Lampert PUK D3 Operating Manual

Operating manual

PUK D3

OPERATING MANUAL (translation)
"PUK D3" with welding microscope "SM5"

Dear Customer,

This operating manual is intended to familiarise you with the commissioning process and operation of your PUK D3 as well
as the associated SM5 welding microscope. Please read the operating instructions carefully and follow the advice given
here diligently. Disruptions and operational faults will thus be avoided. Your personal safety, constant availability and long
service life can be assured by this.

THE COMMISSIONING OF THE DEVICE MUST ONLY BE UNDERTAKEN BY TRAINED SPECIALISTS AND ONLY
WITHIN THE SCOPE OF APPROPRIATE USE. THE MANUFACTURER ACCEPTS NO LIABILITY FOR DAMAGES
CAUSED THROUGH INAPPROPRIATE USE AND IMPROPER OPERATION. THE “GENERAL SAFETY
REQUIREMENTS” AND "PERSONAL BODY PROTECTION" CHAPTERS MUST BE READ BEFORE COMMISSIONING.

Please keep these operating instructions safe.

The equipment produced by “Lampert Werktechnik GmbH” fulfils the conformity requirements of the CE mark and is
constructed in accordance with the VDE guidelines.

The eye protection systems used on the "SM5" welding microscope are tested and certified by DIN-CERTCO (DIN
department for eye protection).

Only use original spare parts for maintenance and overhaul work. Our customer service department will naturally be happy
to help you.

THE DEVICE MUST ONLY BE OPENED OR MODIFIED BY AUTHORISED CUSTOMER SERVICE PERSONNEL,
OTHERWISE ALL GUARANTEES AND WARRANTIES ARE VOID.

LAMPERT WERKTECHNIK GMBH

November 2017

© Lampert Werktechnik GmbH 2

017 2

TABLE OF CONTENTS

1 WARNING AND INFORMATION SIGNS Pg. 2

2 FIELD OF APPLICATION Pg. 3

3 SAFETY REQUIREMENTS

3.1 General safety requirements Pg. 3

3.2 Personal body protection and hazards

3.3 Hazards of shielding gas cylinders Pg. 4

3.4 Risk of allergic reactions Pg. 4

4 SETUP AND INSTALLATION

4.1 Set-up of the device Pg. 4

4.2 Description of the rear of the device Pg. 5

4.3 Connection of eye protection and

LED illumination of the microscope SM5 Pg. 5

4.4 Connect shielding gas supply Pg. 5

4.5 Inserting the electrodes into the handpiece Pg. 6

4.6 Connect power supply Pg. 6

4.7 Configuration of the welding microscope Pg. 6

5 COMMISSIONING

5.1 Description of the front-side controls Pg. 7

5.2 Description of menu items Pg. 8

5.3 Switching on the device Pg. 9

5.4 Adjusting for the correct gas flow Pg. 9

5.5 Control level “settings” Pg. 9

6 SELECTION OF THE WELDING PARAMETERS

AND USER LEVELS Pg. 10

6.1 Selection of the welding parameters Pg. 10

6.2 Expert menu Pg. 12

6.3 Help Function Pg. 12

6.4 Programming Pg. 12

6.5 Loading saved programs Pg. 13

6.6 Fixation welding Pg. 13

6.7 Retention welding function Pg. 13

7 WELDING INSTRUCTIONS

7.1 Introduction to welding Pg. 13

7.2 Welding with the smoothing mode Pg. 14

7.3 Retention welding Pg. 14

7.4 Welding with the foot switch Pg. 14

7.4.1 Fixation welding Pg. 14

7.4.2 Retention welding with foot switch Pg. 15

7.5 Basics and tips Pg. 15

7.6 Sharpening the electrodes Pg. 15

8 CARE OF THE SYSTEM COMPONENTS

8.1 Care of the welding equipment Pg. 16

8.2 Care of the microscope Pg. 16

9 TECHNICAL DATA Pg. 17

9.1 Technical data welding device Pg. 17

9.2 Technical data microscope Pg. 17

9.3 Optical data microscope Pg. 17

9.4 Technical data LCD shutter Pg. 17

9.5 Type plate Pg. 18

9.6 Warning notices Pg. 19

10 TROUBLESHOOTING Pg. 19

10.1 Welding device Pg. 19

10.2 Microscope Pg. 20

11 SPARE PARTS LIST Pg. 21

12 DISPOSAL INFORMATION Pg. 21

13 EC-DECLARATION OF CONFORMITY Pg. 21

Wa

rning!

“Warning” identifies a potentially dangerous situation. If this is not avoided, the consequences can be death or
severe injuries.

Caution!

"Caution!" identifies a potentially hazardous situation. If this is not avoided, the consequences can be slight or
minor injuries as well as property damage.

Note!

“Note” identifies the product at risk from the hazard and possible damage to the equipment.

Important!

"Important!" designates user tips and other especially useful information. This is not a signal word for hazardous or
dangerous situations.

1. WARNING AND INFORMATION SIGNS

© Lampert Werktechnik GmbH 2

017 3

2. APPROPRIATE USE (FIELD OF APPLICATION)

• Outdoor operation is impermissible. Use this device

only in dry rooms!

• PUK D3: the application of spot welds to all customary

dental alloys as well as titanium for the manufacture of
new articles and for repairs on dental work.

WELDS INSIDE AND ON THE HUMAN BODY ARE PROHIBITED.

GENERALLY NO LIABILITY IS ACCEPTED FOR THE DURABILITY OF THE WELDING. WE RECOMMEND
THAT THE WELDING BE CHECKED IN EVERY CASE.

SM5: Observation and microscopic viewing of objects
through the ocular of the microscope and illumination of
the working area.

The SM5 unit may only be used for welding if it has been
properly connected to a PUK fine-welding device.

3. SAFETY INSTRUCTIONS

3.1 GENERAL SAFETY REQUIREMENTS

PERSONS WHO WEAR ACTIVE IMPLANTS (HEART PACEMAKERS) MUST MAINTAIN A SAFETY
DISTANCE OF 20 CM BETWEEN THE WELDING CURRENT CABLE / SOURCE OF THE WELDING
CURRENT AND THE IMPLANT

The opening of the device is only permitted when
undertaken by an electrician. Before opening

remove the mains cable and ensure that the
device is de-energised. Discharge any components in the
device that could hold electrical charge.

In case of doubt or uncertainty, always consult with a
specialist. Our customer support department is naturally
always available to assist you with their professional
trained personnel, appropriate tooling and equipment.
Always use the original cables and ensure that workpiece
clamps are properly attached.
Both the mains and welding currents can be a source of
danger.

The device must be isolated from the mains power when
undertaking any repair or maintenance work on the power
source. The power socket is to be clearly blocked when
undertaking any work on the system beyond minor
manipulations where it is necessary to leave the
workplace, even for brief periods.

The highest and thus the most dangerous voltage in the
welding circuit is the no-load voltage. The highest
permissible no-load voltages are recorded in the national
and international regulations in accordance with the type
of welding current, construction of the current source and
the extent of the electrical hazard to the workplace.
If it can be assumed that risk-free operation is no longer
possible, the unit must be put out of operation and
secured against being unintentionally restarted.

It can be assumed that risk-free operation is no longer
possible, if

• the equipment shows visible signs of damage,

• malfunctions occur,

• or the equipment is no longer working.

The PUK must, as standard, be operated with a mains
voltage of 115 V~.
Yellow-green wire = protective earth terminal (PE). The
other wires L1 and N are to be connected to the phase
and neutral conductors of the power plug.

The welding device is factory-adjusted to 115 V!

This means that as a result of the tolerance range of
+/- 10 %, the system can also be operated at 110 V~.
Devices configured to voltages other than 115 V will be
designated as such by means of a label.

THE DEVICE MUST ONLY BE OPENED BY
AUTHORISED SERVICE PERSONNEL!
IF THE DEVICE HAS BEEN CONFIGURED FOR A
CUSTOM VOLTAGE, THE TECHNICAL DATA ON THE
DEVICE SPECIFICATION PLATE APPLY! MAINS
PLUGS MUST CORRESPOND TO THE MAINS
VOLTAGE AND POWER CONSUMPTION OF THE
WELDING EQUIPMENT (see technical data!)
THE FUSING FOR THE MAINS SUPPLY MUST BE
MATCHED TO THE POWER CONSUMPTION OF THE
WELDING EQUIPMENT!
ONLY USE THE SUPPLIED MAINS CABLE!

THE PUK D3 IS A PIECE OF ELECTRICAL EQUIPMENT. NATIONAL REGULATIONS ON TESTING
INTERVALS AND THE SCOPE OF REQUIRED RECURRING SAFETY-RELATED TESTS MUST BE
OBSERVED.

© Lampert Werktechnik GmbH 2

017 4

3.2 HAZARDS AND PERSONAL BODY PROTECTION

Please also observe the relevant regulations of the respective country.

RISK OF INJURY FROM RADIATION OR HEAT:
Protective gloves must be worn when welding.
Uncovered areas of the skin must be protected from
the UV radiation generated during welding in order to
avoid skin damage.
Wear suitable dry protective clothing with no synthetic
fibers.
The workpiece and the electrode tip can become very
hot during welding – risk of burns.
Welding can cause sparks and spatters – risk of burns.

EYE PROTECTION WHEN WELDING:
Never look into the arc without eye protection; always
use a welding mask with certified protective glass.
In addition to light and thermal radiation, which can
cause dazzling and burning, the electric arc also emits
UV radiation. With insufficient protection this invisible
ultraviolet radiation causes very painful conjunctivitis,
which can first be noticed hours later, and can also
cause permanent eye damage.
The Lampert eye protection systems with its integrated
LCD protective welding screen offers reliable protection
against these risks and provides permanent protection
from UV / IR rays in both light and dark state. The
protective class of the filter is defined such that
dazzling by the arc is effectively prevented.
Persons who are nearby to the electric arc and
assistants must also be informed of the dangers and

equipped with the appropriate protection; if necessary
set up protective partition walls.

EYE PROTECTION WHEN OPERATING THE LED
ILLUMINATION:
Never look into the LED lamp or its reflections without
eye protection; use protective shield or safety glasses
with suitable protective glass.

SMOKES AND GASES:
When welding, especially in small spaces, ensure that
there is an adequate fresh air supply or use an external
extractor fan, as smoke and hazardous gases occur.

EXPLOSION HAZARD – DANGER WHEN
WELDING ON CONTAINERS:
It is not permitted to carry out welding on containers
that have been used for storing gases, propellants,
mineral oils or similar, even if they have been empty for
a long time, as there is a risk of explosions caused by
residues.
Particular regulations apply to fire and explosion
endangered spaces.

OTHER DANGERS:
The electrode tip installed in the handpiece means a
risk of injury (stabbing and scratching of e.g. hand, face
and eyes).

3.

3 HAZARDS OF SHIELDING GAS CYLINDERS

Observe all applicable safety measures when
ha

ndling gas cylinders as well as the safety
regulations for handling gases. Gas tanks must
especially be secured against falling over / falling down

and heat (max. 50°C); it is particularly important to
ensure they are not subjected to sunlight for extended
periods and that they are protected from severe frost.

3.4 RISK OF ALLERGIC REACTIONS:

Please note that the device's raw materials that
could come into contact with the operator's skin

may cause allergic reactions in susceptible people.

4.

SETUP AND INSTALLATION

4.1 SET-UP OF THE DEVICE

The system is to be set up so that cooling air is able to
reach all of the surfaces of the housing without
hindrance. The device may not be covered! The device
is to be placed on a non-combustible surface! The
device should be set up on a base that is solid, level,

and insulated - ideally on a suitable workbench. Fasten
the two hand supports for the microscope with 2 Allen
screws using the supplied Allen key by inserting the
screws into the designated holes from underneath the
microscope baseplate and into the hand supports.

© Lampert Werktechnik GmbH 2

017 5

4.2 DESCRIPTION OF THE REAR OF THE DEVICE

(Fig. 2)

(1) FUSEBOX ("Fuse")

(2) MASTER MAINS SWITCH as well as

AC POWER SOCKET

(for connecting the mains cable)

(3) CONNECTION SOCKET FOR EYE PROTECTION SYSTEM

AND LED MICROSCOPE ILLUMINATION

(4) CONNECTION SOCKET FOR FOOT SWITCH

(5) TYPE PLATE

(6) SERIAL NUMBER

(7) PROTECTIVE GAS CONNECTION ("Argon Gas")

For 6.0 mm diameter pressure hose (max. 4,0 bar / 58 psi)

(8) APPROVED MAINS VOLTAGE FOR THIS DEVICE

4.3 CONNECT EYE PROTECTION AND LED ILLUMINATION OF THE WELDING MICROSCOPE TO THE PUK:

The circular connector for the eye protection system and
the LED illumination should be inserted into the
connecting socket (3) on the rear of the PUK welding

device (marked in red and yellow colour) and is to be
tightened in place with the coupling nut (hand tight)..

WARNING!

ONLY SUITABLE ORIGINAL EYE PROTECTION SYSTEMS FROM LAMPERT MAY BE CONNECTED TO THE
WELDING SYSTEM! OTHER EYE PROTECTION SYSTEMS ARE NOT APPROVED AND CAN LEAD TO
PERMANENT HEALTH DAMAGE OR DAMAGE TO THE WELDING DEVICE.

ALWAYS OBSERVE THE OPERATING INSTRUCTIONS FOR THE CONNECTED EYE PROTECTION SYSTEM

4.4 CONNECT SHIELDING GAS SUPPLY:

Fasten the suitable flow regulator with the corresponding
tool to the shielding gas tank. ATTENTION: In doing so,
always observe the enclosed special operating
instructions provided. (Where possible, use argon with

min. 99.9 % purity, e.g. "Argon 4.6"). The pressure hose is
to be fastened by hand with the help of the quick coupling
adapter to the flow regulator as well as the shielding gas
connector (7) on the rear of the device.

CHECK REGULARLY THAT ALL OF THE HOSE CONNECTIONS AND GAS HOSES ARE IN OPTIMAL
C

ONDITION, ARE PROPERLY FASTENED AND ARE AIRTIGHT!

1

3

5

4

2

8

7

6

© Lampert Werktechnik GmbH 2

017 6

4.5 INSERTING THE ELECTRODES INTO THE WELDING HANDPIECE:

PLEASE ALWAYS CHECK THAT THE MACHINE IS SWITCHED OFF, PRIOR TO EXCHANGING THE
ELECTRODES. THIS PREVENTS UNCONTROLLED TRIGGERING OF THE WELDING PROCESS.

(Fig. 3)

(Fig. 4)

(Fig. 5)

Lightly rotate the nozzle (10) back and forth and in doing
so, pull it off of the handpiece (13). It is only pushed-on, not
screwed in place.

Release the threaded electrode connection (12), insert a
well sharpened tungsten electrode (11) and tighten up
(hand-tight – do not use a tool to tighten).

The correct length for the electrode can easily be checked
and corrected if necessary by means of the milled marks
on the handpiece clamping arm (Fig. 4).

Now replace the nozzle.

The electrode must protrude approx. 4 - 6mm out of the
nozzle (Fig. 5).

ONLY USE THORIUM OXIDE FREE ORIGINAL ELECTRODES

Subsequently insert the connector of the handpiece as
straight as possible into the socket (23) on the front of
the PUK and fasten in place by tightening the coupling

nut hand-tight in a clockwise direction. Insert the
connecting cable used into the socket (24) on the front
side of the housing.

4.6

CONNECT POWER SUPPLY:

Insert the power cable with the mains connector into the
corresponding socket (2) on the rear of the housing and

insert the mains plug into a suitable socket with the correct
mains voltage.

CAUTION!

AS SOON AS THE MASTER MAINS SWITCH ON YOUR
PUK IS SWITCHED ON, THE VOLTAGE IS APPLIED TO
THE CONNECTED CROCODILE CLIPS OR CABLES. IT
IS TO BE ENSURED THAT THESE PARTS ARE NOT
ALLOWED TO COME INTO CONTACT WITH

ELECTRICALLY CONDUCTIVE OR EARTHED PARTS,
SUCH AS THE HOUSING, ETC. IN DOING SO, THERE
IS NO RISK FOR THE OPERATOR, WITH THE
EXCEPTION OF POSSIBLE CIRCUMSTANCES
ARISING FROM OPERATING ERROR.

4.7 CONFIGURATION THE WELDING MICROSCOPE:

ESSENTIAL PRIOR TO THE INITIAL WELDING OPERATION: PRECISE CONFIGURATION OF THE
MICROSCOPE OPTICS

FIRST STEPS

Align the handpiece holder so that you are able to
comfortably introduce a workpiece with your hands to the
tip of the handpiece mounted in the supporting arm. It
should be possible to comfortably place both hands and
palms on the baseplate hand supports. You also have the
option of changing the angle of inclination for the
microscope. In order to do so, release the locking screw

(14) on the stand, angle the
microscope to the desired position
and re-fasten the screw. A metal
pin extends from the stand to
support the microscope on your
working surface.

© Lampert Werktechnik GmbH 2

017 7

ADJUSTING THE INTEROCULAR DISTANCE

Look through the two oculars (17) and move the ocular
tubes (15) inwards or outwards by holding the prism
housing (18) still and moving them in or out. The
interocular distance is correct if the range of vision as

viewed through the two oculars is complete and is united
into a single image. The interocular distance should be
individually set for each user.

FOCUSING

Mount the welding handpiece
with clamped electrode into
the supporting arm. Rotate the
focusing knob (20) to a
medium focus range. Adjust
the mounting height of the
microscope head: Hold the
microscope head (19) with one

hand, without touching one of the lenses, and use the

other hand to release the screw on the head bracket. The
head can now be moved. Look through the oculars and
move the microscope head up or down until the object
appears focused. The correct distance between the
handpiece holder and the microscope head amounts to
approx. 6 cm on the stand rod. Now re-tighten the
adjusting screw on the head bracket once more.
Subsequently use the focusing knob (20) to focus the
image.

DIOPTRE ADJUSTMENT

The sleeve for adjusting the dioptre (16) is fitted to the left­hand ocular (17). In the normal position, the lower part of
the tube is aligned to the marking on the ocular tube. In
the event of differing vision in both eyes: Open the right
eye only, look into the right-hand ocular (15) and adjust

the focus using the focusing knob (20). Now look through
the left-hand ocular with your left eye and adjust the focus
by turning the dioptre control (16) on the left tube (17) until
the image appears focused.

5.

COMMISSIONING

5.1 DESCRIPTION OF THE FRONT-SIDE CONTROLS

(Fig. 1)

(21) TOUCHSCREEN-DISPLAY with slide function

(22) CONNECTION SOCKET FOR HANDPIECE (-)

(23) SOCKET (-)

For connecting the blue contact terminal for fixation welding

(24) SOCKET (+)

For connecting contact elements such as contact terminals and

clamps.

(25) ROTARY CONTROLLER
Select the welding power/time or switch to the next user level

• Pressing the rotary controller for short time (< 1

second) switches from the power (POWER) parameter

to the pulse duration (TIME) parameter.

(It jumps back to power automatically after 1 second)

• Turning the controller to the left or the right changes

the selected parameter.

• Pressing the controller for longer time (> 1 second)

switches to the next user level, see chapter 5.2.

21

25

23

24 22