Junior 3000 Instruction for Use March 2017

Features and controls

  a   b 





 Handrest with electrode opening mechanism  Lower click-stop electrode holder  Upper click-stop electrode holder  Manual button  On / Off light  Switch for selecting “Welding” (weld symbol a) or “Soldering” (solder symbol b) mode  Switch for selecting welding power (I or II)

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 







 Outlet for hand electrodes  Outlet for hand electrodes  Combination outlet with power-supply switch, power plug and fuse holder  Outlet for foot switch  Housing with tray

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Contents 1. Manufacturer... 5 2. Safety information... 5 2.1 Intended use... 5 2.2 Danger symbols and markings... 5 3 General notes and disposal... 6 4. Description and usage... 6 4.1 Application... 6 5. Technical data... 6 6. Components supplied... 7 7. Unpacking and start-up procedure... 7 8. Operating instructions... 7 8.1 Spot welding... 7 8.1.1 Spot welding with “click-stop“ electrodes... 10 8.1.2 Spot welding with hand electrodes (optional accessory)... 11 8.2 Soldering... 12 8.2.1 Soldering with click-stop electrodes... 13 8.2.2 Soldering with hand electrodes (optional accessory)... 14 8.3 Heat treatment... 15 8.3.1 Annealing of wires... 15 8.3.2 Tempering of wires... 15 8.3.3 Stress relieving of wires... 16 8.3.4 Procedure for soft annealing, tempering and stress relieving... 16 9. Troubleshooting... 17 10. Dentaurum Customer Service – Equipment... 18 11. Care and maintenance... 18 12. Spare parts for click-stop holders... 18 13. Optional accessories... 19 13.1 Spare parts for hand electrodes... 20 13.2 Installation of the holder for hand electrodes... 21 14. Schematic... 22 15. Welding charts... 24 15.1 Noninium® wires... 24 15.2 remanium® wires... 25 15.3 remaloy® wires... 26 15.4 rematitan® SPECIAL wires... 27 15.5 Other materials... 28 16. Quality information... 29 17. EC-Declaration of Conformity... 30

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Dear customer Thank you for choosing a quality product from Dentaurum. It is essential to read these instructions carefully and adhere to them to ensure safe, efficient use and ensure that you and your patients gain full benefit. Instructions for use cannot describe every eventuality and possible application. In case of questions or ideas, please contact your local representative. As our products are regularly upgraded, we recommend that you always carefully read the current Instructions for use supplied with the product and stored in the internet at www.dentaurum.com, even though you may frequently use the same product.

1. Manufacturer Dentaurum GmbH & Co. KG I Turnstr. 31 I 75228 Ispringen I Germany

2. Safety information  aution: Read through the instructions for installing and operating the unit carefully C before switching it on. Only then should the unit be switched on.

2.1 Intended use The Junior 3000 is only intended for the welding and soldering of orthodontic appliances. It is not intended to be used for any other purpose. The use of the unit for its correct purpose includes „„compliance with all the instructions contained in the Instructions for use. The Junior 3000 is not suitable for prosthetics work, in particular not for the processing of „„precious metals alloys „„cast partial denture alloys or non-precious metal alloys for ceramics When a Dentaurum product is taken out of operation once and for all, the disposal regulations of the country of operation apply. Dentaurum or the dental trade is available to answer questions regarding the correct disposal of any specific product.

2.2 Danger symbols and markings In the Instructions for use, the following symbols are used to indicate sources of danger to the user: This symbol indicates direct danger to the life or health of the user. Disregarding this warning may involve a serious risk to health.  his symbol indicates important safety instructions. Disregarding this warning may cause T damage to the unit and / or other property.  his symbol gives important information on the correct use of the unit. Disregarding this T information may cause the unit to malfunction.

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3. General notes and disposal Always wear safety goggles when soldering or welding. o use the Junior 3000 to its full advantage, study the following notes carefully T before using it for the first time.  he unit requires high voltage. In order to avoid accidents, the unit should only T be opened by Dentaurum Customer Service’s personnel or authorized service technicians. When a Dentaurum product is taken out of operation once and for all, the disposal regulations of the country of operation apply. Dentaurum or the dental trade is available to answer questions regarding the correct disposal of any specific product. Note: This symbol indicates that products with this marking should not be disposed of together with household garbage. The legislator does not allow commercial customers to return electronic waste via municipal collection points. Further information is available from Dentaurum or specialist dental traders.

4. Description and usage 4.1 Application The Junior 3000 spot-welding unit fulfils all the requirements for producing optimum weld or solder joints in orthodontic appliances: „„2-stage setting of welding energy „„Soldering stage with fixed setting „„Ergonomic design „„Outlets for optional accessories

5. Technical data Mains connection Rated power Impulse current Fuse Insulation class Dimensions Weight Color: Base and hand rest: Manual button:

230 V 50 / 60 Hz REF 077-000-00 115 V 50 / 60 Hz REF 077-000-01 115 W 1200 A 2 A, time-delay fuse (for 230 V); 3.15 A, time-delay fuse (for 115 V) B 335 x 310 x 130 mm (13 1/4’’ x 8’’ x 5 1/4’’) (W x D x H) approx. 7 kg/17 lbs housing RAL 9001 white RAL 1515 blue RAL 9006 white-aluminum

The rating plate with the number is on the back of the unit.

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6. Components supplied The basic set contains the following items: Junior 3000 unit „„Power cable „„Screwdriver for changing electrodes „„File for solder electrodes „„1 x spare fuse „„Instructions for use

7. Unpacking and start-up procedure Should you notice any damage which may have occurred in transit, notify Dentaurum Customer Service (page 18) or the dealer you got the unit from without delay  efore using the unit, ensure that the power supply voltage corresponds to the B operating voltage stated on the rating plate on the back of the unit. Plug the power cable into the power cable outlet  and then into the power supply outlet. The unit is now ready for operation.

8. Operating instructions 8.1 Spot welding Always wear goggles for welding work.  hen using the hand electrodes for welding, the electrodes must not touch each W other at the electrode holders, otherwise an electric current will flow through the electrode holders and the hand electrodes, and cause poor welding results. In order to meet the complex requirements for constructing orthodontic appliances, the Junior 3000 is fitted with 7 different copper electrodes for welding. These have special contact tips/surfaces. The click-stop electrode holders ,  permit quick and easy changing from one electrode to the other. When the holder is turned to the desired position, the electrodes click into the correct position in relation to one another.

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Maximum load on unit If the unit is being used over several hours, only one welding pulse at the most should be activated every 5 seconds. However, if it is only being used for a few minutes (max. 30 minutes) a pulse can be activate devery second. Electrode combinations and designs for welding: for welding:

for welding:

brackets, tubes, hooks and loops wire to wire

wire to bands

Upper electrode REF 085–000–00

Upper electrode REF 085–200–00

Upper electrode REF 085–100–00

Lower electrode REF 086–000–00

Lower electrode REF 086–100–00 or REF 086–300–00

Lower electrode REF 086–200–00

For recommended welding settings, see separate table (p. 24ff.) 

Notes „„ Electrodes must always be clean. Clean, polished electrode tips that are correctly

positioned are essential for perfect welding. „„ Objects being welded must always be free of dirt and grease and have a clean metallic

surface. Polishing the tips Fold a piece of sandpaper (grain 600) with the rough side outwards and push it between the electrodes. Draw the sandpaper back and forth between the tips until the entire surface of both tips is polished. Remove any burrs which are created on the electrodes. If the electrodes no longer function correctly after a longer period, they can generally be re-worked slightly using the electrode file REF 083-300-00. However, if the size of the electrode tip is affected, replace the electrode with a new one.

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Applications Welding brackets to bands When welding brackets to band material or pre-formed bands, ensure that the upper electrode is positioned fully on the welding flange of the bracket. Welding tubes to wire The wall of the tube must be in contact with the wire. If the pressure of the electrode is not sufficient to make contact, it is suggested flattening the tube slightly at the contact point with pliers. Spot-welding crossed wires Where the wires are simply crossed, a single spot-weld is usually adequate to connect them properly. In many cases, it is advisable to solder the wires in addition to welding. In this case, take into account that heating the wires when soldering them to strengthen the joint also causes the mechanical properties of the wires to deteriorate. Checking a weld The simplest method is to make a visual check of the weld quality of a specific spot-weld, e. g. a weld-on component (bracket) onto a band. Clearly visible light brown points on the inside of the band indicate a successful weld. 8.1.1 Spot welding with the click-stop electrodes Procedure 1. Turn power switch  to position “I”. The green pilot light  turns on. The unit is now ready for use. a 2. Press switch  to position a to select the “welding” mode.  3. Set the desired welding energy at switch  (stage   I or II) 4.  Press hand rest  down and set the desired b combination of copper electrodes on the click-stop electrode holders  and . 5. Press hand rest  down and insert workpiece. When pressure on the hand rest is reduced, the electrodes close and fix the workpiece in position.

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6. Activate the welding pulse with the manual button  or foot switch (special accessory). 2-3 adjacent welding pulses are enough to create a perfect welded joint. 7. Release the workpiece by pressing the hand rest  and repeat the welding process if necessary. 8. After completing the welding process, turn the unit off and turn the power switch  to position “0”.



 

8.1.2 Spot welding with hand electrodes (optional accessory) This process is recommended when for example wires have to be fixed against one another on the model. The components removed from the model should then be re-welded or soldered at the click-stop electrodes. Procedure 1.Turn the upper electrode head on the click-stop holder  one turn (45°) to the left or the right. 

The upper and lower electrodes must not touch each other.

2. P ush the plugs of the hand electrodes into the outlets  and . 3. Turn power switch  to position “I”. The green pilot light  turns on. The unit is now ready for use. 4. Press switch  to position a to select the “Welding” mode. 5. Set the desired welding energy at switch  (stage  I or II)

a  

6.  Clamp a notched electrode REF 081-501-00 b into each of the clamping sleeves of the manual electrodes and then touch the workpiece with the notched tips at a short distance from the welding point. The notches of the electrode prevent it from slipping off the wire element. 7. Activate the welding pulse with the manual button  or foot switch. 2-3 welding pulses are enough to create a perfect welded joint. 8. After completing the welding process, turn the unit off and turn the power switch  to position “0”.

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Note When welding with the hand electrodes, the welding power must be set higher (stage 2) than with the click-stop holder. The welding energy setting depends on the cross section of the material being welded. (See separate charts p. 24ff.).

Recommended accessory: Connect foot switch REF 080-116-00 to outlet .

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8.2 Soldering  When soldering, always wear safety goggles. If soldering takes too long, the soldering carbon will be damaged.  hen using hand electrodes for soldering or heat-treating, the electrodes must not W touch each other at the electrode holders. However, if they do touch one another, a fault signal will be given. If the carbon electrode is used, the current flows through the electrode holder and through the hand electrodes, causing poor soldering results. „„For soldering purposes, one of the copper electrodes is replaced by a carbon electrode

(soldering electrode REF 085-300-00). The heat created by the electrical resistance is stored mainly in the carbon tip, whereas the metal parts themselves absorb only a slight amount of heat. The soldering process differs from the welding process by using solder and flux. „„During electric soldering, the carbon electrode leads to continuous heating until the solder is melted. This then flows around the metal parts which are also heated and protected from oxidation by the flux. „„Before soldering, the carbon electrode should be cleaned with the emery file, REF 083-300-00 to remove any flux residues. Such residues have an insulating effect and would hinder the flow of current during the next soldering operation. Replace the carbon electrode before the brass sleeve and the electrode shaft begin to char. „„We recommend using a pencil sharpener to sharpen the soldering carbon REF 081-601-00. To increase the conductivity of the soldering carbon, dip the tip in water before beginning the soldering operation. „„The hand electrodes are not suitable for continuous soldering. „„The soldering carbon offers more resistance to the current than the clamping electrode REF 081-701-00, thus causing heat to build up in the tip of the soldering carbon. Always ensure that the carbon tip is placed where the heat cannot damage the parts.

Solders Universal silver solder Working temperature: 700 °C / 1292 °F

... ready fluxed 1.2 g REF 380-604-50 ... without flux 10 g REF 380-704-50

Dentaflux® ...50 g REF 681-100-00 For all types of orthodontic soldering. If necessary, dilute slightly with water. White gold solder Working temperature: 950 °C / 1742 °F

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... ready fluxed 1.6 g REF 380-600-50

8.2.1 Soldering with the click-stop electrodes First tack weld the parts together with a weld spot. Procedure 1. Turn power switch  to position “I”. The green pilot light  turns on. a 2. Press switch  to position b to select the “soldering” mode. In “soldering” mode, the switch   has no function.   3. Set the electrodes to combination A or B (cf. fig. below). b 4. Apply flux to the section to be soldered and add the solder or apply universal silver soldering paste (REF 380-804-50). 5. Press the hand rest  down and place the workpiece between the electrodes. 6. Align the carbon electrode on the workpiece without applying pressure. 7. Press the manual button  or the foot switch until the solder is melted and the soldering process finished. Electrode combination:



A

B

Note: Please always use the carbon soldering electrode.

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8.2.2 Soldering with hand electrodes (optional accessory) Procedure 1. Turn the upper electrode head on the click-stop holder  one turn (45°) to the left or the right. The upper and lower electrodes must not touch each other. 2. Push the plugs of the hand electrodes into the outlets  and . 3. Clamp the electrode REF 081-701-00 for holding the workpiece and clamp the soldering carbon REF 081-601-00 into the clamping sleeve of the a right and left hand electrode (cf. fig. below). 4. Turn power switch  to position “I”. The green  pilot light  turns on.   5. Press switch  to position b to select the “Soldering” mode. In “soldering” mode, the switch b  has no function. 6. Clamp the tack-welded parts in the clamping electrode as close as possible to the soldering point. 7. Apply flux when using solder in rods or in a roll, e.g. REF 380-604-50, REF 380-600-50 or REF 380-704-50. 8. Place the tip of the soldering carbon as close as possible to the soldering point. 9. P roceed as below a) or b) depending on the type of solder used: a) Press the foot switch. Apply the solder when the solder joint begins to turn red. b) Press the foot switch until the solder has completely melted. 10. If the unit is no longer required, turn power switch  to position “0”. B

Dentaurum Group

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8.3 Heat treatment 8.3.1 Annealing of wires Spring hard chrome nickel stainless steel wires (e. g. remanium®) can be soft annealed at a temperature of approx. 1100 °C / 2012 °F (heat color: bright red). Soft annealed CoCr wires cannot be tempered (hardened)! Complex bending operations (especially around tight radii with thick wires, e. g. outer wires of face bows) should not be done without previous local annealing of the bending area. Soft annealing is also recommended for removing the elasticity from a wire over a certain length, e. g. with a passive lingual or palatal bow. Refer to 8.3.4 for the subsequent procedure.

8.3.2 Tempering of wires Cobalt based alloys, e.g. remaloy®, or Crozat wires can be tempered (hardened). The tempering of the wire elements depends on the time and the temperature. Heat the wire element only briefly using the hand electrodes (heat color: dark brown) at a temperature of approx. 470 °C / 878 °F. In view of the different wire dimensions, it is recommended to determine the optimum hardening conditions experimentally beforehand. Refer to 8.3.4 for the subsequent procedure.

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8.3.3 Stress relieving of wires When spring hard wires are bent, stresses are created in their crystalline structure. The bent wire element can be stress relieved using a suitable heat treatment process. This is done by heating the wire to approx. 550 °C / 1022 °F over a short period of time. (heat color: dark red) Please note that stress relieving of wire elements on the model takes longer as the plaster absorbs a considerable amount of heat. Refer to 8.3.4 for the subsequent procedure.

8.3.4 Procedure for soft annealing, tempering and stress relieving Important! 1.  Turn the upper electrode head on the click-stop holder  one turn (45°) to the left or the right.  he upper and lower electrodes must not T a touch each other. Should they touch, a fault signal will be given.  2. Fit the hand electrodes into outlet  and  and   clamp the notched electrodes REF 081-501-00 into the clamping sleeves. b 3. Connect the foot switch to outlet . 4. T urn power switch  to position “I”. The green pilot light  turns on. 5. Press switch  to position b to select the “Soldering” mode. In “Soldering” mode, the switch  has no function. 6. S et the notched electrode tips in the area of the wire to be heat treated. 7. Operate the foot switch until the wire has reached the temperature (color) for the desired heat treatment process. Bright red Dark red Dark brown

approx. 1100 °C / 2012 °F approx. 550 °C / 1022 °F approx. 470 °C / 878 °F

soft annealing stress relieving tempering

8. Remove the electrodes quickly from the wire. Release the foot switch. 9. On completion of heat treatment, turn the power switch  to position “0”.

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Note: „„ To soft anneal thick wires, we recommend placing these on a conductive, heat-resistant

base, e.g. a graphite slab. „„ Instead of the notched electrode REF 081-501-00, the clamping electrode REF 081-701-00

can be used in a hand electrode to hold the wire element. „„ To practice the techniques necessary for soft annealing, tempering and stress relieving, we



recommend experimenting with the different kinds of wire. Caution: With thin wires only press the foot switch briefly to ensure the wires do not burn or melt!

9. Troubleshooting Fault

Cause

Remedy

1.0 Unit switched on but nothing appears in display

1.1 Not connected to power supply

1.1.1 Connect unit to power supply 1.1.2 Check fuse at power outlet

1.2 Unit fuse defective

1.2.1 Replace fuse. *To change fuse (see below)

2.1 Electrodes or solder carbon dirty or worn

2.1.1 Clean or repalce electrodes or solder carbon

2.0 Welding and soldering power set too low

T he electrodes must be positioned flat in relation to each other 3.0 Welding power set too low 3.1 Welding power on unit set too low 

3.1.1 Set switch  to stage II

The unit operates under high voltage!

 prevent accidents, never open the unit. If malfunctions cannot be corrected as To described above, please contact Dentaurum Customer Service (see page 18). *Replacing the fuse: Unlock the fuse insert on the right-hand side of the combination plug  and pull it out. The fuse is now accessible and can be removed from the fuse holder. 

Pull out the power plug before removing the fuse holder!

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10. Dentaurum Customer Service - Equipment Dentaurum Customer Service - Equipment Dentaurum GmbH & Co. KG I Turnstr. 31 I 75228 Ispringen I Germany (P.O.B. 100 440, 75104 Pforzheim) Tel. + 49 72 31 / 803-211 I Fax + 49 72 31 / 803-295 I [email protected]

11. Care and maintenance The unit requires no maintenance. Only the copper electrodes require filing after use. The copper electrodes should be cleaned to remove any flux residues. If necessary, wipe the cover with a dry or damp cloth. Do not use corrosive cleaning agents! Do not place hot objects in the tray .

12. Spare parts for ”click-stop“ holders Upper electrodes

Lower electrodes REF 086–000–00 1 piece REF 085–000–00

REF 086–100–00

1 piece

1 piece

REF 085–100–00

REF 086–200–00

1 piece

1 piece

REF 085–200–00

REF 086–300–00

1 piece

1 piece

Soldering electrodes

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Spare carbon insert for soldering electrode REF 085–300–00

REF 086–400–00

1 piece

10 pieces

Screws for tightening electrodes

Spare fuse 3,15 A, time-delay fuse (for 115 V)

REF 084-100-00

REF 907-037-10

10 pieces

1 piece Spare fuse 2 A, time-delay fuse (for 230 V) REF 907-047-10 1 piece

Screwdriver for changing electrodes

REF 083–100–00

Emery file for soldering carbon

REF 083–300–00

1 piece 10 pieces

13. Optional accessories Foot or knee switch, combined

Holder for hand electrode

REF 080–116–00

REF 081-204–00

1 pair

REF 081-205–00

Holder, right

REF 081-206–00

Holder, left

1 piece

Hand electrode, single

REF 081-101–00

1 piece

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13.1 Spare parts for hand electrodes Soldering carbon with copper jacket for hand electrode

Electrodes, notched for annealing, tempering, welding

REF 081-601–00

REF 081-501–00

1 piece

Clamping electrode

REF 081-701–00

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1 piece

2 pieces