Operating Instructions

Chapter 2
Sonotrode Assembly

2 Sonotrode Assembly Page
2.1 Safety........................................................... 3
2.1.1 Safety Information for Maintenance and
Setup............................................................. 3
2.1.2 Safe Operation.............................................. 3
2.1.3 Intended Use................................................. 3
2.1.4 Information Provided by the Manufacturer for
the Operator.................................................. 4
2.1.5 Area of Application for the Instructions.......... 4
2.1.6 Operating Personnel Qualifications............... 4
2.1.7 Supplements................................................. 4
2.1.8 About the Warranty Conditions..................... 4
2.2 Function....................................................... 5
2.2.1 Basic Principle............................................... 5
2.2.2 Oscillation Form and Amplitude Progress..... 6
2.3 Converter..................................................... 7
2.3.1 Design and Function..................................... 7
2.3.2 Converter Cooling, Air Treatment and
Functional Elements...................................... 7
2.3.3 Exchanging Converters................................. 8
2.4 Booster......................................................... 9
2.4.1 Design and Function..................................... 9
2.4.2 Technical Data and Equipment..................... 9
2.4.3 Exchanging Boosters.................................. 10
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Chapter 2 / Sonotrode Assembly
Table of Contents
Page
2.5 Sonotrode.................................................. 11
2.5.1 Design and Function................................... 11
2.5.2 Sonotrode Identification Label..................... 12
2.5.3 Exchanging Sonotrode................................ 13
2.6 Tool Holder and Sonotrode Stack............ 14
2.6.1 Design and Function................................... 14
2.6.2 Example: Mounting a 20 kHz Sonotrode
Stack in the Tool Holder.............................. 15
2.6.3 Other Mounting Examples for Sonotrode
Stack with Sonotrode Mounting.................. 15
2.7 Sonotrode Stack, Special Applications... 16
2.7.1 Rotating Systems........................................ 16
2.8 Technical Data........................................... 17
2.9 Troubleshooting ....................................... 19
2.9.1 Excessive Noise.......................................... 19
2.9.2 Cracks in the Sonotrode . ........................... 19
2.9.3 Defective Converter.................................... 20
2.9.4 Excessive Heat on the Contact Surfaces.... 20
2.9.5 Insufficient Electrical Insulation of the Tool
Holder.......................................................... 21
Page 

2.1 Safety
2.1.1 Safety Information for
Maintenance and Setup
• Do not disable the safety features under
any circumstances.
• Always switch off the generator before
changing the sonotrode stack (high volt-
age danger).
• Before removing the covering, turn off
the main switch (high voltage danger).
• Do not remove the converter housing
under any circumstances (high voltage
danger).
• Even minimal mechanical alterations to
the sonotrode can have serious effects
on the vibration behaviour and lead to a
considerably shortened service life.
• Use only original Herrmann sonotrodes.
Consult Herrmann Ultraschalltechnik be-
fore performing any repairs or mechani-
cal alterations.
• Use only original Herrmann adapter bolts
bolts.
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Chapter 2 / Sonotrode Assembly
Safety
2.1.2 Safe Operation
• Prevent the sonotrode from coming into
contact with metal parts during welding
operation.
• Contact between any kind of object and
the sonotrode stack during the welding
cycles other than the welding surface is
prohibited. (e.g., contract with the hold-
down plunger).
• Do not touch the sonotrode during welding
operation (burn danger).
• Contacting the sonotrode without the
material to be welded (e.g., contract with
the bearing surface) can damage the so-
notrode, the converter and/or the genera-
tor.
• Penetration of moisture or fluids can lead
to damage to the converter.
2.1.3 Intended Use
The sonotrode stack is only used for the ultrasonic
welding of thermoplastics.
Other applications, particularly controlling compo-
nents for welding other materials, do not comply with
the intended use and may lead to dangerous situa-
tions.
Proper use includes observation of the information in
the operating instructions and adherence to the main-
tenance and service guidelines.
The sonotrode stack may only be used when it is in
a fully operational condition under observation of the
safety information and potential dangers associated
with the device.
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 Chapter 2 / Sonotrode Assembly
Safety

2.1.4 Information Provided by 2.1.7 Supplements

the Manufacturer for the These operating instructions can be supplemented by
Operator special instructions and instructions on use from the
manufacturer. Please read and follow these additional
instructions carefully.
The operator is responsible
• for correct and intended use of the sonotrode
stack by trained staff
• for providing the operating staff with technical
training and for ensuring that they heed the oper- 2.1.8 About the Warranty
ating instructions
Conditions
• for observing the safety information and safety
guidelines As a rule warranty claims can only be lodged if the
warranty conditions have been observed. The content
• for health and safety and accident prevention ar- of these operating instructions must be followed in
rangements and for ensuring the wearing safety particular.
clothing, especially for measuring noise and
vibrations at the workplace
• for the safety equipment functioning correctly
The operating instructions have been written by the
manufacturer according to knowledge and experience in
the design, manufacture and operation of the sonotrode
stack.

2.1.5 Area of Application for

the Instructions
These chapters contain the basic presentation of the
sonotrode stack as well as the basic operating and
safety information for working with the sonotrode
stack. The instructions do not include general infor-
mation on special ultrasonic processes working with
ultrasonic welding systems.

2.1.6 Operating Personnel

Qualifications
In order to work with the sonotrode stack, the operators
must:
• be instructed in how the welding machine works,
• be familiar with the procedures for assembling
and handling the sonotrode stack,
• be familiar with and observe the applicable safety
stipulations for operating the machine,
• wear the necessary protective equipment and
• be informed of the dangers of operating the ma-
chine in conjunction with the generator.

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Function

2.2 Function
2.2.1 Basic Principle

Sonotrode stack Automobile

Ultrasonic converter Motor Energy conversion

(transducer)

Transformation of the
Amplitude transformer Drive shaft
transmission
booster

Sonotrode Wheels Energy transmitter

Delivery of Energy Delivery of Energy

as mechanical vibration as torque

The ultrasonic sonotrode assembly operates on the principle of the natural resonance of objects. These forms of
motion can be systematically controlled. When the natural resonance of an object is excited by the application of
appropriate impulses, vibration occurs (for example, such as a guitar string when plucked).
The mechanical vibrations are transferred under pressure (welding force) to the pieces to be seamed. This
creates molecular friction in the material structure and interface friction which generates the heat necessary for
melting.
The local temperature (seam zone) causes an increase of the dampening coefficient which in turn causes the
plastic to soften. This results in a self-accelerating reaction, produced by the continual increase of the dampen-
ing factor and a correlative additional increase in temperature.

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Function

2.2.2 Oscillation Form and Amplitude Progress

Amplitude curve
The mechanical resonance unit consists for
example of:
1
1. Ultrasonic converter (transducer)

2. Booster (amplitude transformer)

2

3. Sonotrode

The three individual components are connected by special threaded studs (referred to as coupling or sonotrode
studs) and together form the sonotrode assembly. The unit is designed to produce a suitable resonating fre-
quency at 20 kHz. The unit is driven by the converter acting as the pulse source and generates a sine wave with
a longitudinal oscillation form. The resulting amplitude cycle is illustrated in the diagram above.

Push-
Push Rest-
Rest Pull-phase
Pull phase
The peak to peak amplitude is the total path
that the individual points of the sonotrode
stack travel between push and pull phases.

The amplitude is the length travelled between

the resting position and the push or pull Amplitude
phases.

Peak to peak

The amplitude at the face of the sonotrode (welding surface) influences the welding behavior and for this reason
must be exactly adjusted for the welding task involved. It is therefore of special importance and must be con-
trolled by the converter, the booster and the sonotrode design.
As the mechanical stress on the sonotrode stack is immediately effected by the amplitude and therefore has
a direct influence on the operational life, it is especially important to make sure that the amplitude is never set
beyond what is necessary.

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Converter

2.3 Converter Example of a Converter 20 kHz

2.3.1 Design and Function HF connector

The ultrasonic converter has the task of transforming

electrical energy into mechanical energy. This is ac-
Air connector for
complished with the help of piezoceramic crystals in its
interior. These piezoceramic crystals have an artificially converter cooling
polarity and react to applied current by changing their (optional)
mechanical dimension.
Through the application of high frequency alternating
current to the converter, a wave length alteration occurs
in correlation to the current and frequency. When the al-
ternating current reaches the range of 20 kHz or 35 kHz, Rating plate with
the converter acts as an pulse generator and is able to serial number
excite the natural resonance of the sonotrode stack.

Converter housing

Titanium converter
neck, max. temp. 40 °C

Coupling surface
to booster or sonotrode

2.3.2 Converter Cooling, Air Treatment and

Functional Elements
Heat is produced in the converter during the conver- The cooling efficiency should be checked after ap-
sion of electrical energy into mechanical vibrations. It proximately 30 minutes. The temperature on the
is therefore necessary to cool the converter in continu- converter neck should not exceed 40 ºC. If the tem-
ous operation to avoid excessive thermal stress. perature exceeds this level nevertheless the pressure
Appropriate cooling requires a supply pressure of ap- on the compressed air choke needs to be increased.
prox. 5 bar. The compressed air quality must comply In environments where the temperature varies, the
with ISO 8573-1 class 2 before it is further improved converter temperature should be checked from time to
by the functional elements described in the following. time and the cooling suitably adjusted.
Before beginning operation of the converter, it is abso- Cooling is essential when the activation periods of
lutely necessary to set the amount of cooling air. To do generators reach certain time limits. The cooling must
this choke valves are used to set a minimum pressure follow the manufacturer‘s instructions. Always note
of 0.8 bar that is measured with a pressure gauge. the "Technical data" chapter in these instructions.
The pressure gauge must be attached on a T-connec-
tor directly at the converter cooling connector. This
setting compensates for the varying lengths of hoses
to the converter. A highly pliable pneumatic hose (∅ Generator Cooling is required
6 mm) must be used for the hose connections from output Frequency as of an activation
the distributor to the individual converters. The length Watts kHz period (ED) of
of the hose here should be as short as possible. Pay < 1000 35 25%
careful attention not to kink the hose when laying it!
1700 30 25%
2000 20 25%
4000 20 15%
5000 20 10%

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Converter

2.3.3 Exchanging Converters

Example (b), so-
Example (a), notrode stack with
Exchanging:
sonotrode stack sonotrode holder
1. remove HF connector conventional
2. disconnect the air supply
3. remove the air hoses and then
4. remove the sonotrode stack from the tool holder, 1
5. secure the sonotrode (4) in a vic.

Caution! • Damage incurred during assembly/disassembly 2

may result in malfunctions!
• Use protective jaws!
• Never clamp the sonotrode stack on the converter
housing, but on the sonotrode (4)!
6. Sonotrode stack (a) and (b): detach the converter (1) from the
booster (3) with a useful tool (hook spanner or open-end-span- 3
ner) by turning the hex joint (2) anticlockwise, hold up against
booster.
7. Assembly is performed as described above but in reverse 4
order, please read the section below, ‚Special Notes‘.

Special Notes
• All of the contact surfaces and threads must be completely
clean, dry, undamaged and absolutely free from oil and
grease!
• Use only original Herrmann adapter bolts.
• To fit the components, screw the appropriate adapter bolts
into the threaded hole by hand until the stop is reached. This 1 Converter
ensures that roughly the same number of thread turns are
2 Hex joint
engaged in both components.
3 Booster
• The required torque for the converter-booster and the booster-
sonotrode connection is: 4 Sonotrode

for 20 kHz: 100 Nm

for 30 kHz: 70 Nm
for 35 kHz: 40 Nm

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Booster

2.4 Booster
Example (a), booster with flange
(a) with flange
(b) without flange
Coupling surface
to Converter
2.4.1 Design and Function
The booster (a), or ampli for short, consists of a tita-
nium carrier and a retaining ring, on which the entire
sonotrode stack in the welding machine‘s actuator
unit is mounted. Bore for hook
spanner
The booster (b) is a rotationally symmetric body
made of extremely strong titanium alloy.
The booster’s task is to transform the resonance am-
plitude emitted from the converter to the size required
by the sonotrode and thereby deliver the mechani-
cal oscillation energy created in the converter to the Flange
sonotrode.
The converter‘s oscillation amplitude can be increased
or decreased by changing the ampli which in turn
changes the amplitude supplied to the sonotrode.
Booster transfor-
mation value

Coupling surface
to sonotrode

2.4.2 Technical Data and Example (b), booster without flange

Equipment Coupling surface

to Converter
Available in titanium with
• booster ratio for (a) booster with flange
1 : 0,5 to 1 : 3 for 20 kHz
1 : 1 to 1 : 2,5 for 30 kHz
1 : 0,4 to 1 : 2,5 for 35 kHz

• booster ratio for (b) booster without flange

1 : 1 to 20, 30, 35 kHz
1 : 1,5 to 20, 30, 35 kHz
1 : 2,0 to 20, 30, 35 kHz
1 : 2,5 to 20, 30, 35 kHz
Bore for hook
(subject to technical change) spanner

Coupling surface
to sonotrode

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Booster

2.4.3 Exchanging Boosters

Exchanging:

1. remove HF connector
2. disconnect the air supply
3. remove the air hoses and then Example (b), booster
Example (a), booster without flange
4. remove the sonotrode stack from the tool holder,
with flange
5. secure the sonotrode (4) in a vic.

Caution! • Damage incurred during assembly/disassembly

may result in malfunctions!
• Use protective jaws!
• Never clamp the sonotrode stack on the 1
converter housing, but on the sonotrode (4)!
6. Booster (a) and (b): detach the converter (1) from the booster 2
(3) with a useful tool (a hook spanner or an open-end-span-
ner) by turning the hex joint (2) anticlockwise, hold up against
booster.
7. Booster (a) and (b): detach the booster (3) from the sonotrode 3
(4) with a useful tool (a hook spanner or an open-end-span-
ner) by turning the hex joint (2) anticlockwise.
8. Assembly is performed as described above but in reverse
order, please read the section below, ‘Special Notes’.
• For fitting a booster on the sonotrode, also refer to “Exchang-
ing Sonotrode”.

Special Notes
• All of the contact surfaces and threads must be completely 4
clean, dry, undamaged and absolutely free from oil and grease!
• Use only original Herrmann sonotrode studs.
• To fit the components, screw the appropriate adapter bolts into
the threaded hole by hand until the stop is reached. This ensures 1 Converter
that roughly the same number of thread turns are engaged in 2 Hex joint
both components.
3 Booster
• The required torque for the converter-booster and the booster-
4 Sonotrode
sonotrode-connection is:
for 20 kHz: 100 Nm
for 30 kHz: 70 Nm
for 35 kHz: 40 Nm

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Sonotrode

2.5 Sonotrode Example (a), without integrated holder

2.5.1 Design and Function Coupling surface to Booster

a) without integrated holder

Adapter bolt
The part of the welding device referred to as the ”so-
notrode” has the following functions:
• Transmission of the resonance energy
• Transmission of the pressure
• Transformation of the amplitude
Sonotrodes are available in various lengths. The so-
notrode is made from high-strength titanium alloys,
aluminum alloys or a special steel that demonstrates
excellent acoustical properties.
All Sonotrodes were specially developed for applications
in the nonwovens field and optimised with the help of
Bore for
the finite elements method (FEM).
hook spanner res-
pektive hex joint

Caution! • The manufacture of sonotrodes

is a task requiring a great deal of
special knowledge and insight into
details. Welding surface
• The use of low-quality sonotrodes or
sonotrodes made of unsuitable mate-
rials can destroy the sonotrode stack
or cause considerable damage to the
generator.

b) with integrated holder: Example (b), with integrated holder

Special sonotrode designs are available with integrat-
ed mountings; these allow the sonotrode stack to be Coupling surface to Booster
mounted in a bracket with the sonotrode.

Integrated so-
notrode mounting
sonotrode studs

Welding surface

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Sonotrode

2.5.2 Sonotrode Identification Label

The sonotrode is labelled with some information that Example of a sonotrode identification label:
you should be careful to note.
Every sonotrode has a unique serial number (1) (e.g., XX.XXX/X
WH 10.1 23/1). This number is used for reordering or 1
inquiries. Transf:
WH
2 1:1,4
Transf: (2) indicates the gain factor of the sonotrode.
Using this value the output amplitude of the sonotrode Ampli. max:
can be calculated by multiplying the sonotrode and
booster gain with the output amplitude of the con- 3 1:2,5
verter.
Weight: 1.00 kg
Ampli. max. (3) refers to the maximum allowed gain
ration of booster. To avoid damage to the sonotrode 4 Type XX kHz
stack this should never be exceeded under any cir- X
cumstances. 5
R = 130
The type XX (4) indicates the oscillation frequency 20,
30 resp. 35 kHz of the present sonotrode. 6

"X" (5) indicates the code for coating and thickness.
If the sonotrode welding surface has a polished ra-
dius (6), this is also marked.
1 Serial number
2 Gain factor of the sonotrode
3 Maximum allowed gain ratio of booster
4 Oscillation frequency
5 Code for coating and thickness
6 If present: Radius on the sonotrode weld-
ing surface

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Sonotrode

2.5.3 Exchanging Sonotrode

Exchanging: (a) sonotrode stack (b) sonotrode stack with

conventional sonotrode holder
1. remove HF connector
2. disconnect the air supply
3. remove the air hoses and then
4. remove the sonotrode stack from the tool holder,
5. secure the sonotrode (4) in a vic.
1

Caution! • Damage incurred during assembly/disassembly 2

may result in malfunctions!
• Use protective jaws!
• Never clamp the sonotrode stack on the 3
converter housing, but on the sonotrode (4)!
6. Sonotrode stack (a) and (b): detach the booster (3) from the
sonotrode (4) with a useful tool (hook spanner or open-end-
spanner) anticlockwise, but do not use hex joint (2).
7. Assembly is performed as described above but in reverse
order, please read the section below, ‘Special Notes’.
• For fitting the sonotrode, also refer to “Exchanging Boosters”. 4

Special Notes
• All of the contact surfaces and threads must be completely
clean, dry, undamaged and absolutely free from oil and grease!
• Use only original Herrmann sonotrode studs.
• To fit the components, screw the appropriate adapter bolts into
the threaded hole by hand until the stop is reached. This ensures 1 Converter
that roughly the same number of thread turns are engaged in 2 Hex joint
both components. 3 Booster
• The required torque for the converter-booster and the booster- 4 Sonotrode
sonotrode-connection is:
bei 20 kHz: 100 Nm
bei 30 kHz: 70 Nm
bei 35 kHz: 40 Nm

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 Chapter 2 / Sonotrode Assembly
Tool Holder

2.6 Tool Holder and Sonotrode Stack

2.6.1 Design and Function
The sonotrode stack (1) consists of the converter, booster and sonotrode. The sonotrode
stack is supported at the sonotrode and locked into position on the CS-holder (3) using
the support plate (2) .
The tool holder is held to the mounting plate with 4 mounting bolts (4).

The tool holder has the following functions:

• Hold the sonotrode stack.
• Bear the vertical and horizontal forces during the welding process.
• Position of the sonotrode stack in the actuator unit.

The tool holder is electrically insulated from the rest of the sonotrode stack to enable it to
regulate the gap with the aid of a sensor.

1 Sonotrode stack
2 2 Support plate
3 CS-holder
4 Mounting bolts

Example:Tool holder with 20 kHz sonotrode stack

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Tool Holder

2.6.2 Example: Mounting a 20 kHz Sonotrode

Stack in the Tool Holder
9 1 2
3
1. Insert the assembled sonotrode stack (converter, 4
booster and sonotrode) from the front of the tool
holder (2) until the integrated sonotrode support 5
studs (6) come in contact.
2. Set the clamp strips (3)(7) into place and lightly
tighten all 10 bolts M8 x 30 (4)(8) with washers.
3. Center sonotrode (5) in the tool holder (2) (± 0.2
mm).
4. Press the integrated sonotrode support studs (6)
6
down on the lower clamp strip (7).
5. Tighten all of the M8 x 30 bolts (4)(8) on the lower 7
and upper clamp strips with about 20 Nm torque.
6. Tighten both of the M6 x 100 (1) bolts with 8 Nm
1 M6 x 100 bolts 8
torque.
(These bolts are not on tool holders with welding 2 Tool holder
lengths less than 100 mm.)
7. Slide supporting plate over converter from the rear 3 Clamp strip
and fasten in place. 4 M8 x 30 bolts
5 Sonotrode
Disassembly is performed in reverse order. 6 Sonotrode support stud
7 Clamp strip
8 M8 x 30 bolts
9 Bolts for mounting tool holder on the
actuator unit (20 Nm torque required)

2.6.3 Other Mounting Examples for Sonotrode Stack with

Sonotrode Mounting
“Single” bracket example
(without booster) “Twin” bracket example

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Sonderanwendungen

2.7 Sonotrode Stack, Special Applications

2.7.1 Rotating Systems

Sonotrode stacks are also available in

rotating system versions.

Please note! Rotating systems may only be

fitted, removed and maintained by Herrmann
service staff, otherwise the warranty ceases to
apply.

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Technical Data

2.8 Technical Data

Basic converter Operating Max. power Amplitude2

types frequency Watts µm
kHz
KHS 20 XXX 20 40001 12,0
KHS 30 XXX 30 1700 7,5
KHS 35 XXX 35 1000 6,5
CCS 20 XXX 20 4000 12,5
CCS 30 XXX 30 1200 5,3
CCS 35 XXX 35 600 4,5

XXX = Details depend on housing shape, type of protection, cooling, HF connection

1
= The maximum possible is 5000 watts when using an appropriate generator
2
= Nominal amplitude values which may vary when using different generator types and amplitude settings

Features:
• Efficiency η ≥ 98%

• Titanium converters guarantee a long service life and the transfer of large amplitudes

• Converter housing protection IP 50, alternatively IP 65 / 66

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Technical Data

Examples of converter cooling

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Troubleshooting

2.9 Troubleshooting
2.9.1 Excessive Noise
Possible Causes
• The sonotrode, the booster or the converter were not assembled properly.
• The booster bolt is defective.
• Dirty contact surface.
• Crack in the sonotrode.
• The sonotrode support stud is loose (only for CS-holder).
• Idling rate of the sonotrode stack is too high (see Generator chapter section "Testing the Idling rate").

Solutions
• Tighten the sonotrode, booster and converter according to the instructions (note the torque).
• Use new booster bolt (use only original Herrmann booster bolt).
• Clean contact surface.
• Exchange the sonotrode.
• Fit sonotrode stack correctly.
• Mount the sonotrode stack in the tool holder according to the instructions.

2.9.2 Cracks in the Sonotrode

Symptoms
• Excessive noise develops when the test button on the generator is pressed
(see Generator chapter, section "Testing the Idling Rate").
• Idling rate is too high when the test button is pressed
(see Generator chapter, section "Testing the Idling Rate").
• The welding quality becomes progressively worse and has to be compensated by changing the gap.
• Linear cracks on the sonotrode surface can be seen.
• The generator is overloaded when the test button is pressed
(see Generator chapter, section "Error Messages and Solutions").

Possible Causes
• The sonotrode has been operated at too high of an amplitude (see section “Sonotrode Identification Label”)
• The sonotrode has been altered in an unauthorised way.
• The sonotrode was allowed to continue to operate in idle despite the development of loud noise.
• The sonotrode came into contact with metal.
• Generator‘s control parameters not suitable for application.

Solution
• The sonotrode must be exchanged and sent to the Herrmann company for inspection.
• Adjust control parameters.

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Troubleshooting

2.9.3 Defective Converter

Symptoms
• Excessive noise develops when the test button on the generator is pressed
(see Generator chapter, section “Testing the Idling Rate”).
• Idling rate is too high when the test button is pressed
(see Generator chapter, section “Testing the Idling Rate”).
• Extreme heat in the area of the contact surfaces.
• When the test button is pressed, the generator registers a fault (see Generator chapter
“Error messages and their rectification”).

Possible Causes
• Short-circuit due to moisture in the converter housing.
• Defective sonotrode was used instead of being replaced.
• The sonotrode stack was allowed to continue to operate in idle despite the development of loud noise.
• Metal contact by the sonotrode created excessive feedback to the converter.
• Insufficient cooling of the converter.

Solution
• Converter must be exchanged and sent to the Herrmann company for inspection.
Caution! Never disassemble the converter housing without professional help.

2.9.4 Excessive Heat on the Contact Surfaces

Possible Causes
• The sonotrode, the booster or the converter were not assembled properly.
• Original Herrmann booster bolts were not used.
• Dirty of damaged contact surfaces.

Solutions
• Tighten the sonotrode, booster and converter according to the instructions (note the torque).
• Use original Herrmann booster bolts.
• Clean dirty contact surfaces and perhaps have them repolished.
• If the contact surfaces are damaged send the affected parts to the Herrmann company.

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 Chapter 2 / Sonotrode Assembly
Troubleshooting

2.9.5 Insufficient Electrical Insulation of the Tool Holder

In conjunction with MICRO GAP Control only:
Symptom
• The controls report permanent contact with metal.
Possible Cause
• The electrical insulation of the tool holder is defective.
Solution
• Check the electrical insulation by measuring the voltage resistance. See the following page for procedural
details.

Danger! Turn off the controller prior to checking the electrical insulation!

Recommended Procedure Ist measured elec-

Step trical resistance Insulation Diagnostic
Check resistance between less than 500kΩ ?
Turn off the controller!!
1 Check from dismounted tool and machine fram No No Fault
holder Yes Go to next step
Disconnect HF cable from converter
2 Check from dismounted tool and machine fram No Fault at Converter
holder Yes Go to next step
remove 1st mounting bolt
3 Check from dismounted tool and machine fram No Fault at mounting bolt
holder Yes Go to next step
Repeat for mounting bolts 2, 3,4
4 Check from mounted tool and machine fram No Fault at mounting bolt
holder Yes Go to next step
Remove tool holder from actuator unit
5 Check from dismounted tool to the first cylinder pin No Go to next step
holder Yes Fault at cylinder pin
Check from dismounted tool to the first cylinder pin No Fault caused by dirt
6 holder Yes Fault at cylinder pin

Cylinder pin Ø 10mm, 2x

M8 mounting bolt
holding tool holder to
actuator unit VE, 4x

Schwinggebilde_ENG
02.10 REV: 57_22.05.2009 (K)
Page 21