Operating Instructions FZ2 VARIOmatic
Status 04/98 FZ2_9804E.DOC Page 1
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Gerätebau GmbH
FZ2 VARIOmatic
Operating Instructions
Zubler Gerätebau GmbH
Buchbrunnenweg 26, D-89081 Ulm
Tel. 0731-1452-0, Fax 0731-1452-13
FZ2 VARIOmatic
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Gerätebau GmbH, Buchbrunnenweg 26, D-89081 Ulm Jungingen, Tel.: ++49 731 1452-0 Fax: -13
EG- Conformity declaration
We, Zubler Gerätebau GmbH
Buchbrunnenweg 26
89081 Ulm Jungingen
declare, that the product Dust Vacuum - System
FZ 2 VARIOmatic
®
corresponds to the regulations of the following
directives in regard to protective requirements
89/336/EWG EMV-Directive
73/23/EWG Low-voltage Directive
93/68/EWG CE-Sign
89/392/EWG Directive machines
Any modification not specifically approved by us
voids the validity of this declaration.
Kurt Zubler
Managing Director
Dear customer !
We are happy that you have decided to purchase a Zubler vacuum system and we hope you enjoy working with this
instrument. The FZ2 VARIOmatic is especially quiet and long-lived because we use three-phase turbines without
carbon brushes. A powerful filter system with a large area, combined with an automatic air capacity control, allows very
economical operation with low energy consumption. It is equally suitable for daily professional use or jobs with high dirt
accumulations.
The constant developement of our technology is based on cooperative work with experienced dental technicians. Our main
target is to create a quieter and more comfortable vacuum technology. Performance and economy are always basic
requirements.
Note!
These operating instructions do not contain a description of installation. Its premise is that the vacuum system has already
been installed and connected in your laboratory by experienced personnel. This is only required initially. Since the
installation work can sometimes be very complex, and the customer can seldom do it himself, there is a separate set of
instructions which is available to the dental commercial companies. It is only given out when required.
Claims cannot be made because of the drawings and technical descriptions. We reserve the right to make changes and
improvements, with or without corrections to these instructions.
FZ2 VARIOmatic
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Table of contents Page
1. Table of contents
3
2. Accessories
4
3. Starting operation
5
Switching on
Start blocking
Switching off
4. Using the vacuum outlet
6
Maximum- Function
5. Maintenance
7
Emptying dirt container
Filter change
Exchanging a vacuum port opener
6. Adjustment of the vacuum system
11
Basic settings
Vacuum power
Cleaning interval
Dirt container - Check
Maximum-Lock release
Maximal operation for instrument
7. Adjustment of sensitivity
14
Basic settings
Exact Tuning
Window
Damping
Lag time
8. Functional faults
16
9. Technical data
20
Overview sheet of adjustments
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2. Accessories
Vacuum solutions are determined by many factors. The
vacuum machine is normally not responsible for air noises of
the vacuum system. All system parts must be optimally
matched with each other. The smallest air inlet noise,
effective use of the air capacity and the best possible dirt
acquisition, are as equally important as the quality
characteristics of the vacuum machine.
For hand nozzle work stations, we recommend only the use
of a modern vacuum system and the installation of noise
dampers. We offer the corresponding accessories in our
program.
R 1200 Vacuum funnel
N° 825/241
R 1000 Rectangular pipe
N° 570/065
R 1100 Noise damper for rectangular pipe
N° 825/261
R 1101 Round noise damper L = 270 mm
N° 825/282
R 1102 Round noise damper L = 350 mm
N°825/260
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Operating elements
1 Mains switch ON „I“ Off „0“
2 Button for Maximum
3 LED Maximum
4 LED Container
5 LED Service
3. Starting operation
Switching on the vacuum system
Turn on the mains switch (1) on the vacuum.
It is possible to leave the mains switch of the vacuum system
in the on position, and perform the switching via the central
voltage supply (laboratory main switch).
Mains switch (1) glows green.
After being switched on, the vacuum system first conducts a
self- test. One after another, all internally connected vacuum
paths are checked with maximum vacuum performance.
Then the filter cartridge is cleaned off.
This operation takes approx. 2 minutes.
The vacuum system is now operational ready. The
connected instruments receive mains voltage.
Start blockade (blinking LED Service (5)
The vacuum system does not start and waits, if:
1. the required pressure of min. 5 bar is not present at the
compressed air connection,
2. the Timer for controlling the dirt container has run out,
(see Chapter 5)
3. a vacuum position opener is not closed because an
instrument on an external vacuum position is switched on
or a manual switch is in the ON position (vacuum).
Switching off the vacuum system
The vacuum system can be switched off by the central
laboratory switch or the built-in mains switch.
Note:
Connected instruments and technical machines can remain
switched on and they will also be without power when the
vacuum system is switched off.
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4. Use of the vacuum outlet
The vacuum outlet has been foreseen in order to clean the
surrounding working area and the laboratory floor.
Any vacuum cleaner hose with a connecting piece of 40mm
outside diameter can be used. Special solutions, with longer
hose lengths of high quality, are available from our
accessories program.
The vacuum system switchs itself on as soon as the lid of
the vacuum outlet has been opened.
Maximum - Function
The Maximum - Function works only when the vacuum outlet
is being used. The control operation of the vacuum system
is switched off and a higher under-pressure is created
(vacuum cleaner - principle).
The Maximum - Function is activated with the push of a
button (2). LED Maximum (3) lights.
Pushing the button (2) again, deactivates the MaximumFunction.
Note:
The activated Maximum - Function (LED 3) does not have an
effect on the vacuum operation at the individual vacuum
stations ! As long as even one of the vacuum stations of the
work areas is active, the Maximum - Function remains
inactive for the vacuum outlet.
If the Maximum operation is to be allowed for the vacuum
stations of the work areas, the blocking function must be
released (see Part 6).
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5. Maintenance
Checking the dirt container
When the dirt container requires checking, the LED,
Container (4) blinks. Start will be blocked at the next
switching on of the vacuum system. ( LED Container (4) and
LED Service (5) blink at the same time. Vacuum system
does not start.)
Note
A check of the container is necessary after each sequence of
a Timer. The adjustment of various time intervals can be
read in Chapter 6, „Adjustments of the vacuum system.
Dirt container removal and replacement
1. leave the vacuum system switched on
2. take the front cover off
3. release the clamp strap
4. pull the container out and empty it
5. push the container in to the limit stop
6. push the clamp strap upwards (only until limit stop on the
handle !). The LED Container (4) goes out. The LED
Service (5) continues blinking
7. replace the front cover
8. turn the mains switch (1) off and then on again
9. wait for the operational readiness of the vacuum system
(approx. 2 min)
Emptying not necessary
If emptying is not necessary, perform the above without
steps 4 and 5. When the clamp strap is released, the Timer
is reset to 0 and the next check will be due after the new
cycle of the set time interval..
Lengthening the time interval should be carefully considered
since a check takes very little effort and can prevent an overfill.
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Filter change
The filter cartridge of the vacuum system is a long-term filter
which retains its filtering ability for several months or even
years depending on the amount of dirt accumulated.
We recommend to replace the protective flat-filter when
replacing the filter cartridge.
Attention !
Filter changing should only be performed by trained
personnel !
If declining vacuum power or other reasons raise the
suspicion that there is a filter problem, a telephone
consultation is necessary before loosening or removing
the filter.
Removing the filter cartridge
1. switch off the vacuum system
2. block the compressed air or remove the vacuum system
from the compressed air supply
3. take out the dirt container (as described in Part 5 „Check
dirt container“)
4. take the sheet metal cover out. Loosen 2 screws to do
this (see drawing)
5. remove air container transport protector
6. Take out the air drums by loosening the quick-release
coupling
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7. unscrew the grip screw below the filter cartridge while
firmly holding the filter cartridge.
8. pull the filter cartridge downwards while holding the
clamping strap upwards or unhinging it.
Replacing the filter cartridge
Attention must be paid that there is a central seating
when replacing the filter !
After replacement, turn the cartridge lightly on the
threaded rod in order to guarantee the correct seating.
Then tightly fasten the gripping screw.
Replacement is similar to removal except in the reverse
order (please see steps 1-8).
Replacing the protective flat-filter
The FZ2 is equipped with an additional flat-filter which is
protecting the motors from being polluted in case of a wrong
inserted or broken filter cartridge.
We recommend to replace this filter when replacing the filter
cartridge.
1. Remove the rubber plated cover by unscrewing the
screws to get acces to the flat-filter.
2. Remove the flat-filter by pulling it upwards.
3. Insert a new flat-filter and press the filter tight into the
frame.
4. Ensure that there is no gap or leak where dust could
bypass the filter.
5. Close the front cover again and tighten the screws.
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Exchanging a vacuum port opener
The vacuum stations of a vacuum system are opened and
closed with a pneumatically operated rubber membrane.
These are subject to a lot of stress. After a few 100,000
loading cycles, cracks can appear in even high quality rubber
materials. In this case, the vacuum station does not close
any more and it blows compressed air into the vacuum lines.
The vacuum port openers are plug-type components and are
found in the intake pipes on the back side of the instrument
(picture at left).
With additional vacuum stations and some special
installations, some of the valves can be found within the
vacuum lines to the work station. (picture at right).
1. switch off the vacuum system.
2. In order to determine which valve is defective, follow the
hose from defective work station to the vacuum system.
3. loosen vacuum hose (left picture)
4. loosen the white PA - compressed air hose by turning
back the nipple cap (right picture)
5. remove valve (lower picture)
6. replace with new valve
7. push the white PA - compressed air hose in until the limit
stop (you must overcome a light resistive pressure)
8. connect vacuum hose
9. switch on the vacuum system
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Adjustment of the FZ 2 VARIOmatic®:
Note:
All adjustments are only made once during the
commissioning of the vacuum system. Later adjustments
are only necessary if the connected instruments, application,
or amount of dirt accumulation changes.
Remove the rubber cover on the top of the instrument.
Use the hex keys delivered with the instrument.
2 screws on the underside have to be loosened.
6. Adjustment of the functions of the
vacuum system
Basic factory settings:
Potentiometer = Middle position 12 O´clock
25-30 l/s each vacuum position
Switch
1/2 OFF / ON = filter cleaning every 2 hours
3/4 OFF / ON = check container every 30 days
5 OFF not used
6 OFF = maximum RPM 300 Hz
7 OFF = Maximum only for front plug
8 OFF = 50 Hz (Europe)
Vacuum power
The vacuum power can be set in the range of approx. 20
to 40 liters per second with the trimming potentiometer to
the far left.
This changes the strength of the controlled vacuum in
the vacuum system.
All vacuum stations are affected the same.
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Cleaning intervals
The filter cartridge is cleaned with compressed air. The
frequency of the air bursts for cleaning can be set
according to the amount of dirt accumulation.
Select position of switches 1 and 2 from the chart.
Frequency of checking the dirt container
The dirt container is to be checked or emptied in regular
intervals. To protect the system, the vacuum is blocked
after a programmable Timer cycle has elapsed.
The blocking is released as soon as the clamping of the
dirt container has been released and replaced.
Time sequences can be set according to amount of dirt
accumulation. 1 day corresponds to 8 working hours.
Select position of switches 3 and 4 from the chart.
Blocking of the maximum vacuum power at
a work station.
In the standard adjustment, it is only possible to use the
maximum vacuum power of the vacuum system from the
front vacuum plug (see Chapter vacuum plug)
It is possibe to turn off this Blocking action.
When the maximum operation is turned on (LED
Maximum (3) lights), every vacuum position is furnished
with maximum vacuum power.
To release Blocking, place switch 7 in the ON position.
When the maximum operation is turned off, the vacuum
system functions as it normally does in controlled
operation. The Blocking has no influence.
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Maximum operation for instruments
If the vacuum power of the automatic control operation is
not adequate for instruments with higher dirt
accumulation, work can be performed with the
uncontrolled maximum operation. Requirement is that
the Block is released with switch 7 (see above) and the
maximum operation is turned on.
For a vacuum power of 50-60 l/s, switch 6 to ON
position.
Note:
Maximum operation means uncontrolled operation. If
several vacuum positions are operated at the same time,
the available vacuum power is divided.
A reduced Maximum with switch 6 means:
reduced Maximum = Maximum
Adjustment 60 Hz for theUSA
In Europe switch 8 must always be in the OFF position !
(50 Hz)
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7. Adjustment of sensitivity
It is easy to determine which working position is
connected to which vacuum position number:
1. Switch off all connected instruments.
2. Turn on the instrument to be adjusted. Run the hand
nozzle at a high RPM or under load.
LED under the dedicated switch group with
potentiometer lights.
Basic settings from factory:
Switch 1 ON (high sensitivity)
Switch 2-4 OFF
Pot 9:00 O´clock
This adjustment can be used for most technical
machines such as Schick C1-C3 , KaVo K9-K11.
Exact Tuning
1. Place the Pot to left full stop (Position 8:00 O´clock)
2. With technical machines, use the pre-selecter to set
the lowest RPM, e.g. 5000.
3. Operate knee or foot switch and keep depressed.
Turn on the function instrument without variable RPM
or power setting.
The LED should not light, or must go out after only
lighting shortly.
If the LED still lights at this Pot setting while the hand
nozzle is running, then switch 1, in the OFF position,
must be pushed upwards (lower sensitivity).
Turn the Pot slowly in a clockwise direction (+), until the
LED lights. Leave the Pot in this position.
Adaptation of the instruments on the other vacuum
positions should be performed in the same manner ( see
above).
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Importand basic rule :
Sensitivity not higher than necessary !
Otherwise, voltage line interferences or power
fluctuations at the working position could cause an
independent starting of the vacuum (ghost effect).
It should be checked to see if the sensitivity with the
same threshold value can be reduced with switch 2
(Window, see below).
Switch 1 divides the adjustment of the threshold
sensitivity in 2 areas.
This doubles the Pot - travel for fine adjustment.
OFF (up) = low sensitivity
ON (down) = high sensitivity
Window
With switch 2, on the 4-switch block of every vacuum
position, the width of the characteristic segment effective
for automatic recognition can be changed.
If the vacuum position only opens automatically with an
extremely high sensitivity setting, an attempt can be
made with the be switch position ON and reduction of
the sensitivity by turning the Pot back.
OFF (up) = Window narrow
ON (down) = Window wide
Damping
An attempt can be made to suppress short interference
pulses, which cause an independent release of the
vacuum, by changing switch 3 (position ON).
OFF (up) = lower damping
ON (down) = higher damping
Lag time
With some applications, such as sand blasting, it might
be useful to increase the lag time of the vacuum in order
to to vacuum the remaining dust in the chamber or
immediate area.
OFF (up) = lag time 3 seconds
ON (down) = lag time 8 seconds
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1
2
3
4
8. Functional faults
Vacuum does not function when the power has been
switched on. Service- LED (5) blinks.
Cause:
Start blocking (see Part 3)
Compressed air connection does not have the
necessary pressure of minimum 5 bar yet.
An externally connected instrument on the 5th or 6th
vacuum position is switched on.
Remedy:
Wait until the compressor has built up pressure or set
the laboratory pressure higher.
Control to see if externally connected instruments and
switches on vacuum positions 5 and 6 are switched off.
Vacuum does not function when the power has been
switched on. Container -LED (4) and Service -LED
(5) blink at the same time.
Cause :
the pre-set time for checking the dirt container has
elapsed (see Part 5 „Check of dirt container“).
Remedy:
Pull the clamp strap of the container down and then
push it back up again.
After manipulation of the clamping strap for the dirt
container, the Service -LED (5) still blinks and the
vaccum system does not work.
Remedy:
After manipulating the strap, the vacuum system must
be restarted with the mains switch (see Part 5 „Check of
dirt container“).
Instrument or technical machine does not operate
(no power)
Causes:
a) The vacuum system is not switched off.
b) The vacuum system has not finished its initialising
sequence.
c) The vacuum system is not ready (Fault or start
blocking)
Remedy:
Check the vacuum system, wait for complete initializing
sequence, corresponding to the LED display in the
operating instructions.
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6
7
8
Vacuum system does not start, no LEDs light, green
mains switch does not light.
Cause:
No mains voltage. Instrument or house circuit breaker
switched off.
Remedy:
Check circuit breaker on rear of Vacuum system and
house circuit breaker.
Vacuum system does not start or stops working,
connected instruments do not have power, the
Service -LED (5) is constantly lit (no blinking!)
Cause:
Automatic fuse Nr. 1 released or major fault on the
frequency converter, burned-out motor or electronics
fault.
Remedy:
Check automatic fuse Nr. 1, call Customer Service.
Vacuum system performs initialialization after being
switched on but then automatic fuse Nr. 2 releases
and possibly the corresponding house circuit
breaker also.
Cause:
Several instruments with very high starting power are
connected to the vacuum system, and all of these
instruments were in the switched on condition.
Remedy:
Turn off at least one of the connected instruments to the
vacuum system and do not turn it back on until the
initializing of the vacuum system has been completed.
Switch on the automatic fuse and start the vacuum
system again. Pay attention that not all instruments
connected to the vacuum system are left switched on
when work is completed and the system is turned off.
Vacuum system does not start automatically
Cause:
Threshold sensitivity is set too low for the connected
instrument.
Remedy:
Readjust the threshold sensitivity.
(see Part 7)
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10
11
Vacuum system starts automatically but stops itself
after a time although the instrument is still in use.
Cause:
Threshold sensitivity is set too low.
Remedy:
Slightly increase the threshold sensitivity.
(see Part 7)
Vacuum system switches itself on, runs constantly
or runs for a long time even after the motor of the
connected working instrument is standing still
Cause:
Threshold sensitivity set too high.
Remedy:
Reset the threshold sensitivity
(see Part 7)
Vacuum system turns itself on and off at various
working places. Vacuum positions open
simultaneouly when other instruments are turned on
in the laboratory (Ghost - Effect)
Cause:
a) several instruments with very little basic current,
motor current, separation, or the sensitivity is set too
high at several vacuum positions.
b) Current circuit of the on-site installation is
overloaded, or the vacuum system does not have the
specified, separately fused, 16 A - plug, and it is
connected together with other users on one line.
Remedy:
n Lower threshold sensitivity
n Place damping switch (3) to the ON position (see
Chapter on adjustments)
n Check on-site mains installation and improve
Note:
Thecontrol instrument of the Schick C3 can be equipped
with a data connection which is already installed at the
vacuum system. The instrument can then be operated
absolutely dependably and fault free, via switch
contacts, with the vacuum system.
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13
14
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Vacuum power is too low or too high
Remedy:
The vacuum power can be generally increased or
reduced (see Chapter on adjustments).
Without any changes being made, the vacuum
power is noticably weaker than in the beginning.
Vacuum power falls off with simultaneous opening
of 2 or 3 vacuum positions.
Cause:
Cleaning frequency is too low
Technical fault in the filter system
Remedy:
Never release the filter cartridge without consultation
with Zubler!
Force initialization, (including 3 filter cleanings), by
turning the vacuum system on and off.
If improvement occurs, shorten the cleaning interval (see
Part: adjustments).
Request Customer Service!
Vacuum system works at all 4 vacuum positions
simultaneously, even though only one connected
instrument is in use.
Cause:
Compressed air supply has failed
Remedy:
Check the compressed air supply of the vacuum system.
A constant air noise is heard at one vacuum position
as soon as the vacuum system is turned on via other
instruments and vacuum power is present at this
place.
Cause:
Rubber membrane of the vacuum position valve is
defective.
Remedy:
Request a new vacuum position valve. Check Chapter 8
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9. Technical data
4-Position Vacuum system FZ 2 VARIOmatic®
Number of vacuum inlets 4 (automatically opening)
Dimensions
Width:
Depth:
Height:
334 mm
600 mm
810 mm
Voltage 230V~ 50/60 Hz
Power 1900 W
Maximum total power 3000 W
Required connection value 16 A
Vacuum turbines 2 each, three phase, without collector
Max. total vacuum power approx. 100 l/s
Air capacity per vacuum position
controlled 18-40 l/s one adjustment for all positions
Average sound pressure level *
at 0.5m / 1m distance to instrument
1 Vacuum position at approx. 30 l/s
2 Vacuum positions at approx. 60 l/s
3 Vacuum positions at approx. 90 l/s
0,5m 1m
Lp (A) 53 dB 49 dB
Lp (A) 59 dB 55 dB
Lp (A) 61 dB 57 dB
Volume of the dirt container 12 l
Filter use category BIA C
effective filter area 2.3 m²
Required compressed air connection min. 5 bar
Weight 72 kg
10. Spare parts
Vacuum Port Opener
Main Filter Cartridge
Protective Flat Filter
Order No.
752/060
556/034
556/070
* all noise emission values are only for the vacuum system FZ 2 VARIOmatic®
Air inlet noises at the work place are dependent on vacuum systems and instruments and are not considered in the measurements.
Sound pressure levels are based on the acoustic power measurements according to ISO Standard 9614-2 (Accuracy class 2)
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