DENTAURUM Assistent 3000 User manual

Assistent 3000
REF078-000-00
Instructions for use
EN

2
Features and Controls










Handrest with electrode opening mechanism
Lower ”click-stop“ electrode holder
Upper ”click-stop“ electrode holder
Manual button
6-stage LED display
Pad for selecting ”welding“ mode
Pad for selecting ”soldering“ mode, stage I
Pad for selecting ”soldering“ mode, stage II
Pad for selecting ”continuous soldering“ mode
Pad for reducing welding energy
Pad for increasing welding energy

3

 


Outlet for hand electrodes
Outlet for hand electrodes
Combination outlet for power supply, power plug and fuse holder
Outlet for foot switch
Housing with tray
Fuse holder

4
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.......................................................................................................................................6g
6. Components supplied ..........................................................................................................................7h
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 ................................................................................. 9
8.1.2 Spot welding with hand electrodes (optional accessory) ........................................................... 10
8.2 Soldering........................................................................................................................................... 12
8.2.1 Soldering with ”click-stop“ electrodes ..................................................................................... 13
8.2.2 Soldering with hand electrodes (optional accessory)................................................................. 14
8.2.3 Continuous soldering............................................................................................................... 15
8.3 Heat treatment ................................................................................................................................. 15
8.3.1 Annealing of wires................................................................................................................... 15
8.3.2 Tempering of wires ................................................................................................................. 16
8.3.3 Stress relieving of wires............................................................................................................ 16
8.3.4 Procedure for soft annealing, tempering and stress relieving ................................................... 16
9. Power-saving mode.............................................................................................................................. 17
10. Troubleshooting ................................................................................................................................. 18
11. Dentaurum Customer Service – Equipment...................................................................................... 19
12. Care and maintenance....................................................................................................................... 19
13. Spare parts for ”click-stop“ holders.................................................................................................. 19
14. Optional accessories........................................................................................................................... 20
14.1 Spare parts for hand electrodes ....................................................................................................... 21
14.2 Installation of the holder for hand electrodes................................................................................... 22
15. Schematic............................................................................................................................................ 23
16. Welding charts ................................................................................................................................... 25
16.1 Noninium®wires.............................................................................................................................. 25
16.2 remanium®wires ............................................................................................................................. 26
16.3 remaloy®wires ............................................................................................................................... 27
16.4 rematitan®SPECIAL wires ................................................................................................................ 28
16.5 Other materials ............................................................................................................................... 29
17. Quality information ........................................................................................................................... 30
18. EC-Declaration of Conformity ........................................................................................................... 31

5
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
Caution: Read through the instructions for installing and operating the unit carefully
before switching it on.
2.1 Intended use
The Assistent 3000 is only intended for welding and soldering of orthodontic appliances. The use of
the unit for any other purpose is prohibited. The use of the unit for its correct purpose also includes
 compliance with all the instructions contained in the Instructions for use
The Assistent 3000 is not suitable for prosthetics work, in particular not for the processing of:
 precious metal 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.
This symbol indicates important safety instructions. Disregarding this warning may cause
damage to the unit and / or other property.
This symbol gives important information on the correct use of the unit. Disregarding this
information may cause the unit to malfunction.

6
3. General notes and disposal
Always wear safety goggles when soldering or welding.
To use the Assistent 3000 to its full advantage, study the following notes carefully
before using it for the first time.
The unit requires high voltage. To avoid accidents, the unit should only 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 the dental trade.
4. Description and usage
4.1 Application
The Assistent 3000 spot-welding unit fulfils all the requirements for producing optimum weld or
solder joints in orthodontic appliances:
 6-stage setting of welding energy
 2-stage setting of soldering energy
 Easy-to-use pads for accurately setting welding and soldering strengths on the LED display
 Electronic charge and discharge logic for thyristor control
 Ergonomic design
 Outlets for optional accessories
5. Technical data REF078-000-00
Mains connection: 110 V – 240 V, 50 / 60 Hz
Rated power 140 W
Impulse current 2000 A
Fuses 3,15 A, time-delay fuse / 1 A, medium time-lag
Insulation class B
Dimensions 335 x 310 x 130 mm (13 ¼" x 8" x 5 ¼") (W x D x H)
Weight approx. 8 kg/ 18 lbs.
Color housing RAL 9001 white
Base and hand rest: RAL 1515 blue
Manual button RAL 9006 white-aluminum
The rating plate with the number is on the back of the unit.

7
6. Components supplied
The basic set contains the following items:
 Assistent 3000 unit REF 078-000-00
 Power cable
 Screwdriver for changing electrodes
 File for solder electrodes
 1 x spare fuse (3.15 A, time-delay fuse)
 1 x spare fuse (1 A, medium time-lag)
 Instructions for use
7. Unpacking and start-up procedure
Should you notice any damage which may have occurred in transit, notify immediately Dentaurum
Customer Service (page 19) or the dealer who supplied the unit.
Caution: Before using the unit, ensure that the power supply voltage corresponds to
the operating voltage stated on the rating plate on the back of the unit.
The voltage is automatically set between 110 V and 240 V.
Plug the power cable into the power cable outlet and then into the power supply. The unit is
now ready for operation.
8. Operating instructions
8.1 Spot welding
Always wear safety goggles for welding work.
When using the hand electrodes for welding, the electrodes must not touch each
other at the electrode holders, otherwise an electric current will flow through the
electrode holders and the hand electrodes, causing poor welding results.
In order to meet the complex requirements for constructing orthodontic appliances, the
Assistent 3000 is fitted with 7 different copper electrodes for welding. These have special contact
tips or 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.

8
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 activated every
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 charts (p. 25ff.)
Notes
 Electrodes must always be clean. Clean, polished and correctly set electrode tips are
essential for good welds.
 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 of operation, 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.

9
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
previously selected mode appears again. The unit
is now ready for use.
2. Press pad to select the “welding” mode. The
figure last shown on the LED display appears
again. If for example LED 5 lights up, welding
stage 5 is set.
3. Set the desired welding energy using pad 
or . The figure selected is shown in the LED
display. The welding energy can be set in steps from 1-6. The unit’s electronics must adjust to the
figure selected. Some seconds may therefore pass before the LED on pad lights up to show it
is ready for use. Only then is it possible to activate the first welding pulse.
4. Press hand rest down and set the desired combination of copper electrodes on the click-stop
electrode holders and .







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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.
6. Activate the welding pulse with the manual
button or foot switch (optional 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 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. Push the plugs of the hand electrodes into the
outlets and .
3. Turn power switch to position “I”.The mode
last set is displayed.
4. Press pad to select the “welding” mode. The
figure last shown on the LED display appears
again. If for example LED 5 lights up, welding
stage 5 is set.
5. Set the desired welding energy using pad or . The figure selected is shown in the LED
display. The welding energy can be set in steps from 1-6. The unit’s electronics must adjust to the
figure selected. Some seconds may therefore pass before the LED on pad lights up to show it
is ready for use. Only then is it possible to activate the first welding pulse.
6. Clamp a notched electrode REF 081-501-00 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”.










11
Note
When welding with the hand electrodes, the welding energy must be set higher than for the
click-stop electrode holder. The welding energy setting depends on the cross section of the
material being welded. (See separate charts p. 25ff.).
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.
When using hand electrodes for soldering or heat treatment, the electrodes must
not 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 ................. ready fluxed 1.6 g REF380-600-50

13
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 previously
selected mode appears again.
2. Press pad (stage I) or pad (stage II) to select
the “solder” mode. When the unit’s electronics are
ready, the green pad LED or lights up.
3. Set the electrodes to combination A or B (cf. fig.
below).
4. Apply flux to the section to be soldered and add
the solder.
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.







14
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 right
and left hand electrode (cf. fig. below).
4. Turn power switch to position “I”.
5. Press pad (stage I) or pad (stage II) to select
the “solder” mode. When the unit’s electronics are
ready, the green pad LED or lights up.
6. Clamp the tack-welded parts in the clamping
electrode as closely as possible to the soldering point.
7. Apply flux when using solder in rods or in a roll, 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. Proceed 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”.
Hand electrode with
soldering carbon
Hand electrode with
clamping electrode







15
8.2.3 Continuous soldering
Press key to select the “continuous soldering”
mode.
The soldering process is initiated by pressing
the manual button or foot switch once. It
is ended by pressing the manual button 
or foot switch a second time. Disregarding
this instruction will cause the electrodes to
burn out.
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.







16
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.
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 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.
The upper and lower electrodes must not
touch each other. Should they touch, a fault
signal will be given.







17
2. Fit the hand electrodes into outlet and and clamp the notched electrodes REF 081-501-00
into the clamping sleeves.
3. Connect the foot switch to outlet .
4. Turn power switch to position “I”.
5. Press pad (stage I).
6. Depending on the material’s cross section, press pad (solder stage II). Carry out tests!
7. Set the notched electrode tips in the area of the wire to be heat treated.
8. Operate the foot switch until the wire has reached the temperature (color) for the desired heat
treatment process.
Bright red approx. 1100 °C/ 2012 °F soft annealing
Dark red approx. 550 °C/ 1022 °F stress relieving
Dark brown approx. 470 °C/878 °F tempering
9. Remove the electrodes quickly from the wire and release the foot switch.
10. On completion of heat treatment, turn the power switch to position “0”.
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
in a hand electrode can be used 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. Power-saving mode
In the "welding" mode, the unit is fitted with a power saving mode. If the unit remains unused
for longer than 10 minutes when switched on, a number of important functions are switched off
automatically. This is shown by the pad LED flashing red. This function saves electric power.

18
10. 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 3.15 A
time-delay fuse
*To change fuse (see below)
2.0 Set welding and soldering
power too low
2.1 Electrodes or solder carbon dirty
or worn
2.1.1 Clean or replace electrodes or
solder carbon
The electrodes must be positioned
flat in relation to each other
2.2 Welding or soldering power set
too low
2.2.1 Increase power with pad 
3.0 LED display indicates:
4 LEDs flash
3.1 Unit overheated 3.1.1 Switch unit off and
allow it to cool
4.0 LED display indicates:
6 LEDs flash. Check the
electrodes
4.1 In solder function: copper
electrode used instead of
carbon electrode
4.1.1 Select carbon electrodes
4.2 New soldering carbon inserted
(good conduction) and high
power
4.2.1 Select stage 1
5.0 No welding function 5.1 Fuse Pos. 17 defective 5.1.1 Replace fuse 1 A medium
time-lag
*To change fuse (see below)
The unit operates under high voltage!
To prevent accidents, never open the unit. If malfunctions cannot be corrected as
mentioned above, please contact Dentaurum Customer Service (see page 19).
*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!
**Replacing the fuse for the welding function:
Use a screw driver to turn the fuse holder anti-clockwise. Remove the fuse holder. Take out the
fuse.

19
11. Dentaurum Customer Service
Dentaurum Customer Service
Dentaurum GmbH & Co. KG I Turnstr. 31 I 75228 Ispringen I Deutschland
(P.O.B. 100 440, 75104 Pforzheim)
Tel. + 49 72 31 / 803-211 I Fax + 49 72 31 / 803-295 I [email protected]
12. Care and maintenance
The unit requires no maintenance.
Only the copper electrodes require filing after use. Carbon electrodes must also be cleaned after
use to remove flux residues.
Replace the electrodes in the case of excess wear and tear. To this end, open the electrode screws
with a screwdriver, size 2.5 mm x 0.4 mm.
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 .
13. 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 Spare carbon insert for soldering electrode
REF085–300–00 REF086–400–00
1 piece 10 pieces

20
Screws for tightening electrodes Spare fuse 3.15 A, time-delay fuse
REF084–100–00 REF907-037–10
10 pieces 1 piece
File for soldering carbon REF083–300–00
10 pieces
Spare fuse (1 A, medium time-lag)
REF908-678-09
1 piece
14. Optional accessories
Foot or knee switch, combined Holder for hand electrode
REF080–116–00 1 piece REF081-204–00 1 pair
REF081-205–00 Holder, right
REF081-206–00 Holder, left
Hand electrode, single
REF081-101–00 1 piece