9.1 Waste disposal of microflame unit...........................56
9.2 Waste disposal of electrolyte ..................................56
9.3 Waste disposal of vaporizer liquid...........................56
10 Manufacturer’s contact address ............................ 57

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1 General
Carefully read the present Operating and Service Instructions,
in particular the Important safety warnings, before you start
operating the unit or before you carry out any repair or service
works.
It is assumed that any service staff carrying out repair works
possess the required basic electrical knowledge and safety-
related special knowledge. Basic and self-evident safety
instructions are therefore not repeated for the individual
instructions in each section.
We reserve the right to carry out technical modifications on the
units due to advanced development.
1.1 Structure of the present service
instructions
Carefully read before any repair or service work.
Description of simple measures of maintenance and upkeep of
the unit.
Instructions on trouble shooting, repair and service of the unit.
The major spare parts are listed. If a more detailed list of spare
parts is required please contact the manufacturer.
Safety warnings
Maintenance
Repair and service
Spare parts list

Important safety warnings
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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 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!
Electrolyte solution can cause severe chemical burns!
Always wear base-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 base-resistant suction device which is
not operated by mouth.
Instructions for the
operator
Intended use
Operating staff
Mains connections
Risks due to electric
current
Risks caused by
electrolyte

Important safety warnings
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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 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.
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 distilled water), touch the cap nuts on the top part of
the unit or the metal screws on the housing with both hands.
Risk of burning and fire! Hang the burner 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.
Risks caused by
vaporizer liquid
Risks caused by
burnable gas and gas
flame
Exclusion of laibility

Repair and service
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Service manual_microflame_EN
7
Repair and service
2.1 Demands on service staff
The present service manual is intended to be used by
instructed specialized service staff. Legitimate users of the
manual are all service staff who do not require to be instructed
on the risks caused by and during works on the electrical
system. It is assumed that any service staff carrying out repair
works possesses the required basic electrical knowledge and
safety-related special knowledge on the work with and on
appliances operated at mains voltage and on the handling of
concentrated bases and solvents.
2.2 Liability
The service staff must be acquainted with the particular safety
instructions given in the present manual and learn to apply the
safety instruction correctly before carrying out any of the
described service works.
The manufacturer cannot be held liable for any service work
carried out by service staff members. The responsibility for the
minute observance of the prescribed safety instructions and for
the safe and proper execution of the service measures taken
lies solely with the executing service staff.
2.3 Testing aids, tools and inspection equipment
In addition to the standard electromechanical equipment the
following testing and inspection aids and tools and protection
gear are required for carrying out the repair and service works
described in the present manual:
Goggles, rubber gloves, smock
Software and adapter cable for diagnosis purposes and for
resetting the service intervals, depends of production year
(available from MIG-O-MAT)
For taking the electrolyte liquid out of the reactor
D.C. current probe / clamp-on ampere meter (measuring range
> DC 170 A) for measuring the electrolysis current
For measuring D.C. and A.C. voltages and for electric continuity
measurings
For leak checks on the reactor tank
Protection gear
Software
Vacuum pump
Current probe
Multimeter
Manometer

Repair and service
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2.4 Safety instructions
Maintenance, service and repair works must be carried out
by instructed specialized staff only.
Observe and follow the safety instructions below when
carrying out any maintenance, service or repair works that
require the handling of electrolyte or vaporizer liquid:
Caution when handling electrolyte! Risk of chemical burn!
Strong acid base!
Risk of chemical burn due to spilling base or splashes of base
from the filling duct during filling!
Always wear protective gloves and goggles when handling
hazardous substances!
Caution with open filling duct of the electrolyte reactor!
Risk of fire and explosion due to ignition sources!
Risk of ignition of the detonating gas in the electrolyte reactor
due to ignition sources!
Keep unit away from any ignition sources! Do not use the
burner flame to shine into the filling duct!
Caution with open filling duct of the electrolyte reactor!
Risk of fire and explosion due to electrostatic
discharging!
Risk of ignition of the detonating gas in the electrolyte reactor
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. This will branch off any possible electrostatic
charging of the operator without any risk (mains cable must
be connected to the mains)!
Caution when handling vaporizer liquid! Risk of fire and
explosion due to ignition sources!
Risk of ignition of the flammable liquids contained in the unit,
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!
CAUTION!
WARNING!
WARNING!
WARNING!
WARNING!

Repair and service
MIG-O-MAT Mikrofügetechnik GmbH
Service manual_microflame_EN
9
Caution when handling vaporizer liquid! Risk of fire and
explosion due to electrostatic discharging!
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. This will branch off any possible electrostatic
charging of the operator without any risk (mains cable must
be connected to the mains)!
WARNING!

Malfunction and service indications in the
display
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3 Malfunction and service indications in the
display
3.1 Service interval has run down
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.
The service level can be called by changing the display.
Press the key to indicate the gas drawing hours and the
service level:
„100 %“ service level is he standard status of the unit when
delivered or when the unit has been serviced. The reactor
should be serviced every two years or when a service level of
„0 %“ is indicated.
A signal tone and a message in the display indicate when the
unit must be serviced:
Service interval
has run down!
The signal tone can be silenced by pressing any key. Operation
of the unit may continue for a limited period of time.
Carry out the service measures described in section 7 as soon
as possible.
Caution: The manufacturer cannot be held liable for any
damage on persons, or for damage on the equipment caused
by operation of the unit after the service interval has run down!
In case of malfunctions of the unit caused by thermal
overcharging or overpressure, the gas production is
automatically stopped: the unit changes the set value to zero. A
signal tone indicates the malfunction. Close the valve at the
hand piece. The signal tone can be silenced by pressing any
key.
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.
Show service level
Transformer
overload

Malfunction and service indications in the
display
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3.2 Excess temperature
If the allowed reactor temperature of 80°C is exceeded, the
display shows the following malfunction message:
Excess temp.!
Let cool down!
An excess reactor temperature may be caused by the following:
•Filling level of electrolyte too low: check the filling level.
•Ventilator not operating: check if the ventilator operates
during drawing of gas, or at a temperature of approx. 40°C
without drawing of gas. The ventilator speed is controlled
depending on the reactor temperature.
•Adverse ambient conditions:
- the unit is placed at an insufficiently ventilated workplace
- the lateral ventilation openings are blocked
- extremely high ambient temperature
- extreme utilization with at least one of the above adverse
conditions
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 ventilator will then
stop operating, too. If the noise of the operating ventilator is too
loud switch the unit into stand-by operating mode by pressing
the on/off key . In this mode, the ventilator speed is reduced.
Cooling down will take considerably longer!
3.3 Faulty pressure control
If the pressure control device has broken down the unit
automatically switches off and the display shows the following
malfunction message:
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
faulty or damaged (see Section 6.6).
Causes
Cause

Malfunction and service indications in the
display
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3.4 Excess pressure –safety pressure switch broken
If the safety pressure switch is broken the display shows the
following malfunction message
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.

Trouble shooting
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4 Trouble shooting
Malfunction / Fault
Possible cause
Remedy
The unit does not build up
any pressure:
The set pressure is e.g.
150 mbar, the actual
pressure does not reach
the set pressure value
(with burner hand piece
closed!)
Unit is leaking.
Carry out the leak check and
check if there is a leak in the gas
route.
If a leak is detected (indicated in
the display) search for the leak
as described in Section 6.1.
Unit builds up pressure
extremely slowly, the set
pressure is not reached or
it takes extremely long
until the set pressure is
reached.
Unit is leaking.
Carry out the leak check and
check if there is a leak in the gas
route.
If a leak is detected (indicated in
the display) search for the leak
as described in Section 6.1.
Electrolyte filling level too low.
Check filling level, refill distilled
water if required.
Reactor output is reduced due to
contaminated or too old
electrolyte.
Check reactor performance as
described in Section 6.3.
Flame is very weak and
„sits“ on the nozzle
(nozzle tip is glowing).
The set pressure, e.g.
150 mbar, is reached.
During operation the
actual pressure goes
down to a value which
does not produce the
same flame as before
with the same nozzle.
Set pressure is too low for the
nozzle size used, unallowable
nozzle size (too large).
Check if the used nozzle is
allowed for the unit. If the nozzle
size is OK increase the set
pressure value.
Very small leak in the unit.
Carry out the leak check and
check if there is a leak in the gas
route.
If a leak is detected (indicated in
the display) search for the leak
as described in Section 6.1.
Electrolyte filling level too low.
Check filling level, refill distilled
water if required.
Gas route is partly obstructed.
Check gas route for obstructions
as described in Section 6.2.

Trouble shooting
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Reactor output is reduced due to
contaminated or too old
electrolyte.
Check reactor performance as
described in Section 6.3.
Malfunction
Possible cause
Remedy
The flame is instable.
The nozzle is obstructed.
Clean or replace the nozzle.
The gas route is partly
obstructed.
Check the gas route for
obstructions as described in
Section 6.2.
The vaporizer liquid has been
consumed.
Remove remaining vaporizer
liquid and fill new vaporizer
liquid, clean the glass.
No gas at the nozzle / no
flame possible.
When the valve at the
hand piece is opened the
actual pressure does not
go down (even with
removed nozzle).
Gas route is obstructed.
Check the gas route for
obstructions as described in
Section 6.2.
Gas production is
automatically switched off
due to excess
temperature.
The display shows the
malfunction message:
Excess temperature
Excess reactor temperature
(max. 80°C).
Let unit cool down.
Foam inside gas hose.
Unit has been overfilled.
Check the filling level, reduce if
necessary (suck off electrolyte)
as described in Section 5.1.
Electrolyte is contaminated.
If the filling level is OK (no
overfilling), exchange the
electrolyte (drain reactor as
described in Section 5.1) and
clean the reactor (see Section
7.5).
The display is dark, unit is
dead.
Faulty fuse(s) on circuit board or
main switch.
Check fuses and replace if
necessary (Section 5.4 / 12.4.1).

Trouble shooting
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Service manual_microflame_EN
15
(Main switch on the unit
rear is switched on and
the start button in the
display has been
pressed.)
Circuit board faulty.
If the fuses are OK, replace the
circuit board
(Section 6.7).
Malfunction / Fault
Possible cause
Remedy
The display shows the
following malfunction
message: Operating
pressure control faulty
The hose to the pressure sensor
on the circuit board is obstructed
by residues of electrolyte
(electrolyte has been overfilled).
Check the hose to the pressure
sensor, replace if necessary
(Section 6.5).
The pressure sensor on the
circuit board is damaged
(electrolyte has been overfilled).
If the malfunction message
continues to be displayed after
exchange of the obstructed hose:
replace the pressure sensor
(Section 6.7).
The display shows the
following malfunction
message: Excess
pressure!
Faulty safety pressure
switch!
The safety pressure switch is
faulty.
Replace the safety pressure
switch (Section 6.8).

Preparatory measures
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5 Preparatory measures
5.1 Remove the electrolyte from the reactor
For shipment of the microflame unit, and for particular
maintenance works, remove all electrolyte from the unit.
For emptying the electrolyte reactor use a suitable base-
resistant suction device (waterlock), or e.g. a simple suction
device consisting of a PVC hose and a plastic bottle or a
syringe.
Fig. 5.1 Plastic bottle and hose for removal of electrolyte from the
reactor
Caution! Strong acid base!
Risk of severe chemical burn on skin, mucous membranes
and eyes!
Do not suck any electrolyte through a hose by mouth!
To prevent dangerous chemical burn when handling
electrolyte always wear protective gloves and goggles!
1. Switch off the microflame at the mains switch at the back of
the unit.
2. Open the screw cap of the filling duct for electrolyte.
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.
WARNING!
How to proceed
A
B

Preparatory measures
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Service manual_microflame_EN
17
Example plastic bottle with PVC hose:
1. Insert the hose into the filling duct of the reactor and push
it down as far as it goes.
2. Compress the plastic bottle, then create a vacuum by
releasing the bottle.
3. As soon as electrolyte starts flowing through the hose,
pull off the bottle and hold the hose end into an base-
resistant container. Let all electrolyte drain into the
container.
5. Keep the electrolyte in an base-resistant container and
clearly mark the container. Store the container at a safe
place and keep it away from unauthorized persons, in
particular from children. Or dispose of the electrolyte as
described in Section 9.2.
5.2 Remove the vaporizer liquid from the vaporizer glass
For shipment of the microflame unit, and for particular
maintenance works, remove all vaporizer liquid from the unit.
For the disposal of the vaporizer liquid observe the instructions
given in Section 9.3.
Caution when handling vaporizer liquid! Risk of fire and
explosion due to ignition sources and electrostatic charging!
When handling vaporizer liquid keep away from any ignition
sources!
Avoid 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
vaporizer glass container (the mains cable must be connected
to the mains supply). This will branch off any possible
electrostatic charging of the operator without any risk!
1. Press the on/off key in the operating panel to switch off
the gas production.
2. Unscrew the fastening ring by turning it to the left (see
fig. 7.2.D).
3. Remove the vaporizer glass. Move the complete top part to
the side to facilitate removal of the vaporizer glass.
4. Drain the vaporizer liquid.
5. Fill the vaporizer liquid into a specially marked container
and store out of reach of unauthorized persons, in particular
of children. 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).
WARNING!
How to proceed

Preparatory measures
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5.3 Open the unit
Repair and maintenance works that require the unit to be
connected and opened must be carried out by authorized
specialized staff only.
Risk of electric shock due to live parts inside the unit!
Pull the mains plug before you open the unit!
The manufacturer cannot be held liable for any damage
caused by unauthorized repair works on the unit.
5.4 Open the operating panel for detail repair on
electronics
For repair works on the circuit board or the pressure sensor it is
only necessary to open the operating panel:
1. Separate the unit from the mains!
2. Unscrew the screws at the operating panel.
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.
Opening of the unit
by authorized,
specialized staff
only
WARNING!
How to proceed