Zubler VARIOstar D50 User manual

®
dental & technik
VARIOstar
K50
T50
www.zubler.de 1
Operation Manual 01-2018
en
brushless
Handpiece

2 2
Page

33
Page
Important instructions and warnings
1. For your safety, please read all operating instructions before putting the device
into operation.
2. Observe the occupational health and safety regulations of the employer’s liability
insurance.
3. Before starting, ensure the supply voltage corresponds to the data on the type plate.
4. Remove the chuck-/service-tools before switching the device on.
5. Provide good lighting, safety glass shields, eye protection and an extraction
system at the workplace.
6. The handpiece is intended exclusively for dry grinding.
7. Before using the handpiece, make sure the tool is seated firmly and cannot be
pulled out.
8. Use only functional, certified tools (drill bits, milling bits, cutting disks, polishing
tools, grinding tools, etc.) and observe the tool manufacturer’s instructions for use
(e.g. maximum permissible speed of rotation).
9. Make sure that the handpiece does not start unintentionally or run unsupervised.
10. Operate the handpiece only with a tool or pin locked in the chuck.
11. Do not turn the chuck while the handpiece is rotating.
12. Clean the chuck regularly according to the instructions (never use compressed air
for cleaning / see section 2.1).
13. Repair and maintenance work on the electrical part of the equipment may only be
performed by an approved or certified repair technician.
14. Electrical devices may not be used in a damp or wet environment.
15. For 115V, use the grounded power cable SVT3x18AWG with IEC socket and
grounded plug.
16. Any interruption in the protective ground conductor inside and outside the device
or loosening of the protective ground connection can lead to the device posing a
threat to the operator. Intentional interruption is not permitted.
17. In case of defects or damage where safe operation is no longer ensured, the
device must be secured against unintentional use.
18.
This device is not suitable for use in potentially explosive environments or on patients.

4 4
Contents
0. Introduction Page 5
0.1 Declaration of conformity
0.2 General notes
0.3 Scope of delivery K50
0.4 Commissioning K50
0.5 Scope of delivery T50
0.6 Commissioning T50
1. Operation Page 10
1.1 Handling K50 kneecontroller
1.2 Handling D50 tabletop controller
1.3 Handling the handpiece
2. Maintenance Page 15
2.1 Changing the fuse in the controller
2.2 Malfunction
2.3 Cleaning and replacing the chuck
2.4 Replacing the motor cable
2.5 Spindle change is simple
2.6 Troubleshooting
3. Data Page 20
3.1 Technical data
3.2 Scope of delivery
VARIOstar K50
3.3 Scope of delivery
VARIOstar T50
3.4 Product overview VARIOstar
and Spare parts
4. Safety notes Page 22
5. Warranty terms Page 23
Page

0.
55
Thank you!
We are delighted that you have chosen
the Zubler VARIOstar D50 and we hope
that you will enjoy working with it. The
constant further development of our
technology is based on cooperation with
experienced dental technicians. Our primary
goal is to construct dental equipment of
maximum quality, flexibility and sustaina-
bility. Performance and profitability are
the basic prerequisites for this.
In order to ensure trouble-free usage, ple-
ase read the operation manual carefully.
Introduction
0.1 Declaration of conformity
Page
We, Zubler Gerätebau GmbH
Buchbrunnenweg 26
89081 Ulm Jungingen
hereby declare that the products
VARIOstar K50
VARIOstar T50
conform to the regulations of the following EU
directives:
2006/42/EC Machinery Directive
2014/35/EU Low Voltage Directive
2014/30/EU EMC Directive
This declaration loses its validity if the products
are modified without our agreement.
Kurt Zubler
Chief Executive Officer
Fig. 1

12
1
3
21
19 11
2
4
17
18
20
6 6
1 Knee controller
2 Handpiece
3 Table mount
4 Handpiece stand
11 On/Off switch
12 Digital speed display
13 Socket for handpiece
14 Socket for data cable 15
Socket for external display
16 Power cord connector
17 Flat spanner
18 Chuck tool
19 Knee plate
20 Power cord
21 Fixing knob
22 Assembly diagram
0.3 Scope of delivery: VARIOstar K50 knee controller
Functional principle: Thanks to its special
brushless design, the VARIOstar K50/T50
handpiece enables smooth, fatigue-free
and thus economical working in continuous
operation. The device is constantly moni-
tored for overload through microprocessor
control. An additional thermal fuse provides
the handpiece with increased safety.
0.2 General notes
Fig . 2
Page

16
15
14
13
3
ZUBLER Gerätebau GmbH
Buchbrunnenweg 26
D-89081 Ulm
Tel. [phone] / www.zubler.de
VARIOstar K50
Drehzahl 50.000/min
Spannung AC 230V
Leistung max. 270W
F: T2A
K50 / 00-11111-22
Made in
Geramay
77
Fasten the table mount 3at your
workplace with the help of the assembly
diagram 22. You can find the assembly
diagram between the knee controller 1
and the table mount 3.
Hook the knee controller 1into the table
mount 3and push the knee controller 1
into the table mount 3to the stop; secu-
re the knee controller with the fixing
knob 21.
Connecting the handpiece
Connect the VARIOstar handpiece 2to
the socket 13 (align to the notch) and
secure the plug by twisting the ring.
Place the motor handpiece 2in the
handpiece stand 4.
Connecting the power cable
nCompare the voltage specification on
the type plate with the mains voltage.
nIf they match, plug the power cable
into socket 16.
nThen plug the power plug into the
main power socket.
0.4 Installing the VARIOstar K50 knee controller
Type plate
(see below)
Fig . 4
Fig . 3
Page
Connecting the SL-AP data cable
(Zubler suction only!)
Connect socket 14 with the data socket
of your Zubler suction unit (align to notch
and secure by turning). The data connec-
tion enables a disturbance free working.
If using the data cable SL-AP the power
cord 20 must not be plugged into the
power socket of the suction unit.

6
2
17 18
20
4
12
24
5
T2
23
11
8 8
2 Handpiece
4 Handpiece stand
5 Tabletop controller T50
6 VARIO foot pedal
11 On/Off switch
12 Digital speed display
13 Socket for handpiece
14 Socket for data cable
16 Power cord connector
26 Socket for VARIO foot pedal
20 Power cord
23 Tool tray
24 Speed knob
0.5 Scope of delivery: Tabletop controller VARIOstar T50
Page
Fig . 5

13
26
16
14
Zubler Gerätebau
numberplate
Tension XXXXXX
Number:
Fone:
ZUBLER Gerätebau GmbH
Buchbrunnenweg 26
D-89081 Ulm
Tel. [phone] / www.zubler.de
VARIOstar T50
Drehzahl 50.000/min
Spannung AC 230V
Leistung max. 270W
F: T2A
K50 / 00-11111-22
Made in
Geramay
99
Connecting the handpiece
Connect the VARIOstar handpiece 2to
socket 13 (align to notch and secure by
turning).
Installing the VARIOstar T50 desktop controller
Connecting the knee-/foot-pedal
Connect the VARIOstar Foot Pedal 6to
socket 26 (align to notch and secure by
turning).
Connecting the power cable
After comparing the Power Supply data
with the Voltage requirement data on the
type plate, plug the Power Cord 20 into
Power Cord Connection 16, then into the
Power Supply or Wall Outlet.
Connecting the SL-AP data cable
(Zubler suction only!)
Connect socket 14 control unit with the
data socket of your Zubler suction unit
(align to notch and secure by turning).
The data connection enables a distur-
bance free working.
If using the data cable SL-AP the power
cord 20 must not be plugged into the
power socket of the suction unit.
Page
Fig . 6
Fig . 7
Type plate

Without written modication from you to SERIART G2 within 24 hours conditions above are considered as agreed and accepted
MOD. 47 rev .03 Car tiglio
25-03-2015
Overlay
ZUBLER
Leonardo Senoeni
Polyplate
date
description
customer
product line
drawing by
ATTENTION !!! this drawing may contain modications necessar y to the technical feasibility of the ar ticle
Glossy P olicarbonate 175m
like Alicia
Material 1 Material 2
ZUBFROPOL0000 glossy/matt Acrilyc Adhesive
like Alicia
Chrome - lik e Alicia button
Ral 7011
HKS 15
Matt br ushed - lik e Alicia
Glossy tansparent
Colors Finish
Code
modif. rev01 date
sheets
deliver y
notes
General tollerance ±0.2
MATT ZONE GLUE ZONE
EMBOSSED
GLOSSY ZONE NO GLUE ZONE
11.50 mm
15.50 mm
1.
T2
T3
L3
T1 L1 L212
T4
50
10 10
Operation
The handpiece 2is started by
pressing the knee plate 19. Due to the
wide range of movement you can control
the speed with ease.
Cruise control
The cruise control is enabled by pressing
pushbutton T1, LED L1 lights up.
Pressing and holding the knee plate 19
for 3 sec. on the desired speed will acti-
vate the cruise control and the handpiece
is running even without pressing the
knee plate 19.
To stop the handpiece, press the knee
plate 19 again or press pushbutton T1 to
disable the cruise control, LED L1 is no
longer lit.
Turn the controller ON (I) using the mains
switch 11.
The speed display 12 indicates the pre-
selected speed. You can change the
speed with pushbutton T4 (+)or T3 (-).
1.1 Operating the VARIOstar K50 knee controller
12 Digital speed display
L1 LED Automatic Speed
Control
L2 LED safety switch
L3 LED anticlockwise rotation
T1 Automatic speed control
T2 Safety switch
T3 - pushbutton / counterclock-
wise rotation
T4 + pushbutton / clockwise
rotation
Page
Fig . 8

12
1
19 11
1111
Speed limit
The VARIOstar K50 is equipped with an
adjustable speed limiter to limit the maxi-
mum speed (e.g. 10k rpm for cutting
disc).
Press pushbutton T2 to deactivate the
speed limiter, LED L2 lights up.
Press pushbutton T2 again to activate the
speed limiter, LED L2 is no longer lit.
The speed limiter is factory set to 40k rpm.
Changing the speed limit
Press and hold pushbutton T2 until LED
L2 starts flashing. Adjust the maximum
speed with pushbutton T4 (+) or T3 (-).
(max. 40k rpm).
To save the setting press pushbutton T2
again, LED L2 no longer flashes.
Changing the direction of rotation
Changing to CCW:
Switch ON (I) the control unit with the
mains switch 11, while pressing and hol-
ding pushbutton T3, LED L3 lights up.
Changing to CW:
Switch ON (I) the control unit with the
mains switch 11, while pressing and hol-
ding pushbutton T4, LED L3 is no longer lit.
The rotational direction is factory set to CW.
Fig. 9
Page
Caution: Observe the tool manufacturers
specified speeds.

12 12
Page
11 On/Off switch
12 Digital speed display
24 Speed knob/
Direction switch
T2 “maximum” Button
L1 LED
L2 LED “max”
L3 LED left
1.2 Operating the VARIOstar T50 tabletop controller
Fig . 10
Cruise control
(with Foot-/Knee-pedal only!)
The cruise control is enabled by pressing
the speed knob 24, LED L1 lights up.
Pressing and holding the Foot-/Knee-
pedal 6for 3 sec. on the desired speed
will activate the cruise control and the
handpiece is kept running.
To stop the handpiece press the Foot-/
Knee-pedal 6again shortly or press the
speed knob 24 to disable the cruise
control, LED L1 is no longer lit.
12
24
11
T2
L3
L1
L2
Turn the controller ON (I) using the mains
switch 11.
The speed display 12 indicates the pre-
selected speed. Use the speed knob 24,
to set the desired maximum speed.
Manual Start/Stop (without Foot-/
Knee-pedal only!)
Press the speed knob 24 to start/stop the
handpiece manually.

1313
Fig . 11
Speed limit
The VARIOstar T50 is equipped with an
adjustable speed limiter to limit the maximum
speed (e.g. 10k rpm for cutting disc).
Press pushbutton T2 to deactivate the
speed limiter, LED L2 lights up.
Press pushbutton T2 again to activate the
speed limiter, LED L2 is no longer lit.
The speed limiter is factory set to 40k rpm.
Changing the speed limit
Press and hold pushbutton T2 until LED
L2 starts flashing. Adjust the maximum
speed with speed knob 24. (max. 40k rpm).
Press pushbutton T2 to save the setting,
LED L2 stops flashing.
Changing the direction of rotation
The rotational direction can be toggled by
switching ON (I) the control unit with the
mains switch 11, while pressing and holding
the speed knob 24. Once the direction is
set to CCW, LED L3 lights up.
The rotational direction is factory set to CW.
Page

29
27
30
45
31
14 14
open
close
Tool change:
The chuck on the handpiece is opened or
closed by turning the grip 27.
The chuck 30 is opened and the tool can
be removed.
After inserting the tools the chuck 30 is
closed again by turning the grip 27 in the
opposite direction.
An optional 3.00 mm chuck can be used
(see 2.1)
In order to avoid deformation of the
chuck, a tool or the pin provided must
always be inserted in the chuck.
Check before using the handpiece that
the tool is seated firmly and cannot be
pulled out.
Only change the tool with the motor
turned off!
1.3 Operating the handpiece
27 Grip
28 Cap
29 Pin
30 Chuck
31 Tip
45 Motor cable
Page
Fig . 12
Page

16
2.
16
1515
If the handpiece is overloaded or blok-
ked, the device switches off for safety
reasons. Switch the device off and on
again. The device is ready for use
again immediately.
2.2 Malfunctions
2.1 Changing the main fuse
Repair and maintenance work on the
electrical part of the device may only
be carried out by technical personnel
or by persons trained in the factory
who have been instructed about the
safety regulations. For maintenance
work, disconnect the power cord or
isolate the device from the power
supply so there is no electrical current.
The fuse is located in the fuse drawer in
the power input connector 16. Open the
drawer and replace the fuse. The fuse
value is marked on the type plate.
Reasons for a blown fuse: short-circuit in
the device or overvoltage.
Return the device to your distributor for
evaluation if the cause is unclear.
Page
Zubler accepts no warranty claims if
the Micromotor VARIOstar K50/T50 is
not operated in accordance with the
operation manual.
Fig. 14
Maintenance
Fig. 13

30
Ø2,35 Ø3,00
18
31
17
·
Í
¸
»
¶
{
º
Ø2,35 Ø3,00
16 16
2.3 Cleaning or replacement of the chuck
Page
2.3.1 Removing the chuck
¶Open the chuck 30 and remove the tool.
·Push the chuck tool 18 onto the chuck 30.
¸Fix the chuck 30.
ÍTurn the chuck 30 with the help of the
chuck tool 18 until the flanks of the
spindle are visible at the tip 01 and
the flat spanner 17 can be inserted.
ºInsert the flat spanner 17 and hold it
tight.
»Open the chuck 30.
{ Turn the chuck tool 18 counter-clockwise
to loosen and unscrew the chuck 30.
Screw in the chuck 30 in the clockwise
direction up to the end stop and lightly
tighten it.
Fig . 15
Fig . 16
Fig . 17
Fig . 18

30
1717
2.3.2 Cleaning the chuck
Remove accumulated dirt if possible using
a suitable twist drill (max. 2 mm). Then
clean in an ultrasonic bath, repeating if
necessary. Dry the chuck well with com-
pressed air!
Also clean the cone before inserting. To
do this, dip one end of a Q-Tip in cleaning
agent (Vaseline). Ensure that the handpi-
ece opening is held vertically down-wards
in order to prevent liquid getting into the
ball bearing. Clean the cone with rotary
movements. Subsequently, dry the cone
using the dry end of the Q-Tip.
Do not blow out with air! Lightly grease
the chuck all round on the cone and on
the thread side and insert in the shaft.
Do not clean handpieces
with compressed air!
Page
Fig. 19
The digital display in the handpiece stand,
which is available as an accessory, can be
connected to the knee controller via
socket 15.
The VARIOstar K50 knee controller also
includes a data interface/switching
signals for controlling an extraction
system. To use this function, connect
your extraction system to the K50 knee
controller via socket 14.
Fig . 20

50 45
51
52
18 18
2.5 Spindle change is simple
Page
Unscrew the cap 52 from the motor and
release the cable by pulling off the hand-
piece connector 50.
Plug in a new motor cable 45 and secure
it with the cap 52. Use only an original
motor cable with a new cap 52.
The instructions for changing the spindle
(OrderN° 896-1003) are attached to the
replacement spindle.
2.4 Replacing the Motor Cable
45 Motor Cable
50 Handpiece Connector
51 Motor Cable Connector
52 Cap
Fig. 21

1919
Otherwise contact your distributor.
Malfunction Cause Remedial action
Handpiece does not
start.
The speed display on the
controller does not show
any display
The speed of the handpi-
ece does not increase
Check whether the controller
is switched on and the motor
speed display is lit.
Check whether the chuck of
the handpiece is closed (check
that the tool is firmly seated)
Check whether the handpiece
is plugged into the controller.
Check whether the foot pedal
is plugged into the controller.
Check whether the controller
is switched on (On/Off switch
11)
Check whether the controller
is connected to the mains
supply.
Check whether the fuse in the
controller (mains cable con-
nector) has blown.
The maximum speed of the
handpiece must be set with
the speed knob (T50).
The maximum speed of the
handpiece must be set with
the safety switch T2 (K50)
Unplug the mains cable 20
and plug it in again; switch
on the mains switch 110,
see 1.2.
Open and close the chuck
mechanism.
Plug in and secure the
handpiece cable (see 0.4 &
0.6). Plug in and secure the
foot pedal (see 0.6)
Unplug the power cable
and plug it in again. Switch
on the On/Off switch 11.
Replace the fuse
(see 2.4)
Adjust the setting with the
speed knob 24.
Adjust the safety switch T2
(see 1.1)
2.6 Troubleshooting
Page

3.
20 20
3.2 Scope of delivery VARIOstar K50:
Knee control unit VARIOstar K50 230V 804-3012
Knee control unit VARIOstar K50 115V 804-3011
Table mount 896-1022
Fixing knob 896-1023
Assembly diagram 896-1024
Power cord 896-1020
Operation Manual
Data
Page
3.1 Technical Data:
Dimensions: VARIOstar K50 VARIOstar T50
Control unit
Width 95mm 180mm
Height 250mm 140mm
Depth 310mm 200mm
Weight 5,6kg 7,1kg
Rated voltage AC 230V/115V AC 230V/115V
Rated frequency 50/60 Hz 50/60 Hz
Power consumption (max.) 270W 270W
VARIOstar Handpiece VARIOstar
Speed range 1.000- 50.000/min
Max. Torque max. 7,8Ncm
Protection class I
Length 162mm
Diameter 30mm
Weight 235g