Gesswein Ultramax df User manual

Instruction Manual

for

Models: DF and SF

201 Ha cock Ave., Bridgeport, CT 06605, USA

1-203-366-5400 FAX 1-203-366-3953 Order toll-free 1-800-243-4466

Web site: gesswei .com E-mail: i fo@gesswei .com • #890-2080/0412

Gesswein shall in no way be liable for:

• Damages incurred during shipment.

• Failures or damages due to misuse, abuse, improper installation or abnormal

exposure to dirt, corrosives or extreme temperatures.

• Failures or damages due to operation, intentional or otherwise, above rated

capacities.

• Unauthorized expenses for removal, inspection, transportation, repair

or rework, as well as consequent failures or damages.

• Power packs and handpieces that have been tampered with or dismantled

in any way.

11. Warranty

Gesswein guarantees your ULTRAMAX DF/SF will be free of defects in materi-

al and workmanship for a period of one year from date of shipment. Within the

warranty period, Gesswein or the manufacturer will repair or replace

defective units. All claims must be made in writing to Gesswein and must include

date of purchase and serial numbers of power pack and ultrasonic handpiece.

DF/SF componentsUltramax SF Ultramax DF

1. Introduction

Please read this instruction manual thoroughly before using your ULTRAMAX.

For more than two decades, Gesswein has brought the benefits of ultrasonic

polishing and finishing to mold and diemakers. Manual polishing can’t compete

with the ease of use, quality of results or time savings of using ultrasonic energy

with conventional abrasive tools. As the recognized leader in the field, Gesswein

continues to bring you the best that technology has to offer.

With 45 watts of output power, our DF and SF units are unaffected by metal

hardness. Even the toughest metals, including tungsten carbide and titanium, are

no match. Everything from milled surfaces to rough EDM surfaces can be polished

to a mirror finish using all grades of finishing stones, sintered, resin and plated

diamond tools, files and ceramic stones as well as metallic and nonmetallic lapping

tools with diamond compound.

ULTRAMAX DF and SF compact power packs operate the UF-9700 ultrasonic

handpiece. Additionally, ULTRAMAX DF can operate any one of 12 Power Hand

2X 30V DC mechanical handpieces.

Control panel layout is easy to read and employs large power control touch pads.

Output power (DF and SF) and mechanical handpiece speed (DF only) are con-

trolled by these touch pads, an optional Variable-Speed Foot Rheostat or an

optional On/Off Foot Switch. Built-in protection circuitry prevents damage to both

the UF-9700 ultrasonic handpiece and Power Hand 2X mechanical handpieces.

Note: Because the new ULTRAMAX DF and SF units provide greater output power, it is important to

follow the instructions on proper usage of clamp tools, found later in this manual.

10. Troubleshooting Chart

IMP RTANT: ULTRAMAX DF/SF power packs and UF-9700 ultrasonic handpiece

are sealed units. To protect your warranty, do not dismantle.

Problem Possible Cause ..............................Remedy

No vibration • Loose connection of plugs..........................Check

• Switches not in correct position..................Check

Low vibration • Power output setting in MIN position ........Increase power output

• Tool or 6/4mm Tool Adapter

is insufficiently secured ..............................Fasten securely

• Tool is too short or too long........................Adjust tool length*

• Too much pressure applied to tool ............Reduce pressure

Decreased • Tool or 6/4mm Tool Adapter has

vibration during become unfastened ....................................Fasten securely

operation and/or • Stone or tool broken ..................................Replace tool and reset On/Off

......................................................................and Reset Switch

zero vibration • Custom tool is causing circuit overload ....Replace tool and reset On/Off

......................................................................and Reset Switch

Abnormal noise • Loose joint or bent tool ..............................Fasten securely or replace

from tool ......................................................................or straighten tool

Abrasive stone • “CLAMP TOOL” mode not being used ......Check

breaks or wood • Thickness of abrasive stone not correct ....Replace tool**

lap begins to burn • Power output setting is too high ................Reduce power output

• Too much pressure applied on tool ..........Use less pressure on the tool

*See chart in 6.3.

2. Features

1. Increased maximum output power of 45W

2. Broader operating frequency range of 20.0-30.0kHz

3. Greater tool amplitude range of 4-40 microns

4. Regulated power feedback for automatic output power reduction

5. Tool control touch pads for ordinary tools and clamp tools

6. Steady power and tool amplitude settings

7. Increased torque for all Gesswein Power Hand 2X 30V DC mechanical

handpieces*

8. Instant rotary handpiece reversing switch for improved handling on edges,

corners and radius surfaces*

9. Electronic feedback circuitry for maintaining speed of rotary handpiece with

increased pressure on the work surface*

10. Motor overload protection for all Power hand 2X handpiece armatures*

*ULTRAMAX DF only.

9. perational Precautions

√Use only 6mm Clamp Tool Holders with the UF-9700 handpiece. Do not use

4mm holders – they will damage the handpiece.

√Ensure that the “CLAMP TOOL” selector switch is depressed when using

clamp tools of any kind.

√For maximum efficiency, ensure all threaded and clamp tools and tool holders

are securely fastened. Loose connections will cause reduced power output.

√Inspect tools, holders and handpiece screw threads for dirt and rust. All male

and female screw threads and all tool shoulders and interfaces must be kept

clean and true. Use acetone, wire scratch brush and cotton ear swabs to clean.

√Use only Gesswein ordinary tools with the UF-9700 handpiece for maximum

efficiency. If custom clamp tools are used, please refer to the chart in 6.3 for

size recommendations.

√Avoid touching tools mounted in the UF-9700 handpiece while they are

ultrasonically vibrating. They may be hot enough to cause burning.

√Do not use highly viscous lubricants. Use Gesswein Stoning and Lubricating

Oil. Do not allow lubricants to enter the UF-9700 handpiece (as can occur

when the handpiece is held with the tool pointing upward). Lubricant oils can

penetrate into the handpiece and cause deterioration of components.

√Protect the UF-9700 handpiece from sharp impact.

√Protect the handpiece cable from impact, sharp objects and excessive heat.

Do not twist cable or bend sharply at the strain relief.

√For operating comfort, use the earplugs provided.

√When in use, make sure the power pack ventilation grills located on the rear

and bottom of the units are not covered or obstructed.

√When not in use for extended periods, turn off the On/Off and Reset Switch.

Doing so will prevent your mounting a tool in the UF-9700 handpiece while the

unit is on.

√eep the power packs away from excessive heat, humidity and corrosive

chemicals.

√Always disengage handpiece and power pack by the plugs — not the cords.

Note: Gesswein cannot accept responsibility for the incorrect use of ULTRAMAX DF/SF

power packs and/or UF-9700 ultrasonic handpiece.

3. Specifications

Power Pack

Model ULTRAMAX DF ULTRAMAX SF

Electrical 115 or 230V, 50/60Hz 115 or 230V, 50/60Hz

Frequency (range) 24kHz (20.0-30.0kHz) 24 Hz (20.0-30.0khz)

Amplitude (stroke) 4-40 microns 4-40 microns

Frequency Adjustment Auto feedback system Auto feedback system

Ultrasonic Power Output 45W maximum 45W maximum

Power Hand 2X Output 0-30V DC N/A

Output Adjustment

(power and stroke) Continuously variable Continuously variable

Power Source 115V, 1 Ph, 50/60Hz 115V, 1 Ph, 50/60Hz

(230V available) (230V available)

Power Consumption 200VA 100VA

Dimensions 63⁄8"W x 11"D x 81⁄4"H 7"W x 81⁄4"D x 6"H

Net Wt. 8 lbs. 5 lbs.

Ultrasonic Handpiece

Model UF-9700

Transducer B.L.T. electrostrictive

Cable Length 2.0m (curl cord)

Screw Thread M6; M4 with adapter

Dimensions 5"L x 9⁄16" dia. tapered to 13⁄32"

Net Wt. 4.5 oz.

8. Detailed Features and Safety Devices

A. On/Off and Reset Switch (DF/SF) – Automatically turns off when ultrasonic

tool is improperly attached, insufficiently tightened or of the wrong size

(DF/SF); automatically turns off when Power Hand 2X rotary handpiece collet

release mechanism is left in the release position (DF only). To reset, attach

ultrasonic tool properly or move Power Hand 2X collet release mechanism to

the secure position, then turn switch on.

B. Regulated Power Feedback System (DF/SF) – Drops output power to minimum

when ultrasonic handpiece is lifted from the workpiece; returns output power to

last setting when ultrasonic handpiece reestablishes contact with the workpiece.

Increases handpiece transducer life and keeps handpiece and tools cool during

extended operation.

C. Memory function (DF/SF) – Saves the last output power setting as long as the

Main Power Switch is on.

D. Angled Front Panel (DF/SF) – Ensures clear view of all controls.

E. Carrying Handle (DF/SF) – Provides portability.

F. Standard Fuse (DF/SF) – Allows easy replacement with a Phillips screwdriver.

ULTRAMAX DF: 2A in 115V model, 1.5A in 230V model. ULTRAMAX SF: 1.5A in

115V model, 1A in 230V model.

G. Small and Beveled Protector Sleeves (DF/SF) – Small protects ordinary tools;

beveled protects clamped tools.

H. Forward/Reverse Rotation Function (DF only) – Allows Power Hand 2X hand-

piece to run in forward and reverse. Brings handpiece to a complete stop

before changing direction, protecting motor armature from damage.

I. Motor Overload Protection Circuitry (DF only) – Slows then stops Power hand 2X

Handpiece in the event of overload. Brings handpiece back up to original speed

once it is lifted from the workpiece, triggers a buzzer and turns off the On/Off and

Reset Switch in the event of abnormal overload. To reset, fix problem

(i.e., replace bent or broken tool), then turn on the On/Off and Reset Switch.

J. Electronic Feedback Circuitry (DF only) – Maintains Power Hand 2X handpiece

speed as work force increases.

K. Electronic Transformer (DF only) – Allows reliable Power Hand 2X handpiece

operation.

L. Cooling fan (DF only) – Operates continuously when Main Power Switch is on.

4. Accessories*

•UF-9700 Ultrasonic Handpiece

•Wooden Handpiece Case

•Handpiece Rest

•Power Cord

•Replacement Fuse

•Plastic Tool Box

•Cloth Tool Holder

•Flat Diamond File,

1T x 5W x 133L, #200

•Flat Diamond File,

1T x 5W x 133L, #320

•Chisel Diamond File,

0.5T/1W x 4W x 44L, #200

•Chisel Diamond File,

0.5T/1W x 4W x 44L, #320

•Flat Diamond Stone,

1T x 3W x 41L, #200

•Flat Diamond Stone,

1T x 5W x 41L, #200

•Flat Diamond Stone,

1.5T x 6W x 80L, #200

•Flat Resin-Bonded Diamond Stone,

3T x 6W x 22L, #200

•Flat Resin-Bonded Diamond Stone,

3T x 6W x 22L, #320

•Flat Ceramic Stone Tool,

0.8T x 4W x 40L, #600

•Flat Ceramic Stone Tool,

0.8T x 4W x 40L, #800

•Flat Ceramic Stone Tool,

1T x 6W x 40L, #600

•Flat Ceramic Stone Tool,

1T x 6W x 40L, #800

•Round Ceramic Stone Tool,

3D x 30L, #600

•Round Ceramic Stone Tool,

3D x 30L, #800

•Flat Wood Lapping Tool,

3.2T x 6W x 30L

•Round Wood Lapping Tool,

3D x 30L

•Clamp Tool Holder (M6) for 0.8T Flat

•Clamp Tool Holder (M6) for 1.1T Flat

•Clamp Tool Holder (M6) for 3.1T Flat

•Clamp Tool Holder (M6) for 3.3T Flat

•Clamp Tool Holder (M6) for 3.2D Round

•Tool Adapter (M6 to M4)

•Wrench (M8)

•Wrench (M10)

•Wrench (M13)

•Allen ey (M2.5)

•Small Protector Sleeve for UF-9700

•Beveled Protector Sleeve for UF-9700

•Earplugs

*Measurements in mm.

ptional Accessories

Contact Gesswein for information on the complete line of tool accessories and

Power Hand 2X mechanical handpiece options.

Tool Type utput Indicator Recommended Ultrasonic Selector Switch

Position Tool Application Choice

Stroke: Up to 40 microns.

Coarse finishing using dia-

mond files and stones from

200 to 320 grit.

Stroke: Up to 30 microns.

Medium finishing using ruby

stones and diamond tools

over 320 grit.

Stroke: Up to 20 microns.

Middle finishing using hard

wood laps, resin-bonded dia-

mond stones, ceramic stones

and abrasive stones.

Stroke: Up to 10 microns. Super

finishing using soft wood laps

with diamond compound. Ordinary Clamp

Tool Tool

Ordinary Clamp

Tool Tool

Ordinary Clamp

Tool Tool

Ordinary Clamp

Tool Tool

7. Recommended Ultrasonic Settings

Clamp Tools

Front Panel

Rear Panel

5. Parts Nomenclature

5.1 ULTRAMAX DF Power Pack

1. Main Power Switch

2. Main Power Indicator Lamp

3. On/Off and Reset Switch

4. On/Off Pilot Lamp

5. Output Socket for optional foot

rheostat/switch

6. 30V DC Output Socket for Power

Hand 2X handpiece

7. Output Socket for UF-9700

ultrasonic handpiece

8. Output Power Control Touch Pads

9. Power Hand 2X Selector Switches:

Forward Rotation

Reverse Rotation

10. Power Hand 2X Function Pilot

Lamps

11. Ultrasonic Selector Switches:

•Ordinary Tool

•Clamp Tool

12. Ultrasonic Function Pilot Lamps

13. Carrying Handle

14. Ventilation Grills

15. Input Power Socket

16. Fuse Holder/Fuse

17. Specifications and Serial

Number Plate

rdinary

Tools

(6 and 4mm

threaded)

Power Hand 2X Mechanical Handpieces (DF only)

A. Select a Power Hand 2X 30V DC handpiece. Secure a tool to the handpiece,

carefully following the provided instructions. Connect the handpiece to the

30V DC Output Socket on the ULTRAMAX DF front panel.

B. Check to ensure single-phase voltage available is the same as that marked

on the Specification Plate located on the ULTRAMAX DF rear panel. Connect

the ULTRAMAX DF power cable to the main power supply, and turn the Main

Power Switch on. The Main Power Indicator Lamp lights up.

C. Use the Power hand 2X Selector Switches to select the rotational direction of

the tool. Press to run in the forward direction (normal rotational direction)

or to run in the reverse direction.

D. Use the Output Power Control Touch Pads on the front panel of your ULTRAMAX

DF to change handpiece speed.

Note: It is recommended that power be reduced to the MIN setting at startup since the unit is

preset to start the mechanical handpiece at approximately half speed (i.e., 6 or 7 LED bars on

the Output Indicator).

E. With handpiece speed selected, push On/Off and Reset Switch on. The On/Off

Pilot Lamp lights up. Providing all equipment has been connected as directed,

your Power Hand 2X handpiece should now be operational.

F. To control output power by foot control, follow the same procedures for the

UF-9700 Ultrasonic Handpiece.

Note: To revert to manual control, follow steps C through D. The optional foot rheostat/switch need

not be disconnected from the unit.

5.2 ULTRAMAX SF Power Pack

1. Main Power Switch

2. Main Power Indicator Lamp

3. On/Off and Reset Switch

4. On/Off Pilot Lamp

5. Output Socket for optional

foot/rheostat switch

6. Output Socket for UF-9700

ultrasonic handpiece

7. Output Power Control

Touch Pads

8. Ultrasonic Selector Switches:

•Ordinary Tool

•Clamp Tool

9. Ultrasonic Function Pilot Lamps

10. Carrying Handle

11. Ventilation Grills

12. Input Power Socket

13. Fuse Holder/Fuse

14. Specifications and Serial

Number Plate

Front Panel

Rear Panel

6.4 Commissioning

UF-9700 Ultrasonic Handpiece (DF/SF)

A. Select an ultrasonic tool and tightly secure in the UF-9700 handpiece.

Connect UF-9700 to Ultrasonic Output Socket on ULTRAMAX DF/SF.

B. Check to ensure single-phase voltage available is the same as that marked

on the Specification Plate located on the ULTRAMAX DF/SF rear panel.

Connect the ULTRAMAX DF/SF power cable to the main power supply, and

turn Main Power Switch on. The Main Power Indicator Lamp lights up.

C. Depress the “ORDINARY TOOL” Selector Switch to use ordinary factory

premounted tools. Depress the “CLAMP TOOL” Selector Switch to use tools

mounted in Clamp Tool Holders.

D. Use the Output Power Control Touch Pads on the front panel of your

ULTRAMAX DF/SF to adjust output power (and tool amplitude).

Note: Tool amplitude increases from 4 microns at the MIN Output Indicator setting to 40 microns

at the MAX setting.

E. With output power selected, push On/Off and Reset Switch on. The On/Off Pilot

Lamp lights up. Providing all equipment has been connected as directed, your

UF-9700 handpiece should now be operational.

Note: For suggestions on output power selections, see Ultrasonic Tool section.

F. To control output power by foot control, connect the Variable-Speed Foot

Rheostat or On/Off Foot Switch to the Output Socket for optional foot

rheostat/switch.

G. Using the Variable-Speed Foot Rheostat precludes having to use the On/Off

and Reset Switch. Depressing the foot rheostat turns the unit on (in this

sense, it acts as an on/off switch). Increasing pressure on the foot rheostat

increases output power (and tool amplitude). Lifting completely off the foot

rheostat turns the unit off. The On/Off Pilot Lamp goes out.

H. When using the On/Off Foot Switch, first manually select an output power level,

then turn the On/Off and Reset Switch on. Depressing the foot switch brings the

handpiece to the selected power level. Lifting completely off the foot switch

brings outback power back to the MIN setting. The On/Off Pilot Lamp stays on.

Note: To revert to manual control, follow steps C through E. The optional foot rheostat/switch need

not be disconnected from the unit.

5.3 UF-9700 Ultrasonic Handpiece

The UF-9700 ultrasonic handpiece accepts 6mm threaded tools and Clamp Tool

Holders. Additionally, 4mm threaded tools (but not 4mm Clamp Tool Holders) can

be used with a 6/4mm Tool Adapter.

Note: Use only 6mm Clamp Tool Holders with the UF-9700 handpiece. Do not twist or bend the

UF-9700 cord sharply.

1. UF-9700 Ultrasonic Handpiece

2. UF-9700 Control Panel Plug Connector

3. Medium Clamp Tool Holder

4. Large Clamp Tool Holder

5. 6/4mm Tool Adapter

6. 4mm Threaded Tool

7. Small Protector Sleeve

8. Beveled Protector Sleeve

Note: The UF-9700 is a sealed unit. To protect your warranty, do not attempt to dismantle.

7 6 5 1

Clamp Tools

Clamp tools include any and all tools, abrasives and laps secured by means of a

Clamp Tool Holder. Gesswein Clamp Tool Holders are made to match the reso-

nant frequency of ULTRAMAX DF and SF. The manufacturer does not accept lia-

bility for other manufacturers’ holders.

When using clamp tools, depress the “CLAMP TOOL” selector switch on the front

panel of the ULTRAMAX DF or SF. Selecting “CLAMP TOOL” cuts power output to

provide efficient polishing motion. “CLAMP TOOL” mode eliminates the excessive

heat buildup that causes abrasive stones to break down and wood laps to burn.

perational Hints for Clamp Tools

•Use only 6mm Clamp Tool Holders. Do not use 4mm holders – they will

damage the UF-9700 handpiece.

•Do not apply excessive pressure on the tool. ULTRAMAX DF and SF polish

best when only a small amount of pressure is applied. The more pressure

applied to the work surface, the less cutting power.

•Do not use highly viscous lubricants when polishing – they reduce ultrasonic

vibration and cutting power. Use Gesswein Stoning and Lubricating Oil for best

results.

•If an abrasive stone breaks in its holder, apply less pressure on the work surface

and/or reduce output power. If a wood lap begins to burn, reduce output power.

•To maintain maximum cutting power, periodically retighten the cap screw on

the Clamp Tool Holder during use as the abrasive wears and loosens slightly

in the holder.

•When making your own clamp tools, refer to recommended sizes listed below

for some commonly used materials.

Recommended Sizes for Clamp Tools

Material Profile (mm) Recommended Length (mm)

Wood 3ø Below 40 Above 70

3 x 6 40 80

3~5 x 15 30 80

Brass 2ø 30 50

3ø 20 60

2 x 2~8 35 60

Abrasive Stone 1.5~3 x 6~15 25 80

Ceramic Stone 2~3ø 30 60

0.8~2 x 4~10 40 60

Important: When using clamp tools, make sure “CLAMP TOOL” selector switch is depressed.

6. General Description of Use

6.1 Function

Electric power to ULTRAMAX units is supplied from a 115V AC* source.

ULTRAMAX DF and SF power packs convert this power source to a 24kHz

electrical signal. The signal is sent to the UF-9700 ultrasonic handpiece, which

converts it to mechanical reciprocating motion.

ULTRAMAX DF also converts the AC power source to direct current (30V DC).

Required power is automatically supplied to Gesswein Power Hand 2X 30V DC

mechanical handpieces according to the speed setting selected.

Since ULTRAMAX DF is specifically designed to function with Power Hand 2X

30V DC handpieces, it cannot be used with Power Hand 20V DC handpieces or

other makes of handpieces.

*230V AC models available.

6.2 Attachment of Tools to UF-9700

Ultrasonic Handpiece

Fasten 6mm threaded tools directly to the

UF-9700 handpiece. Use 10 or 13mm

spanner wrenches as illustrated to tighten

tools securely.

To use 4mm threaded tools in the

UF-9700 handpiece, first attach the

6/4mm Tool Adapter using 10mm span-

ner wrenches, then fasten tools to the

adapter with an 8mm spanner wrench

as illustrated. Do not overtighten.

Spanner

Wrench (10mm)

6mm Threaded Tool

Spanner

Wrench (10 or 13mm)

4mm Threaded Tool

6/4mm Tool Adapter

Spanner

Wrench (8mm)

perational Hints for rdinary Tools

•Do not apply excessive pressure on the tool. ULTRAMAX DF and SF polish

best when only a small amount of pressure is applied. The more pressure

applied to the work surface, the less cutting power.

•Do not use highly viscous lubricants when polishing – they reduce ultrasonic

vibration and cutting power. Use Gesswein Stoning and Lubricating Oil for best

results.

•A high-pitched noise indicates a loose connection or bent tool.

Color Coding for rdinary Tools

All Gesswein ultrasonic tools except abrasive stones are color-coded as indicated

in the chart below.

Color Grit Micron

Red 200 68

Black 320 40

Blue 500 35

White 600 28

Green 1000 15

Use a Clamp Tool Holder for finishing

stones, resin-bonded diamond stones,

ceramic stones and laps.

Fasten Clamp Tool Holders directly to the

UF-9700 handpiece. Use 10mm spanner

wrenches to tighten holders securely. Use

only 6mm Clamp Tool Holders. Do not

use 4mm holders – they will damage the

UF-9700 handpiece.

Firmly secure the stone or lap in the Clamp

Tool Holder with a 2.5mm Allen wrench. If

the tool thickness or diameter is undersized,

do not compensate by overtightening. Use a

metal shim as illustrated.

Note: To obtain the best reciprocation frequencies,

threaded and clamp tools and tool holders must be

securely fastened. Loose connections will cause

reduced power output. To ensure maximum tool

efficiency, all male and female tool threads and all

tool shoulders and interfaces must be kept clean and

true (see Operational Precautions section).

2.5mm Allen Wrench

Metal Shim

Clamp Tool Holder

Stone or Lap

6.3 Ultrasonic Tool Usage

A wide range of threaded and clamp-type tools and tool holders is supplied with

each ULTRAMAX unit. Additional tools and tool holders are available separately.

rdinary Tools

Ordinary tools include all Gesswein ultrasonic tools except those used in Clamp

Tool Holders. Gesswein ordinary factory premounted tools are made to match

the resonant frequency of ULTRAMAX DF and SF. The manufacturer does not

accept any liability for other manufacturers’ tools.

When using Ordinary Tools, depress the “ORDINARY TOOL” selector switch on

the front panel of the ULTRAMAX DF and SF. Selecting “ORDINARY TOOL”

provides maximum cutting power.

perational Hints for rdinary Tools

•Do not apply excessive pressure on the tool. ULTRAMAX DF and SF polish

best when only a small amount of pressure is applied. The more pressure

applied to the work surface, the less cutting power.

•Do not use highly viscous lubricants when polishing – they reduce ultrasonic

vibration and cutting power. Use Gesswein Stoning and Lubricating Oil for best

results.

•A high-pitched noise indicates a loose connection or bent tool.

Color Coding for rdinary Tools

All Gesswein ultrasonic tools except abrasive stones are color-coded as indicated

in the chart below.

Color Grit Micron

Red 200 68

Black 320 40

Blue 500 35

White 600 28

Green 1000 15

Use a Clamp Tool Holder for finishing

stones, resin-bonded diamond stones,

ceramic stones and laps.

Fasten Clamp Tool Holders directly to the

UF-9700 handpiece. Use 10mm spanner

wrenches to tighten holders securely. Use

only 6mm Clamp Tool Holders. Do not

use 4mm holders – they will damage the

UF-9700 handpiece.

Firmly secure the stone or lap in the Clamp

Tool Holder with a 2.5mm Allen wrench. If

the tool thickness or diameter is undersized,

do not compensate by overtightening. Use a

metal shim as illustrated.

Note: To obtain the best reciprocation frequencies,

threaded and clamp tools and tool holders must be

securely fastened. Loose connections will cause

reduced power output. To ensure maximum tool

efficiency, all male and female tool threads and all

tool shoulders and interfaces must be kept clean and

true (see Operational Precautions section).

2.5mm Allen Wrench

Metal Shim

Clamp Tool Holder

Stone or Lap

6.3 Ultrasonic Tool Usage

A wide range of threaded and clamp-type tools and tool holders is supplied with

each ULTRAMAX unit. Additional tools and tool holders are available separately.

rdinary Tools

Ordinary tools include all Gesswein ultrasonic tools except those used in Clamp

Tool Holders. Gesswein ordinary factory premounted tools are made to match

the resonant frequency of ULTRAMAX DF and SF. The manufacturer does not

accept any liability for other manufacturers’ tools.

When using Ordinary Tools, depress the “ORDINARY TOOL” selector switch on

the front panel of the ULTRAMAX DF and SF. Selecting “ORDINARY TOOL”

provides maximum cutting power.

Clamp Tools

Clamp tools include any and all tools, abrasives and laps secured by means of a

Clamp Tool Holder. Gesswein Clamp Tool Holders are made to match the reso-

nant frequency of ULTRAMAX DF and SF. The manufacturer does not accept lia-

bility for other manufacturers’ holders.

When using clamp tools, depress the “CLAMP TOOL” selector switch on the front

panel of the ULTRAMAX DF or SF. Selecting “CLAMP TOOL” cuts power output to

provide efficient polishing motion. “CLAMP TOOL” mode eliminates the excessive

heat buildup that causes abrasive stones to break down and wood laps to burn.

perational Hints for Clamp Tools

•Use only 6mm Clamp Tool Holders. Do not use 4mm holders – they will

damage the UF-9700 handpiece.

•Do not apply excessive pressure on the tool. ULTRAMAX DF and SF polish

best when only a small amount of pressure is applied. The more pressure

applied to the work surface, the less cutting power.

•Do not use highly viscous lubricants when polishing – they reduce ultrasonic

vibration and cutting power. Use Gesswein Stoning and Lubricating Oil for best

results.

•If an abrasive stone breaks in its holder, apply less pressure on the work surface

and/or reduce output power. If a wood lap begins to burn, reduce output power.

•To maintain maximum cutting power, periodically retighten the cap screw on

the Clamp Tool Holder during use as the abrasive wears and loosens slightly

in the holder.

•When making your own clamp tools, refer to recommended sizes listed below

for some commonly used materials.

Recommended Sizes for Clamp Tools

Material Profile (mm) Recommended Length (mm)

Wood 3ø Below 40 Above 70

3 x 6 40 80

3~5 x 15 30 80

Brass 2ø 30 50

3ø 20 60

2 x 2~8 35 60

Abrasive Stone 1.5~3 x 6~15 25 80

Ceramic Stone 2~3ø 30 60

0.8~2 x 4~10 40 60

Important: When using clamp tools, make sure “CLAMP TOOL” selector switch is depressed.

6. General Description of Use

6.1 Function

Electric power to ULTRAMAX units is supplied from a 115V AC* source.

ULTRAMAX DF and SF power packs convert this power source to a 24kHz

electrical signal. The signal is sent to the UF-9700 ultrasonic handpiece, which

converts it to mechanical reciprocating motion.

ULTRAMAX DF also converts the AC power source to direct current (30V DC).

Required power is automatically supplied to Gesswein Power Hand 2X 30V DC

mechanical handpieces according to the speed setting selected.

Since ULTRAMAX DF is specifically designed to function with Power Hand 2X

30V DC handpieces, it cannot be used with Power Hand 20V DC handpieces or

other makes of handpieces.

*230V AC models available.

6.2 Attachment of Tools to UF-9700

Ultrasonic Handpiece

Fasten 6mm threaded tools directly to the

UF-9700 handpiece. Use 10 or 13mm

spanner wrenches as illustrated to tighten

tools securely.

To use 4mm threaded tools in the

UF-9700 handpiece, first attach the

6/4mm Tool Adapter using 10mm span-

ner wrenches, then fasten tools to the

adapter with an 8mm spanner wrench

as illustrated. Do not overtighten.

Spanner

Wrench (10mm)

6mm Threaded Tool

Spanner

Wrench (10 or 13mm)

4mm Threaded Tool

6/4mm Tool Adapter

Spanner

Wrench (8mm)