Trumpf LASERCELL 1005 Operator's Manual
  1. Manuals
  2. Brands
  3. Trumpf Manuals
  4. Industrial Electrical
  5. LASERCELL 1005
  6. Operator's manual
Trumpf LASERCELL 1005 Operator's Manual

Trumpf LASERCELL 1005 Operator's Manual

Laser processing system
Hide thumbs
1
2
3
4
5
6
Table Of Contents
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
Table of Contents

Advertisement

Quick Links

Download this manual
Operator's manual
TRUMPF LASERCELL 1005

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the LASERCELL 1005 and is the answer not in the manual?

Questions and answers

Summary of Contents for Trumpf LASERCELL 1005

  • Page 1 Operator’s manual TRUMPF LASERCELL 1005...
  • Page 3 Operator’s manual TRUMPF LASERCELL 1005 07/2004 Edition:...
  • Page 4 TRUMPF Werkzeugmaschinen GmbH + Co. KG Subject to errors and technical changes.  TRUMPF Werkzeugmaschinen GmbH + Co. KG TRUMPF Werkzeugmaschinen GmbH + Co.
  • Page 5 Before You proceed... This operator’s manual documents the numerically controlled TRUMPF LASERCELL 1005 (TLC 1005) laser processing system. This manual is addressed not only to the user (owner) and the operator of the machine, but also to its maintenance personnel.
  • Page 6 Before You proceed... B337EN00.DOC...

  • Page 7: Table Of Contents

    Table of Contents Chapter 1 Safety For your safety ............... 1-3 Terminology..............1-4 Operating safety............. 1-4 Authorized use of the machine ........1-5 Measures to be taken by the user/operator ..... 1-6 Observe information and warning plates ....1-6 Instructing personnel........... 1-6 Care needed while operating the machine ....
  • Page 8 Hazardous substances........... 1-30 Dust, aerosols and gases ......... 1-30 Cutting oils ..............1-31 Ozone................ 1-32 Polyethylene-coated (PE) tubes ....... 1-32 Hazards from thermal decomposition of ZnSe lenses ................1-33 Lens characteristics ..........1-33 Thermal decomposition..........1-33 Response to accidents..........1-34 Disposal of lenses.............
  • Page 9 Electrical supply............2-23 Power supply..............2-24 Connected loads, fuse protection ........2-25 Teleservice ..............2-26 Network connection............2-26 Compressed air supply ..........2-27 Operating materials ............. 2-29 Laser gases and cutting and inert gases ....... 2-29 Cooling water ..............2-29 Transport ..............
  • Page 10 The modules of the laser cutting center....3-11 The modules of the basic machine ........ 3-14 Machine body............3-16 Motion unit for X, Y, Z (extension arm) ..... 3-17 Drives ................ 3-18 Safety cabin .............. 3-18 Support table............. 3-19 Base plate ..............3-21 Rotary axis with media connection (optional) ...
  • Page 11 Chapter 4 Operation Part 1: Operating devices ............4-9 Control elements other than on the operating panel ................4-9 Control elements of the basic machine......4-9 Control elements of the safety door (electrically driven sliding door)........4-12 Teach panel ..............4-14 Control elements of the JIC version.......
  • Page 12 PRODUCTION – Switch elements......... 4-53 Operation of the switch elements ......4-54 Switch elements for distance control system.... 4-55 Switch elements in general ........4-57 Service switch elements ........... 4-59 Welding switch elements .......... 4-60 PRODUCTION Front safety door switch elements..............
  • Page 13 Manually movable support table indexing switch elements (optional) ..........4-122 Front safety door switch elements for electrically driven sliding doors ..........4-125 Front safety door switch elements for electrically driven lift doors............4-127 TLF laser intervention 1 switch elements ....4-128 TLF laser intervention 2 switch elements ....
  • Page 14 Part 3: Operating the machine ..........4-171 Calling up the online help........4-171 Machine start-up and shutdown....... 4-174 Switching on the machine ..........4-174 Switching off the machine ..........4-175 Switching off the machine in the event of malfunctions/emergencies........4-176 Triggering E-STOP............
  • Page 15 Processing with the production plans -basic machine............... 4-201 Creating a production plan ........... 4-202 Starting production plans ..........4-203 Ending production plans..........4-204 Moving the axes in jog mode ........4-205 Support table indexing ..........4-205 10.1 Indexing support tables ..........4-205 10.2 Undoing electrical indexing ..........
  • Page 16 Diagnostic functions..........4-225 15.1 Error diagnostics ............4-225 15.2 Displaying inputs and outputs of the machine and laser................4-226 Remote diagnostics via pcANYWHERE 1 ....4-227 15.3 15.4 Querying the software version ........4-227 Managing master files ..........4-228 16.1 Uploading an NC program from the disk drive....
  • Page 17 Chapter 5 Setting work Safety information............5-4 Overview of setting work ..........5-5 Checking and setting B and C axes ......5-6 Checking C axis and setting reference offset value..5-7 Checking the B axis and setting the reference offset value ............... 5-9 Selecting processing optics ........
  • Page 18 Changing the gas and air connections at the Z center sleeve ..............5-74 Recording the DIAS characteristic curve ....5-75 Checking and setting the Crossjet......5-76 Setting the flow rate of the welding gas ....5-77 Switching over the welding gas ......... 5-78 Measuring probe (optional).........
  • Page 19 Chapter 6 Machine maintenance General guidelines ............6-3 Maintenance overview ........... 6-4 System lubrication ............6-7 Explanation of the symbols used in the lubrication diagram ................6-7 Lubrication chart............... 6-8 Lubricant table..............6-9 Notes for lubrication chart ..........6-10 Maintenance of mechanical components....6-19 Maintenance on basic machine ........
  • Page 20 Chapter 7 Maintenance of laser Maintenance overview ........... 7-3 Maintenance intervals ............7-4 Vacuum pump ..............7-5 Auxiliary tools and materials ..........7-5 Maintenance work ............7-6 Compressed air filter unit..........7-7 Laser control ..............7-7 Cooling unit ..............7-8 Auxiliary tools and materials ..........
  • Page 21 Chapter 8 Aligning the MSL multi-beam safety light barrier Additional equipment for aligning........ 8-2 System example ............. 8-3 Aligning the light beam ..........8-4 Setting mirror ..............8-6 Cross-hairs to cut out............ 8-7 Chapter 9 Noise levels - Test certificate TLC 1005 Mess Test certificate............
  • Page 22 0-22 Table of Contents B337EN00.DOC...

  • Page 24: Safety

    Chapter 1 Safety For your safety ............... 1-3 Terminology..............1-4 Operating safety............... 1-4 Authorized use of the machine ........1-5 Measures to be taken by the user/operator ..... 1-6 Observe information and warning plates ....1-6 Instructing personnel........... 1-6 Care needed while operating the machine ....1-7 Eliminating malfunctions during operation ....
  • Page 25 Measures taken by the manufacturer ......1-16 Securing the danger zone of the machine ....1-16 Suction unit and compact dust extractor (filtering installation) ..........1-18 Warnings contained in this operator’s manual ....1-19 Symbols ..............1-20 Signalling words ............1-20 Overview of hazards ............

  • Page 26: For Your Safety

    For your safety With the TLC 1005, you have a laser cutting center with the latest technology and which is safe to operate. The declaration of EC conformity and the CE mark on the machine confirm that the TLC 1005 complies with the standard safety and health requirements of the EC Machinery Directive of 98/37/EC.

  • Page 27: Terminology

    Terminology Danger zone The danger zone is the area within and peripheral to the machine, in which the safety or health of individuals is at risk. The danger zone is secured with safety devices (e.g. light grids, safety cabin). User/Owner The user/owner is the person on whose premises the machine has been set up and is operated.

  • Page 28: Authorized Use Of The Machine

    Authorized use of the machine The TLC 1005 is a laser cutting center for cutting and welding flat sheets and three-dimensional workpieces from metallic materials. Intended use also means: • The conditions for installation specified by the manufacturer must be observed and maintenance work must be carried out. •...

  • Page 29: Measures To Be Taken By The User/Operator

    Measures to be taken by the user/operator Observe information and warning plates Always observe the following warning plates and warnings attached to the machine: Warning sign for dangerous electrical current. For machine components for which the distribution voltage is already reduced before the main switch, signs with the following message are also attached in the switch cabinet, on the appropriate component and on the cable: WARNING! LIVE WHEN MAIN SWITCH SWITCHED OFF.

  • Page 30: Care Needed While Operating The Machine

    Care needed while operating the machine • Safety devices and danger Suitable safety equipment for securing the danger zone must zone of the machine be installed as a prerequisite to machine operation. • As a general rule, safety devices may not be removed or put out of operation.
  • Page 31 Danger zone for machines The working area is separated by a lift partition panel for laser machines which are equipped with two-station operation (optional). with two-station operation During the time that processing is active in one of the stations, the workpiece can be loaded or teached in the other one.
  • Page 32 Observing the shutdown The prescribed shutdown procedures must be adhered to for all work concerning the transport, installation, operation, maintenance procedures and repairs as well as for putting the installation into service: • The machine must always be switched off at the main switch, the main switch locked and the key removed for any installation, maintenance or repair work.

  • Page 33: Eliminating Malfunctions During Operation

    Eliminating malfunctions during operation 1. Press FEED HOLD. 2. Eliminate the malfunction using the control panel. 3. If the malfunction cannot be eliminated using the operating panel: press E-STOP. 4. Correct the malfunction with a brief intervention into the machine. 5.

  • Page 34: Duty Of Care When Handling The Cooling Unit

    Duty of care when handling the cooling unit The cooling unit is subject to the range of application of the EU Pressure devices guideline 97/23/EU and the European Standard EN 793, Parts 1-4. The owner is obliged to do the following: •...

  • Page 35: Using The Appropriate Spare Parts And Operating Materials

    Using the appropriate spare parts and operating materials Original parts and Original parts and accessories are designed specifically for the machine. Replacements for original parts and accessories other accessories than those supplied by the machine’s manufacturer have not been inspected and approved by the manufacturer. For this reason, the installation and/or use of such products may under certain circumstances have an adverse effect on the function of the machine and diminish its safety.

  • Page 36: Water Protection

    Water protection In the Federal Republic of Germany, the principle of precaution applies to all machines that use materials which could endanger the quality of water. This principle states that no water contamination may arise from using such substances. This is the main statement §...

  • Page 37: Fire Protection

    Fire protection Having a hand-held fire A hand-held fire extinguisher with powder spray for metal fires (fire class D) should be provided for fire protection since there is a extinguisher readily available danger of the hot slag which accumulates during laser machining inflaming.
  • Page 38 Filtering installations without The following measures should be taken immediately if the filter plates are on fire (smoke coming out of the clean gas outlet): a CO fire extinguishing unit: 1. Switch off the MAIN SWITCH of the machine. 2. Remove the sealing cap on the side and back. Spray extinguishing agent into the openings.

  • Page 39: Measures Taken By The Manufacturer

    Measures taken by the manufacturer Securing the danger zone of the machine Note The machine may only be operated when the safety devices are active. Before each start-up of the machine, the operator must ensure that nobody is in the secured danger area. Safety cabin The machine with a completely closed safety cabin is supplied, as a standard, with one or more cabin doors.
  • Page 40 E-STOP impact button E-STOP impact buttons are located at different points of the laser processing unit. MAIN SWITCH on the laser E-STOP on the teach panel E-STOP on the control panel switch cabinet E-STOP impact buttons Fig. 39483 Depending on the model, there are an additional E-STOP impact buttons on the unit: •...

  • Page 41: Suction Unit And Compact Dust Extractor (Filtering Installation)

    Suction unit and compact dust extractor (filtering installation) The extraction and filtration system provided by TRUMPF in combination with the machine is arranged in such a way that when the machine is used correctly, the aerosols and dust emitted are efficiently separated out (see the section Hazardous substances).

  • Page 42: Warnings Contained In This Operator's Manual

    Warnings contained in this operator’s manual When operating the TLC 1005, actions need to be taken which are a potential source of danger. In this operator’s manual, instructions for conducting such procedures are preceded by a warning. Note Observe the warnings. Follow the directions and prohibitions of the warnings.

  • Page 43: Symbols

    Symbols The symbols indicate the type of danger: General danger symbol; The type of danger is specified in greater detail in warnings marked like this. This symbol warns against dangerous electrical currents. This symbol warns of hazardous laser beams. This symbol warns of electromagnetic fields. Signalling words The warnings are indicated by one of the following key words: •...

  • Page 44: Overview Of Hazards

    Overview of hazards The following overview of hazards shows the main potential risks to life and health which may be caused by the machine. Danger to personnel is avoided by the design and construction of the machine as well as by safety devices in accordance with EC Machinery Directive 98/37/EC.
  • Page 45 Type of hazard Danger point Danger Additional precautions Thermal hazards From contact Hot workpieces Risk of injury Wear protective clothing and gloves. Use tools to take out workpieces. Due to flames or explosions Combustion/explosion with Risk of injury concentration of oxygen Danger from radiation Laser Radiation during...

  • Page 46: Laser Processing

    Laser processing Operating modes of the laser system A difference is made between two operating modes in terms of safety. The operating mode is set at the machine using a key switch. Normal mode In normal mode the laser is operated in the entire intended functional area without maintenance and service (EN 60825-1).

  • Page 47: Dangers Due To Laser Radiation

    Dangers due to laser radiation lasers lasers generate invisible light (electromagnetic radiation) with high energy. Both direct and reflected laser radiation can endanger people. Different biological tissues absorb light differently. It is generally converted into heat and can lead to thermal damage (e.g. burns, destruction of protein).

  • Page 48: Protection Against Radiation

    Alignment lasers Adjustment lasers, or targeting lasers (HeNe lasers, laser diodes), with their red light are used for alignment work. LASER BEAM DO NOT LOOK INTO THE BEAM LASER CLASS 2 Laser warning symbol and laser class 2 warning sign Fig.
  • Page 49 Training facilities in the Federal Republic of Germany include: • Berufsgenossenschaft für Feinmechanik und Elektrotechnik (Trade Association for Precision Mechanics and Electrical Engineering), Postfach 510580, Gustav-Heinemann-Ufer, D– 50968 Cologne, Germany • Physikalisch-Technische Bundesanstalt (Federal Institute of Technical Physics), Bundesallee 100, D-38116 Braunschweig, Germany •...

  • Page 50: Measures Taken By The Manufacturer

    Measures taken by the manufacturer The machine may only be operated if the safety devices are active. • Safety precautions for the The laser unit is covered with a hood. The hood is monitored laser unit and beam by a safety switch and should only be opened using the guideway appropriate tool.
  • Page 51 CAUTION, INVISIBLE LASER RADIATION WHEN COVER OPEN AVOID EYE OR SKIN EXPOSURE TO DIRECT OR SCATTERED RADIATION Signs 2 and 4: Laser warning symbol and instruction Fig. 3616+3606en sign on covers without safety locks (can only be opened using a tool) INVISIBLE LASER RADIATION AVOID IRRADIATION OF SKIN AND EYES BY DIRECT OR...
  • Page 52 Schematic illustration of The circled numbers in the following display indicate the numbered signs listed in the previous section. machine signs " " " " " Fig. 17160 1-29 Laser processing B337EN01.DOC...

  • Page 53: Hazardous Substances

    Hazardous substances Note With regard to hazardous substances, we would like to state explicitly that we can only provide you with some examples of sources of potential danger. You, as owner of the system, must check the potential dangers associated with the specific materials you are machining and undertake any necessary measures.

  • Page 54: Cutting Oils

    Corresponding investigations revealed however negative findings in all samples: nitrosamines could not be detected. If the cutting oils recommended by TRUMPF are used on a chlorine-free basis, polychlorinated biphenylene (PCB) and dioxins will not form.

  • Page 55: Ozone

    Ozone By using titanium-doped discharge tubes, UV radiation is absorbed during high-frequency discharge, meaning ozone will accumulate outside of the discharge tube. Polyethylene-coated (PE) tubes Aliphatic and olefin compounds are released mainly while laser- cutting polyethylene coated tubes: • N-heptane, 1-heptene, heptadiene. •...

  • Page 56: Hazards From Thermal Decomposition Of Znse Lenses

    Hazards from thermal decomposition of ZnSe lenses Lenses made of zinc selenide (ZnSe) are inserted on the machine in the output mirror of the laser unit and as a focusing lens in the cutting head. Lens characteristics Chemical Zinc selenide (ZnSe) composition Coating contains thorium fluoride (thorium content of a lens with * 1": approx.

  • Page 57: Response To Accidents

    R23/25 Poisonous if inhaled or swallowed. Risk of cumulative effects. S20/21 Do not eat, drink, or smoke when working. In the event of skin contact, rinse off immediately with plenty of water. Consult a doctor if you do not feel well (give this description to your doctor for his/her information).

  • Page 58: Disposal Of Lenses

    For the return delivery, make sure you submit the invoice number or delivery order number under which the lens was purchased at TRUMPF. If these details are not specified, acceptance of the return goods will be refused. Hazards caused by flash or very bright...

  • Page 59: Danger Due To High Voltage

    Danger due to high voltage The radio frequency (RF) generator changes low frequency mains energy into radio frequency electrical energy (13.56 MHz). It serves to excite the laser medium. Radio frequency voltages of up to 10,000 V can arise during the operation of the generator.

  • Page 60: Risks From Electromagnetic Alternating Fields

    Risks from electromagnetic alternating fields The radiation of high-frequency electromagnetic fields poses no danger for persons if the generator is operated as intended. Compliance with the guidelines (EMC guideline for limits on radiation according to EN 55011) is ensured by taking constructive measures.
  • Page 61 1-38 Laser processing B337EN01.DOC...
  • Page 63 Chapter 2 Installation conditions TLC 1000 and TLC 1005 The installation specifications contain all information required for the installation of the machine including the following TLF-lasers: Lasers of small series Lasers of large series on laser console on base on the machine body TLF 2000 TLF 8000t TLF 2700...
  • Page 64 Table of contents Installation site ............... 2-5 Space requirements ............2-5 Floor requirements ............2-5 Weight loading ..............2-6 Ambient conditions............2-9 Exhaust air conduction for compact dust extractor ..2-10 Outdoor installation of cooling unit......... 2-11 Gas supply..............2-12 Laser gases..............
  • Page 65 Transport ..............2-32 On delivery: checking the system ........2-35 Unloading machine and transporting to the installation site..............2-35 Transport of TLC 1005 basic machine...... 2-36 Base for machine body ..........2-39 Machine table............2-40 Base plate ..............2-40 System components ..........2-41 Installing the system............

  • Page 66: Chapter 2 Installation Conditions Tlc 1000 And Tlc 1005

    Before the machine is delivered, you must ensure that all the conditions described in this chapter are fulfilled. If this is not the case, the TRUMPF service personnel will not be able to put the machine into service. TRUMPF service department The machine is put into service by TRUMPF service technicians.

  • Page 67: Installation Site

    Installation site Space requirements An installation plan tailored to the configuration ordered by the customer is created for each machine. Also indicated in the plan is the space required for opening the doors of the control cabinet, RF generator, suction unit, cooling unit, and the covering cap of the laser unit.

  • Page 68: Weight Loading

    • Elastic base plate Minimum thickness 250 mm. • Crosswise reinforcement 3.7 cm²/m, double-ply. • Concrete quality (corresponding to tensile strength C 25/30): Cylinder compressive strength • 1PP². – • Ceiling plate/ Load capacity 20 kN/m². free span base plate •...
  • Page 69 Component Weight Distribution of weight [kg] Round table with gearbox approx. 350 Weight is carried by the with out lifting unit (optional) machine body. Round table with lifting unit approx. 500 Weight is carried by the and swivel unit (optional) machine body.
  • Page 70 Component Weight Distribution of weight [kg] Cooling unit for the laser (without The edges support the coolant): main load. TLF 2000 approx. 560 TLF 2700, TLF 3200 approx. 600 TLF 4000 approx. 690 TLF 5000, TLF 6000 approx. 1150 TLF 8000t approx.

  • Page 71: Ambient Conditions

    Ambient conditions Ambient temperature The ambient temperature for the operation of the machine must be between +10 °C and +43 °C. The temperature at the installation site must not be allowed to fall below +4 °C when the system is switched off.

  • Page 72: Exhaust Air Conduction For Compact Dust Extractor

    Exhaust air conduction for compact dust extractor If needed, the exhaust air conduit for the compact dust extractor can be installed to allow the release of clear gas into the open air. The exhaust air conduit must be installed by the customer starting from the clear gas duct of the compact dust extractor.

  • Page 73: Outdoor Installation Of Cooling Unit

    Outdoor installation of cooling unit A weather protection cover is necessary if the cooling unit is to be installed outdoors. In order to allow access for maintenance and repair work, comply with the minimum distances as shown in the drawing. Minimum distance weather protection cover Fig.

  • Page 74: Gas Supply

    Gas supply In all situations involving the gas supply, we strongly recommend that the customer contact the gas supplier. Note Attention must always be given to the relevant norms (e.g. DIN 477 No. 6, DIN EN 559, DIN 8541 part 3, VBG 15, VBG 62 §46 + §47). Gas conduits and electrical cables laid out in the same cable duct.

  • Page 75: Laser Gases

    Laser gases Purity Laser gas Purity Helium (He) 99.996 % vol. Carbon dioxide (CO 99.995 % vol. Nitrogen (N 99.999 % vol. Laser gas – purity Table 2-6 Gas consumption, supply lines, pressure reducer Helium (He) Carbon dioxide (CO Nitrogen (N Gas consumption [l/h] TLF 2000 to TLF 4000...

  • Page 76: Laser Gas Supply From Cylinders

    Laser gas supply from cylinders • The safest, easiest, and most economical way of supplying laser gas is to use individual cylinders. • The gas flow is interrupted when changing cylinders or bundles. • Only use clean conduits for the connecting lines (oil-free, grease-free, and dust-free on both the inside and outside).

  • Page 77: Cutting Gases

    Cutting gases Purity Cutting gas Purity Oxygen (O 99.95 % vol. Nitrogen (N 99.999 % vol. Cutting gas – purity Table 2-8 Note In exceptional cases, nitrogen of the purity 4.6 (99.996) or of other levels of purity can be used as long the following limit values are not exceeded: •...
  • Page 78 Standard pressure cutting is cutting with a pressure of ≤ 6 bar. Standard pressure cutting Oxygen and/or nitrogen are required as cutting gases. During standard pressure cutting with O the minimum line pressure available at the connection point to the machine is 8 bar (with gas consumption of 10 Nm /h, a nozzle Ø1.7 mm and 6 bar cutting gas pressure).
  • Page 79 High-pressure cutting High-pressure cutting is cutting with a pressure of > 6 bar. Oxygen and/or nitrogen are used as cutting gases. High-pressure cutting is offered as an option for processing stainless steel and aluminum alloys. • During high-pressure cutting with N the minimum line pres- sure available at the connection point to the machine is 27 bar /h, a nozzle with ∅...

  • Page 80: Supply Lines To Cutting Gas Supply

    Supply lines to cutting gas supply Cutting gas connection point The customer must provide the supply lines for the cutting gases up to the connection point on the machine. • The supply lines must be installed up to the connection point on the installation plan marked with the symbol shown on the left.

  • Page 81: Cutting Gas Supply With Cylinders Or Bundles

    For ring circuits, it is absolutely necessary that a ball cock be installed between all bifurcating stub cables, so that the pipes can be shut down a section at a time. Note See "Central laser gas supply" for notes on installation and on pressure and leak tests.

  • Page 82: Cutting Gas Supply From Gas Tank

    Requirements at the Standard connection point pressure High pressure High pressure on the machine Min. input pressure line pressure in [bar] 8 Max. input pressure static [bar] 21 Max. cutting gas pressure [bar] 6 Volume rate of flow Nozzle diameter [mm] 1.7 Cutting gas supply –...
  • Page 83 Pressure regulator specifications Standard High pressure High pressure pressure 1st pressure stage (tank) Safety pressure Optional Recommended Recommended regulating system 2nd pressure stage (tapping point) Tapping point Recommended Recommended pressure regulator recommended Back pressure [bar] 0 - 16 4 - 25 Other requirements Suitable for Suitable for...

  • Page 84: Welding Gases (Inert Gases)

    Welding gases (inert gases) Purity Welding gas Purity Helium (He) 99.996 % vol. Argon (Ar) 99.996 % vol. Nitrogen (N 99.8 % vol. Carbon dioxide (CO 99.5 % vol. Welding gas – purity Table 2-15 Supply lines Note The customer must provide the supply lines for the protective gases up to the connection point on the machine.

  • Page 85: Electrical Supply

    Electrical supply The machine is designed for the following nominal voltages: Nominal voltage Frequency 400 V ± 10 % 50 Hz ± 1 % 460 V + 10 %/– 5 % 60 Hz ± 1 % Table 2-17 If the available nominal voltage varies from the nominal voltage specified above (400 V or 460 V), an isolating transformer must be installed.

  • Page 86: Power Supply

    Power supply Residual current protective If a residual current protection device is used on the line side to protect from direct or indirect contact, only type B is permitted. See device EN 50178 pt. 5.2.11.2 (VDE 0160, edition of April 1998). If, when using a residual current circuit breaker, the leakage current of the machine is larger than the set residual current, the machine must be separated from the network using an isolating...

  • Page 87: Connected Loads, Fuse Protection

    Connected loads, fuse protection The following data represents standard values, which may vary depending on the machine equipment: Connected loads of the machine with laser 2000 2700 3200 4000 5000 6000 8000t 12000t Total connected load incl. all possible options and cooling unit [kVA] 64 Maximum fuse protection of the complete system...

  • Page 88: Teleservice

    Teleservice TRUMPF has made the following interfaces available in the control cabinet of the machine: • Interface for telephone: TAE6-N coupling. • Interface for network: RJ45 plug. Telephone modem The connection point for a telephone modem is marked on the connection installation plan with the symbol shown on the left.

  • Page 89: Compressed Air Supply

    Compressed air supply Compressed air connection The connection points for compressed air are marked on the installation plan with the symbol shown on the left. Two separate compressed air connections must be installed by the customer for the machine and Laserpac. •...
  • Page 90 Compressor A suitable compressor must be provided if the compressed air supply to the system is not adequate. Due to the risk of conden- sation build-up, the maximum distance between the compressor and the basic machine should not exceed 50 m. Emergency sealing gas Process gases, cooling water supply and return, and compressed air for sealing gas conduit and beam guide ventilation are...

  • Page 91: Operating Materials

    Operating materials Note The following operating materials must be made available by the customer before the machine is delivered. Laser gases and cutting and inert gases Note Gas types, their purity and connections, hoses, etc. are specified in section 2, "Gas supply." Cooling water Water is needed to cool the laser unit, RF generator, and optical components on the machine.
  • Page 92 Handling Avoid all unnecessary contact with the water (e.g. with hands). Contact with foreign materials, except those specified by TRUMPF, affects the water quality. • Additional water-filling equipment such as pumps, hoses, or stopcocks should be used exclusively for handling the water of the system.
  • Page 93 Outdoor installation If cooling units are installed outside in areas with a risk of frost, cooling water is mixed with the antifreeze agent "purest ethylene of the cooling unit glycol". The mixing ratio depends on the temperature conditions at the actual installation site: Temperature [°C] to -15 Up to -24...

  • Page 94: Transport

    The cross beam and the swivel bearers that are installed in the machine body must be returned to TRUMPF after system installation and start-up. TLC 1005 with raised machine body: It is essential that a crane...
  • Page 95 Dimensions: TLC 1005 Component Length Width Height Weight [mm] [mm] [mm] [kg] Machine body incl. small- series laser unit for working area: X = 1250 mm 5020 3000 3000 5000 X = 2000 mm 5770 3000 3000 6000 X = 3000 mm 6830 3000 3000...
  • Page 96 Dimensions of system Component Length Width Height Weight components [mm] [mm] [mm] [kg] Control cabinet for basic machine 1200 2000 Double cabinet for control system + RF generator for laser: TLF 2000 1420 2100 TLF 2700 1420 2100 1020 TLF 3200 1420 2100 1040...

  • Page 97: On Delivery: Checking The System

    2. Record visible damage caused during transport on the cargo note and have the record countersigned by the truck driver. 3. Report any hidden damage caused during transport to the insurance company and to TRUMPF within 6 days. Unloading machine and transporting to the installation site...

  • Page 98: Transport Of Tlc 1005 Basic Machine

    Transport of TLC 1005 basic machine The transport unit of the basic machine comprises the machine body with laser and laser console , extension arm, beam guideway, instrument panel, suction channel and safety cabin parts as well as rotational axis (optional) and back stop (optional). Raised machine bodies must be separated from the base before being moved for transport;...
  • Page 99 Length of machine body Cross beam with hanging chains Positioning surface for rotational Total length of transport unit 1, 2 Swivel bearer M36, stopping moving device Stopping point of rotational point of cross beam 5, 6 Positioning surface for fixed moving device armored roller Transport unit for TLC 1005 basic machine with laser on laser console...
  • Page 100 Working range Dimension A [mm] X = 1250 X = 2000 X = 3000 X = 4000 Dimension B [mm] 5020 5770 6830 8530 Total length of transport unit for basic machine Table 2-27 Transporting basic machine The basic machine can be transported to the installation site using to installation site a gantry crane, crane truck, or armored rollers.

  • Page 101: Base For Machine Body

    Base for machine body Unload base from truck and Machine body and base are moved separately to the installation site and placed separately on the factory floor next to the actual move to installation site installation site. The machine body must not be set on to the base by the operator.

  • Page 102: Machine Table

    Machine table Transporting machine table The support table is attached to 4 eyebolts M12; 2 tapping holes are at the front and 2 to the rear of the frame surface. Improper transport of the machine table can cause substantial damage to property! As a result of improper transport, the drawers could be damaged.

  • Page 103: System Components

    Installing the system at the The machine body is lowered onto the foundation and leveled by a TRUMPF service technician. installation site If rotational moving devices are used: ½ Leave the machine standing on the rotational moving devices and have four hydraulic hoisting jacks ready for use.

  • Page 104: Preparing The Factory Floor

    Preparing the factory floor Preparing factory floor The factory floor must be prepared by the customer – in accordance with the system's foundation plan – before the system is delivered. • Zero point line for installation in X Zero point line for installation in Y Bore hole for anchoring direction direction...

  • Page 105: Planning Aid

    Planning aid This planning aid is intended to provide you with an overview of the preparations to be undertaken by the customer. You will find detailed information in the relevant subchapters of the installation conditions. Time before Planning criterion Action delivery of the machine 15 weeks Personnel and training...
  • Page 106 Time before Planning criterion Action delivery of the machine 12 weeks, Gas supply Arrange for installation of the but no later than calendar week ... laser and cutting gas supply at the installation site. Decide supply method (cylinders, cylinder bundles, gas tank). Note the valves and fittings required (e.g.

  • Page 108: Description

    Chapter 3 Description Machine concept ............3-3 The Technical data............3-4 Coordinate system, zero point, working range... 3-7 Coordinate system ............3-7 Zero point, working range ..........3-8 The modules of the laser cutting center....3-11 The modules of the basic machine ........ 3-14 Machine body............
  • Page 109 Rotary axis with media connection (optional) ... 3-23 Back stop (optional) for rotary axis ......3-25 Direct drive rotary axis (optional) ......3-26 Beam guideway............3-28 Processing optics............3-32 Central lubrication ............. 3-35 Instrument panel ............3-36 The laser ................ 3-38 Targeting laser ............

  • Page 110: Machine Concept

    Machine concept The TRUMPF LASERCELL 1005 (subsequently referred to as TLC 1005) is a high-volume CNC laser cutting center for cutting, welding or surface treatment of metallic materials. Flat sheets, tubes, profiles, three-dimensional or rotationally symmetrical workpieces can be processed with this device.

  • Page 111: The Technical Data

    0.001 mm or 0.001° Medium positioning accuracy 0.1 mm or 0.015° Medium dispersion 0.03 mm or 0.005° A axis at R=200 mm 0.0083° TRUMPF CNC control Based on Siemens SINUMERIK 840D with PCU 50 processor Hard disk memory 500 MB Disk drive 3.5''...
  • Page 112 Workstation Rotary axis Workspace 360° Max. axis speed 60 rpm Max. moment of inertia 7 kgm ∅ 93 mm Max. available aperture Max. axial load 300 kg (at 400 mm distance to the surface plate) Surface plate: ∅ 400 mm diameter tapping hole 20 x M12...
  • Page 113 Lasers Laser type TLF series Small series: Large series: TLF 2000 TLF 8000t laser from TRUMPF TLF 2700 TLF 12000t TLF 3200 TLF 4000 TLF 5000 TLF 6000 Laser power programmable in 1% steps according to TLF laser used 2000 W to 12000 W...

  • Page 114: Coordinate System, Zero Point, Working Range

    Coordinate system, zero point, working range Coordinate system Depending on its expansion level the machine has a maximum of 6 axes. Axes (B and C axis shown in zero position) Fig. 7188 X axis Horizontal movement of the motion unit lengthwise to the machine Y axis Horizontal movement of the Y carriage...

  • Page 115: Zero Point, Working Range

    Zero point, working range Zero point Reference point Working range 2-D machining Fig. 32542 Zero point of the Z axis The zero point of the Z axis refers to the pivotal point in the B/C gear (see Fig. 36720, Pos. C). Working range, X direction Y direction:...
  • Page 116 Working range For 3-D processing, the working range around the swivel radius (B) of the respective processing optics and around the joint offset (A) for 3-D machining between mid-beam B/C-angular gear and tool tip can be reduced, depending on the position of the B and C axes. Joint offset between B/C angular B axis swivel radius gear beam center and tool tip...
  • Page 117 Risk of collision in the A general risk of collision exists in the 3-D workspace between the Z sleeve/processing optics and the jigs and fixtures, workpieces, 3-D workspace and work tables in the workspace of the machine. There is a particular risk of collision: •...

  • Page 118: The Modules Of The Laser Cutting Center

    The modules of the laser cutting center Machine with TLF laser on laser console - small-series laser TLF laser on support bracket Laser cooling unit Safety cabin Compact dust extractor RF generator Basic machine Switch cabinet of the machine Switch cabinet for laser Operating panel and teach panel Laser cutting center modules Fig.
  • Page 119 Machine with a TLF laser on the base - large-series laser TLF laser on base Laser cooling unit Safety cabin Compact dust extractor RF generator Basic machine Switch cabinet of the machine Switch cabinet for laser 10 Operating panel and teach panel Laser cutting center modules Fig.
  • Page 120 Position Designation Function Description TLF laser Generates the laser radiation TLC 1005 operator’s manual Compact dust extractor Suction unit for fumes and Operator’s manual compact dust airborne particles in the safety extractor (filtering installation) cabin Switch cabinet for machine CNC control system, logic and Electrical Circuit diagram power section, electrical supply TLC 1005...

  • Page 121: The Modules Of The Basic Machine

    The modules of the basic machine Instrument plate Rotary axis (optional) Z clamping sleeve with Back stop (optional) Beam guideway processing optics Machine body Motion unit X,Y,Z Support table Basic machine modules Fig. 32555 Only for machines with small-series TLF laser. With machines with large series laser the instrument plate is on the front on the machine body.
  • Page 122 Position Designation Function Instrument panel Installation of the elements for the pneumatic system, the cutting gas supply and the central lubrication. 2 and 4 Rotary axis and back stop Holds and drives rotationally symmetrical workpieces during processing. Machine body Holds the motion unit, beam generator, beam guideway as well as all components relevant for functions Beam guideway Laser beam guidance between laser unit and processing optics...

  • Page 123: Machine Body

    Machine body High precision with The machine body has been manufactured as a warp-resistant welded assembly. The optimized, closed structure is oriented to high dynamics the distribution of forces. The machine body and extension arm have been calculated and optimized by means of FEM. This enables a high degree of warp-resistance and bending rigidity.

  • Page 124: Motion Unit For X, Y, Z (Extension Arm)

    Motion unit for X, Y, Z (extension arm) The motion unit consists of a cantilever extension arm and the attached Y carriage with integrated Z axis. The motion unit is connected to the machine body via guide rails (X carriage). The main modules of the motion unit include: •...

  • Page 125: Drives

    Drives All drives are digital 3-phase current servomotors from Siemens. The advantages of digital drives are as follows: • Long service life even if subjected to extreme temperatures. • No outlay for maintenance due to long-term magnetic regula- tion. • Protection type IP65: splash protection from water and coolants.

  • Page 126: Support Table

    Support table The support table is designed as a welded construction. The working range is designed with support slats (mild steel or stainless steel) in variable sizes. Suction chambers, including the suction unit coupling, are located under the working range. The suction chambers are sequentially triggered depending on the position of the processing optics.
  • Page 127 Version There are different versions of the support table: • Stationary table: the table is firmly attached to the machine body. • Table can be shifted manually with pneumatic indexing: the tables are guided along round rails (flush mounted) which are cast in the foundation.

  • Page 128: Base Plate

    Base plate The base table is designed solely for machining 3-D workpieces. Flat sheets must not be machined on this table, since the table is not structurally designed for that purpose. Flap Fastening plate Suction piping connection Circumferential support slat Base plate with exhaust trough Fig.
  • Page 129 Installation of fixtures or The base table has a circumferential, machined support slat. There base bridges are spacer holes (∅16 ) with fastening threads (M12) in the table frame in a grid of 250 mm in X and Y directions for mounting fixtures or base bridges.

  • Page 130: Rotary Axis With Media Connection (Optional)

    Rotary axis with media connection (optional) The rotary axis is used for processing tubes or other rotationally symmetrical parts. The rotary axis is a CNC rotary axis with a free aperture in the center (∅93 mm) and a surface plate (∅400 mm) with threaded holes to hold customized clamping devices.
  • Page 131 The surface plate is a rotary plate of ∅400 mm with 36 M12 Surface plate tapping holes for mounting workpieces or fixtures provided by the customer. M12x20 (36x) Rotary plate hole pattern Fig. 35848 Media connection The rotary axis has a rotary transmission leadthrough for con- necting with water and gas supplies for supplying the on-site clamping fixtures which are mounted on the rotary axis.

  • Page 132: Back Stop (Optional) For Rotary Axis

    Back stop (optional) for rotary axis The freely rotating back stop is an extension of the rotary axis (A axis). It is also attached to the machine and can be moved on rails along the X axis. • Version Base plate for connecting the back stop to or customized jigs and fixtures.

  • Page 133: Direct Drive Rotary Axis (Optional)

    Note The feasibility and usefulness of utilizing this axis for the respective application need as a basic principle to be checked by TRUMPF. Torque motor: brushless ring-shaped synchronous motor. 3-26 The modules of the laser cutting center...
  • Page 134 Rotary axis at the machine The rotary axis can be used both horizontally and vertically – in terms of the axis of rotation. It can be attached to a console and to body a rail assembly along the machine body and can be manually shifted or swivelled vertically or horizontally, depending on the respective version, in a manner analogous to conventional rotary axes:...

  • Page 135: Beam Guideway

    Beam guideway With a small-series TLF laser on a laser console Deflection mirror laser unit X/Y axis deflection mirror (Cu) Cutting head deflection mirror X/Y axis deflection mirror (Si) Y/Z axis deflection mirror (Cu) (Si) Deflection mirror (Si) Deflection mirror (Cu) in the 10 Cutting head lens Adaptive telescopic mirror (Cu) angular gear...
  • Page 136 With a large-series TLF laser on a base Beam bending mirror (Cu) AutoLas Plus mirror or deflection Cutting head deflection mirror laser/machine mirror (Cu) in the angular gear (Si) X/Y axis deflection mirror (Cu) 10 Cutting head lens Y/Z axis deflection mirror (Cu) Beam guideway with a large-series TLF laser on a base Fig.
  • Page 137 Completely encapsulated The beam guideway of the machine is completely encapsulated from the beam generator to the processing optics. The beam beam guideway guideway is ventilated with cleaned compressed air to prevent dirt particles and fumes from entering. The laser beam is generated in the resonator of the laser unit. After exiting the resonator, the beam is guided by deflection mirrors through the machine body and motion unit to the processing optics.
  • Page 138 AutoLas PLUS AutoLas Plus is a mechanism for automatic, program-directed adjustment of the focus position to suit the type and thickness of the material according to the laser technology table, and for compensating the focus shift on laser machines across the whole working range.

  • Page 139: Processing Optics

    Processing optics The laser on the TLC 1005 is used as a tool for laser cutting and laser welding. For this, sufficient laser power as well as state-of- the-art technology with respect to processing optics prerequisites. The processing optics can be changed quickly and easily at the machine as needed.
  • Page 140 For welding The following processing optics are available: • Welding head with 150 mm focal length. • Welding head with 200 mm focal length. • Welding head with 270 mm focal length. The laser beam is focussed by a parabolic mirror in the welding head and guided through the welding nozzle onto the workpiece.
  • Page 141 Crossjet (optional) Air is permanently blown horizontally through the nozzle body of the welding head during machining. This seal of air prevents dirt or slag particles from infiltrating beam guideway contaminating the parabolic mirror. The blowing pressure is set by means of the restrictor valve on the instrument panel.

  • Page 142: Central Lubrication

    X, Y, and Z axes can be configured on the machine as required – but only by TRUMPF service personnel. Low-viscosity grease The filling level of the low-viscosity grease reservoir is monitored by the control system.

  • Page 143: Instrument Panel

    Instrument panel On machines with a small series TLF laser, the instrument panel is located under the laser console. The main operating devices can be accessed by removing the cover. On machines with a large series TLF laser the instrument plate is located on the front of the machine body.
  • Page 144 Welding gas unit (He) 11 Welding gas pressure sensor 26 2/2 directional control valve for Welding gas pressure or inert gas) welding beam guideway sensor (He) 12 Welding gas unit ventilation Welding gas shut-off valve (CO or inert gas) 27 2/2 directional control valve for or inert gas) 13 Welding gas shut-off valve cutting beam guideway...

  • Page 145: The Laser

    The laser The standard equipment of the TLC 1005 includes a CO2 laser of the TLF series by TRUMPF. It is possible to use lasers with laser power between 2000 W and 12000 W. TLF stands for: TRUMPF - Laser - Frequency-excited.

  • Page 146: Targeting Laser

    Maintenance-free radial The TLF laser is equipped with a maintenance-free radial turbine blower for circulating the laser gas. The shaft in the blower is turbine blower magnetic and thus stored in a contactless position. In the blower there is no abrasion through mechanical ball bearings. Radio-frequency excitation TLF lasers are excited by a high-frequency alternating current.

  • Page 147: Electrical Installation

    Software The safety interface is programmed modularly within the software and configured and activated by means of application data from TRUMPF. Interface in the switch The safety interface is wired with a 40 pole HAN-DD plug: M+100-X51.
  • Page 148 Safety interface description: Signal from user Signal to user E-STOP circuit: same function as the E-STOP button at the control panel of the machine A1, A2 Connect E-STOP switch up to the E-STOP circuit of the (1st channel) machine. D1, D2 Note: the bridges in the switch cabinet must be removed.

  • Page 149: Digital User Interface (Optional)

    Digital user interface (optional) The digital user interface is a module with 16 digital inputs and 16 digital outputs. The inputs and outputs can be set and called up directly in the NC program. Application With the digital user various process components can be directly addressed and activated by the NC program interface, for example supply devices, customer devices or other automation com- ponents.

  • Page 150: Compact Dust Extractor

    Compact dust extractor The machine is equipped with a compact dust extractor (filtering installation) with or without a CO fire extinguishing device, an oversized material collector and a spark arrester. The suction power is 2000 m The suctioned air is channelled into the compact dust extractor via a system of pipes.

  • Page 151: Control System/Programming

    Control system/programming Control system Basis Siemens SINUMERIK 840D: SINUMERIK 840D by Siemens provides the TLC 1005 with an open control system. The standard configuration includes the following functions: • 3-D path correction. • Spline interpolation based on NURBS. • Several kinds of transformation. •...

  • Page 152: Programming

    TRUMPF. With ToPs 100, NC programs for machining flat sheets can be generated quickly, reliably and to a great extent automatically. ToPs 400 ToPs 400 is a programming system from TRUMPF for two- dimensional tube machining on 2-D and 3-D laser cutting machines. 3-45 Control system/programming B337EN03.DOC...

  • Page 153: 3-D Programming

    It is connected control panel and used for teach-in programming only. All the actions required for teaching can be carried out from the teach panel. TRUMPF has extended the unit’s basic functionalities, such as e.g. entering technologies, programming standard geometries, as well as carrying out auxiliary functions.
  • Page 154 Teach probe (optional) The teach points can be registered using the processing optics or using a teach probe located in the processing optics. There are different teach probes for the cutting head and for the welding head. For cutting head For laser welding head Teach probe Fig.

  • Page 155: Sensor System

    • Checking the seam after laser welding. TSD seam sensor system (optional) The Seam sensor system TSD (TRUMPF Seam Detector) is an image processing system developed by TRUMPF for measuring joint positions in connection with welding applications. Seam sensor (camera) with welding head Fig.
  • Page 156 The control system regulates the axis position based on these measured values in a way which compensates for advance movement. Note Description, operation and maintenance: see operator’s manual Seam sensor system TSD – TRUMPF LASERCELL. 3-49 Sensor system B337EN03.DOC...

  • Page 157: Dias Distance-Control System

    DIAS distance-control system The TLC 1005 is for cutting equipped as standard with the contact- less automatic distance control system DIAS: DIAS stands for Digitales Intelligentes Abstands-System (digital intelligent distance system). Constant distance With the distance control system, the distance of the cutting nozzle to the sheet is calculated capacitively, with the cutting nozzle between nozzle and sheet forming this capacity together with the sheet surface.

  • Page 158: Options

    Options Measuring probe (optional) The cutting head or laser welding head can also be equipped with a Renishaw measuring probe (tactile measuring probe). At an angle of 120° to the nozzle, the measuring sensor is put onto and fastened to the processing optics which has been prepared accordingly.

  • Page 159: Welding Wire Feed (Optional)

    Welding wire feed (optional) Welding wire feed is an option for welding applications with supplementary wire. The wire feed is designed for steel or aluminum wire with ∅ 0.8 mm, 1.0 mm or 1.2 mm. The coil at the Z axis and the drive at the welding head can be removed. Note The rotation of the welding head around the C axis is restricted to + 200°...

  • Page 161: Chapter 4 Operation

    Chapter 4 Operation Online help The control system is fitted as standard with an online help function for operating and programming the machine. All information on operating the machine which can be found in the programming manual and in this chapter can be called up by pressing keys at the control system.
  • Page 162 Part 1: Operating devices ............4-9 Control elements other than on the operating panel . 4-9 Control elements of the basic machine ......4-9 Control elements of the safety door (electrically driven sliding door) ........4-12 Teach panel..............4-14 Control elements of the JIC version ....... 4-15 Control elements on the start post of the pallet changer ..............
  • Page 163 PRODUCTION – Switch elements ......... 4-53 Operation of the switch elements......4-54 Switch elements for distance control system .... 4-55 Switch elements in general ........4-57 Service switch elements..........4-59 Welding switch elements........... 4-60 PRODUCTION Front safety door switch elements ... 4-61 Safety door status display switch elements....
  • Page 164 Switch elements for suction unit......4-121 Manually movable support table indexing switch elements (optional)..........4-122 Front safety door switch elements for electrically driven sliding doors ..........4-125 Front safety door switch elements for electrically driven lift doors............4-127 TLF laser intervention 1 switch elements ....4-128 TLF laser intervention 2 switch elements ....
  • Page 165 Integrated MDC activity (optional)......4-161 10.1 MDC message texts ............. 4-161 10.2 MDC Creating and modifying message texts ....4-162 10.3 MDC Displaying and editing machine data ....4-164 10.4 MDC Creating and modifying interruptions ....4-166 10.5 MDC Evaluating machine data........4-167 10.6 MDC Display of the times in a list.........
  • Page 166 Filling the zero point memory for individual axes with the current axis position ........4-188 Deleting the zero point memory for all axes ....4-191 Deleting the zero point memory for individual axes..4-193 Working with the summary production plan... 4-195 Creating a summary production plan ......
  • Page 167 Operating the laser ............ 4-219 14.1 Switching on the laser ..........4-219 14.2 Switching off the laser ..........4-220 14.3 Igniting the laser beam ..........4-220 14.4 Switching off the laser beam ........4-221 14.5 Opening the beam trap..........4-221 14.6 Closing the beam trap ..........
  • Page 168 Acknowledging maintenance........4-240 Operating the integrated MDR ........4-241 20.1 Creating a message text ..........4-241 20.2 Assigning a message text ..........4-242 20.3 Splitting up an interruption period......... 4-243 20.4 Evaluating machine data ..........4-244 Evaluating the ODC interface........4-245 21.1 Opening a LOG-file ............

  • Page 169: Part 1: Operating Devices

    Part 1: Operating devices Control elements other than on the operating panel Control elements of the basic machine MAIN SWITCH E-STOP on the teach panel E-STOP on the control panel Control elements of the basic machine Fig. 39483 Operation B337EN4_1...
  • Page 170 Control element Prerequisites Explanation None This switch will turn the electricity supply for the machine and the control system on and off. MAIN SWITCH None Pressing the impact button: Stops all path movements of the machine, pallet changer, and any other E-STOP available devices.
  • Page 171 Control element Prerequisites Explanation Parallel interface Service socket Disk drive Teach panel connection Control elements not on the operating panel Fig. 39438 Control element Explanation Parallel interface for connecting peripheral devices, e.g. to data backup Service socket Voltage is also present, even after MAIN SWITCH OFF.

  • Page 172: Control Elements Of The Safety Door (Electrically Driven Sliding Door)

    Control elements of the safety door (electrically driven sliding door) The electrically driven safety doors can be opened and closed manually using switch or control elements on the safety cabin or automatically by means of the machining program. E-STOP Illuminated button ACKNOWLEDGE LOADING ILLUMINATION safety cabin Safety door control panel TLC 1005...
  • Page 173 Control element Prerequisites Explanation None Pressing the impact button: Stops all path movements of the machine, pallet changer, and any other E-STOP available devices. The cutting gas and/or the cutting gas supply is interrupted. Closes the beam trap and switches off the laser beam.

  • Page 174: Teach Panel

    (control panel user interface) and is used exclusively for teach-in programming. All the actions required for teaching can be carried out from the teach panel. TRUMPF has extended the unit’s basic functionalities, such as e.g. entering technologies, programming standard geometries, as well as carrying out auxiliary functions.

  • Page 175: Control Elements Of The Jic Version

    Control elements of the JIC version If the electrical installation conforms to JIC, there are also key switches on the switch cabinet of the laser. Key switches on the laser switch cabinet Fig. 27492 Danger of electrical shocks The safety circuit of the machine has been bypassed. All live components carry dangerous charges! ½...
  • Page 176 Key switch Service Operation Under Voltage Trip inactive active The safety circuit of the machine has The safety circuit of the been bypassed. All electrical system is active. Opening components of the machine are a door (switch cabinet, RF electrically charged. Opening a door generator, etc.) activates (switch cabinet, RF generator, etc.) the E-STOP.

  • Page 177: Control Elements On The Start Post Of The Pallet Changer

    Control elements on the start post of the pallet changer linear changer) The machine can be optionally equipped with a pallet changer in X and/or in Y direction. The pallets are operated: • Manually via switch elements or via external start posts. •...
  • Page 178 Danger of persons being struck or crushed in the area of the travelling tables ½ Before pressing a button to set a machine table in motion, the operator must ensure that no persons are within the travel range of the pallet. RESET LIGHT BARRIER CLAMP (customized)
  • Page 179 Control element Prerequisites Explanation None Pressing this button: Interrupts control system operations and resets the control system to its RESET switch-on condition. Deletes all active error messages. Stops and ends an active program. The reference points are retained. Device needs to have been applied. customized applications e.g.
  • Page 180 Control element Prerequisites Explanation None Pressing this button acknowledges FEED HOLD. Any machining program interrupted is resumed. Start Automatic program is active. Pressing this button acknowledges the loading of the pallet. The pallet travels A summary production plan is being into the working area.

  • Page 181: Z Axis Brake Switch

    Z axis brake switch The brake of the Z axis can only be released via a rotary switch in the machine switch cabinet (see: Part 3, “Operating the machine”, section “Releasing the Z axis drive brake”). Caution As soon as and for as long as the rotary switch is at “ON”, the Z axis will move down without braking until it reaches the stop (Z=0).

  • Page 182: Operating Panel With Color Display

    Operating panel with color display LASER LASER LASER TEST Operating devices of the machine Color display Operating devices of control system Fig. 39434 4-22 Operation B337ENE4_1...

  • Page 183: Control Elements On The Machine

    Control elements on the machine LASER LASER LASER TEST 10 11 12 13 14 15 16 17 18 19 20 MACHINE ON/OFF START KEY SWITCH FEEDRATE POTENTIOMETER KEY SWITCH TEACH PANEL ESTABLISH HOME POSITION BEAM BLOCK LASER ON/OFF JOG MINUs FEED HOLD BEAM ON/OFF POTENTIOMETER...
  • Page 184 Control element Prerequisites Explanation control system ready Pressing this button switches operation. machine on or off. E-STOP is not active With MACHINE ON: Light barriers must be active. The power supply for the drives is MACHINE activated. Test cycles are performed for ON/OFF monitoring the supply devices (com- pressed air, axes, oil supply etc.).
  • Page 185 Control element Prerequisites Explanation None Pressing this button: Control system operations are inter- rupted and the control system is reset to its switch-on condition. Deletes all RESET active error messages Stops and ends an active program The reference points are retained. MACHINE ON Pressing this button: FEED HOLD is not active.
  • Page 186 Control element Prerequisites Explanation The beam trap is opened or closed by Service mode is active. pressing this button. Laser beam is switched off. Button lights up if the beam trap is open. BEAM TRAP OPEN/SHUT None Error messages are acknowledged after eliminating the error by pressing this button.
  • Page 187 Control element Prerequisites Explanation None With the potentiometer, the cutting gas pressure is changed by around ±20 %. POTENTIOMETER CUTTING GAS PRESSURE None The potentiometer is used to regulate the speed of the axes within a range of 0-120 %. FEED JOG mode: POTENTIOMETER...
  • Page 188 Control element Prerequisites Explanation None Service mode is called up by turning the key switch. KEY- SWITCH The beam trap is closed. SERVICE MODE Axes can no longer be moved. Service mode on. Service mode off. None The safety circuit of the laser is inter- rupted by turning the key switch.
  • Page 189 Control element Prerequisites Explanation None The teach panel is switched on or off by turning the key switch. With teach panel active: SWITCH The machine can now only be operated TEACH PANEL by means of the teach panel. LASER TEST is set automatically and the beam trap cannot be opened.

  • Page 190: Control Elements Of The Control System

    Control elements of the control system 9 10 11 12 13 LASER LASER LASER TEST 15 16 17 18 DIAGNOSTICS ESCAPE FOCUS MENU MAINTENANCE/INITIAL START-UP 9 ENTER EXIT WINDOWS TOOLING DIGIT BLOCK HELP PROGRAMMING PAGE UP FOCUS SETUP FAST CURSOR AND TOGGLE PRODUCTION PAGE DOWN ZOOM...
  • Page 191 Control element Prerequisites Explanation None The activity buttons are used to select PRODUCTION individual activity fields. In switch-on condition, the control system is in the PRODUCTION activity field. SETUP PRODUCTION SETUP activities never active simultaneously. Either PRODUCTION PROGRAMMING or SETUP is selected. Either PROGRAMMING or MAINTEN- ANCE can be additionally selected.
  • Page 192 Control element Prerequisites Explanation None The cursor appears in the selected frame if the FOCUS button is pressed. Function selection and data entries can FOCUS be carried out there. It is possible to move forwards within a selected frame with the FOCUS and the cursor keys.
  • Page 193 Control element Prerequisites Explanation Focus is in a selection field. A selection field is opened on the screen upon pressing the TOGGLE key. A term can be selected within this TOGGLE selection field using the cursor keys. The selection field is closed again with the same key.

  • Page 194: Ascii Keyboard

    ASCII keyboard The keyboard for operating the control system is in the drawer underneath the user interface. S croll PrtSc P ause F10 F11 F12 SysRq Lock Break Caps Scroll Lock Lock Lock H om e Pape § & Insert N um Lock ’...
  • Page 195 CAPS LOCK It is possible to use only upper case letters with the help of the <CAPS LOCK> button. Pressing this key once makes it unnecessary to hold the <SHIFT> key down. This function is cancelled by pressing the key again. ENTER The <ENTER>...

  • Page 196: Part 2: User Interface

    Part 2: User interface User interface layout Menu bar Display area Status bar Softkey bar Message line Fig. 27980 Menu bar The white menu bar shows the available topic blocks from which individual topics can be selected. The menu bar is selected by pressing the FOCUS MENU key.

  • Page 197: Status Bar

    Status bar The status bar directly under the menu bar displays symbols and abbreviations which indicate the current settings of the machine and the control system: Laser ready for operation Read-in block active Malfunction Feed block active Laser beam off, beam trap closed Read-in block and feed block active Laser beam off, beam trap open Machine in JOG submode (SETUP...

  • Page 198: Message Line

    Message line The black message line is divided into three fields and is used to display error messages and other kinds of information. Error message If an error occurs, the control or machine element (e.g. NC, PLC, MMC) which caused the error is displayed in the first field of the message line.

  • Page 199: Machine Submodes

    Machine submodes The machine can operate in three different submodes: • AUTOMATIC submode. • MDA submode. • JOG submode. The three machine submodes must be clearly distinguished from the six activity fields of the control system: • PRODUCTION activity. • SETUP activity.

  • Page 200: Mda Submode

    MDA submode Definition Parts programs can be created and executed block-by-block in MDA submode (Manual D ata A utomatic). In addition, you can enter the desired movements into the control system specifically in the form of individual NC program blocks using the keyboard. The entered program blocks are executed after pressing the "Start"...
  • Page 201 The superordinate PRODUCTION and SETUP activities can not be both selected simultaneously. The control system is either in the PRODUCTION activity field or in the SETUP activity field. The active activity field is indicated by the illumination of the corresponding button to the right of the screen. In addition, a subordinate activity can be selected from group 2.

  • Page 202: Production Activity

    PRODUCTION activity PRODUCTION Single job After the control system is started up, the menu >Production >Single job will be shown on the user interface. In the PRODUCTION range of activities, NC programs are selected, and then processed fully automatically. Machine axes Fig.
  • Page 203 Geometry axes Fig. 39476en The names of all machine axes are listed one under the other in the first column of the table. In the position column to the right of this, the current positions (actual positions) of these axes are displayed in the workpiece coordinate system (WCS).
  • Page 204 Program information Information on the NC program currently selected is displayed on the right-hand side of the screen: • Selected program: displays the program name of the currently selected NC program. • Active program: the program designation of the currently active program section will be displayed.
  • Page 205 TLF laser status Fig. 36342en • Laser power: current laser output in watts • System pressure: current gas pressure in resonator in hPa • Resonator status: − Start-up: after the laser is switched on with the Laser ON/OFF button, the automatic power-up cycle will start and the resonator status "Start-up"...
  • Page 206 • Active operation mode: the active operating mode of the laser is displayed. − Operating modes with service mode OFF: LPC normal, LPC analog, LPC cycles. − Operating modes with service mode ON: Alignment On, Alignment OFF • Active submode: the active submode is displayed. Possible submodes of the laser are: CW, PULSING F, PULSING T.
  • Page 207 Producing switch elements Fig. 39430en The Production switch elements are displayed on the left-hand side of the monitor parallel to the single job. It is possible to select all of the switch element groups which belong to the PRODUCTION activity; the switch elements can be operated parallel to the processing program currently running.
  • Page 208 Production plan (production plan summary Fig. 27959en • Status: the status of the sheet job will be displayed. − Free: the sheet job has been released for processing. − Blocked: the sheet job will not be taken into account during processing.
  • Page 209 Program data Fig. 36344en The program data of the NC program currently selected is displayed in the form of a table. The names of the main program and the first seven subroutines are in the first line. The current position of the machine in the NC program section (block number) during the execution is displayed in the second line.
  • Page 210 Active functions Fig. 36345en The NC and machine functions which are active during the execution of a program are displayed. Functions of the PLC are displayed in the list of active synchronous actions while language commands and NC functions are displayed in the list of active G functions / NC instructions.

  • Page 211: Production - Machine Components

    PRODUCTION – Machine components In the "PRODUCTION - Machine components" menu, components of the machine can be displayed and then hidden again. Components need to be deactivated if a mechanical defect prevents them from working properly. As a result it is possible, for example, to execute NC programs containing automatic loading or unloading cycles nevertheless.

  • Page 212: Production Program Options

    PRODUCTION Program options If the machine is working in the submode AUTOMATIC or MDA, the program mode can be changed via the program mode. Program options Fig. 36346en The following program options can be selected using the FOCUS key, and activated or deactivated with the TOGGLE key: •...

  • Page 213: Production - Switch Elements

    • Correct rapid feed: The correction switch for the feed rate also affects the rapid feed rate. • Programmed stop: the program execution is stopped at the block in which the M01 is programmed. • Program test: the setpoint display in the axis table "simulates" the travel motions.

  • Page 214: Operation Of The Switch Elements

    Operation of the switch elements The switch element status is shown by symbols arranged on the screen: • If two buttons are displayed two specific switch statuses are possible (normal case). • A single button means that there is only one definitive status. •...

  • Page 215: Switch Elements For Distance Control System

    Switch elements for distance control system Switch elements for distance control system Fig. 39018en • Teach probe: press the switch element to work with the teach probe. The following apply when operating with the teach probe: The DIAS III distance control system is not active. It is not possible to ignite the laser.
  • Page 216 • Collision recognition: press the switch element when the reaction time of the distance control system is to be modified. The reaction time of the distance control system after a recognized collision will be influenced with this switch element until the triggering of FEED HOLD. The selected reaction time is self-holding.

  • Page 217: Switch Elements In General

    Switch elements in general General switch elements Fig. 39020en • He-Ne targeting laser: press the switch element to switch the He-Ne targeting laser on or off. • Gas change timer: switch the switch element to ON when different cutting gases are to be used for piercing and cutting. The residual gas can escape from the gas line during the applied delay of about 10 s.
  • Page 218 • Max. laser output: The maximum laser power valid for and usable on the system will be displayed. The reason for this is as follows: systems used for cutting and welding generally use lasers with a higher laser output. The maximum laser output can be restricted by means of an application parameter (service function) in order to protect the lens in the cutting head from excessive laser output.

  • Page 219: Service Switch Elements

    Service switch elements Service switch elements Fig. 35184en • Releas. brakes w/o Z: press the switch element to release the brakes of the X and Y axes. Closed. Released. • Lubrication cycle status: status display; the status of the major automatic lubrication cycle will be displayed. Off.

  • Page 220: Welding Switch Elements

    Welding switch elements Welding switch elements Fig. 27965en • Welding head release: press this switch element to cancel E-STOP after a collision involving the welding head during machining. The axes are switched on again. 4-60 Operation B337EN4_3...

  • Page 221: Production Front Safety Door Switch Elements

    PRODUCTION Front safety door switch elements Switch elements of the front safety door Fig. 35185en • Safety door open: press switch element in order to open the safety door. This switch element has no effect if the safety door has been isolated. Undefined.
  • Page 222 • Reference safety door : press switch element in order to reference the safety door. Not applied. Reference run not active: as long as the safety door is not referenced, the switch element will continue to flash red/green. Reference run active. Referenced.

  • Page 223: Safety Door Status Display Switch Elements

    Safety door status display switch elements Safety door status display switch elements Fig. 36067en • Status of left safety door: Status display; the status of the left-hand safety door is displayed. Closed. In motion. Open. • Status of front safety door: Status display; the status of the front safety door is displayed.

  • Page 224: Left Pallet Changer Status Display Switch Elements

    Note If a manual maintenance door has been applied to the machine, the status of the door is displayed: • Closed. • Undefined. Left pallet changer status display switch elements Switch elements of the left pallet changer Fig. 27777en • Position table X 1: Status display;...

  • Page 225: Front Pallet Changer Status Display Switch Elements

    Front pallet changer status display switch elements Front pallet changer switch elements Fig. 27778en • Position table Y: Status display; the coordinates of the table position are displayed. • Position table Y 1: Status display; the coordinates of the table position are displayed.

  • Page 226: Right Pallet Changer Status Display Switch Elements

    Right pallet changer status display switch elements Switch elements of the right pallet changer Fig. 27779en • Position table X 2: Status display; the coordinates of the table position are displayed. 4-66 Operation B337EN4_3...

  • Page 227: Maintenance Switch Elements

    Maintenance switch elements Switch elements for maintenance Fig. 35186en • Reset lubricat. count.: press the switch element to reset the lubrication counter to zero. • No. of lubrications: the number of major lubrication cycles which have been carried out will be displayed. •...

  • Page 228: Suction Unit Switch Elements

    Suction unit switch elements There is a customized default setting for every machine based on the applied machine data. This default setting is effective in auto- matic mode as long as no other function has been programmed for the suction unit in the NC program. The applied default setting of the vacuum flaps can be changed in JOG mode.
  • Page 229 Switch elements for suction unit Fig. 27775en • Table suction status (optional): Status display; status of the flaps along the suction channel. The flaps are opened or closed automatically in the machining program, depending on the position of the processing optics. Closed.

  • Page 230: Manually Movable Table Indexing Switch Elements

    Manually movable table indexing switch elements Electrical indexing There is an indexing bolt on both the left and right edges of each support table (left and right indexing areas). Only the two outer indexing bolts engage when separated support tables are coupled and moved into the working area of the machine.
  • Page 231 Indexing switch elements Fig. 30895en • Indexing active: actuate this switch element if you want to either index the table/tables or undo the indexing. This switch element is effective for all four indexing pins (left and right indexing areas). Not applied this switch element is not effective in active two-station operation.
  • Page 232 • Right index active: actuate this switch element if you want to index the table in machining station 2 or undo the indexing. Not applied. This switch element does not work if two- station operation is deactivated (partition panel removed) and for machines without two-station operation.

  • Page 233: Switch Elements For Tlf Laser Statuses 1

    Switch elements for TLF laser statuses 1 Switch elements for TLF laser statuses 1 Fig. 27966en • Vacuum pump: actuate this switch element if you want to check whether the vacuum pump is switched on or off. • Fast purge: actuate this switch element if you want to check if purge fast is switched on or off.

  • Page 234: Switch Elements For Tlf Laser Statuses 2

    Switch elements for TLF laser statuses 2 Switch elements for TLF laser statuses 2 Fig. 27808en • Turbine mains voltage: actuate this switch element if you want to check whether the turbine power supply is switched on or off. • Turbine 1 Start: actuate this switch element if you want to check whether "turbine 1 start"...

  • Page 235: Production Tables

    The parameter values of the respective LTT are displayed in duplicate. If there is a deviation between the values in the working laser technology tables table and the nominal values, then the display in the TRUMPF LTT is framed against a dark background. •...
  • Page 236 Table parameters - General Fig. 39420en • Rated laser output: maximum output of the laser in watts. May not be changed. • Material: material type/material thickness in 1/10 mm. • Material thickness: material thickness in mm. • Lens focal length: focal length of the lens (5" or 7.5") in the cutting head, in inches.
  • Page 237 General cutting Fig. 39421en • Manual setting dimension : setting dimension in mm. States the position of the focus relative to the nozzle tip. This value has to be set manually at the cutting head. • Acceleration: acceleration of the X, Y, and Z axes in m/s² until the axes have reached the programmed cutting speed (max.
  • Page 238 Cutting a large contour Fig. 39422 Cutting a medium contour Fig. 39423en 4-78 Operation B337EN4_3...
  • Page 239 Cutting a small contour Fig. 39424en • Kerf: width of the kerf in mm. The value entered is only used when working with activated kerf correction (cycle TC_LASERCORR_ON). • AutoLas Plus setting dimension: AutoLas Plus setting dimension in mm. States the position of the focus relative to the nozzle tip during piercing.
  • Page 240 Piercing - General Fig. 39425en • AutoLas Plus setting dimension: AutoLas Plus setting dimension in mm. States the position of the focus relative to the nozzle tip during piercing. The dimension is set automatically via the AutoLas Plus facility. Applies to machines with AutoLas Plus. This parameter is not required for machines without AutoLas Plus. 4-80 Operation B337EN4_3...
  • Page 241 Piercing Fig. 39426en • Piercing time: time in seconds after which the execution of the ramp cycle will be aborted; valid for editing with and without SprintLas. • Ramp cycle number: number of the ramp cycle which is executed when piercing the material. •...
  • Page 242 Vaporization Fig. 39427en • AutoLas Plus setting dimension: AutoLas Plus setting dimension in mm. States the position of the focus relative to the nozzle tip during piercing. The dimension is set automatically via the AutoLas Plus facility. • Vaporizing time: time in seconds for which the laser beam stays ignited during vaporizing.
  • Page 243 Marking Fig. 39428en • AutoLas Plus setting dimension: AutoLas Plus setting dimension in mm. States the position of the focus relative to the nozzle tip during piercing. The dimension is set automatically via the AutoLas Plus facility. • Nozzle distance: distance between the lower edge of the nozzle and the material surface in mm.
  • Page 244 Dot marking Fig. 39429en • Geometry AutoLas Plus setting dimension: AutoLas Plus setting dimension in mm. States the position of the focus relative to the nozzle tip during piercing. The dimension is set automatically via the AutoLas Plus facility. • Nozzle distance: distance between the lower edge of the nozzle and the material surface in mm.
  • Page 245 The "Manage laser technology tables" mask opens: Press Copy to copy a laser technology table and store it under a new name. Press Standard to apply the TRUMPF default values (all parameters) to the working table. Press Delete to delete a laser technology table.

  • Page 246: Laser Power Cycles

    Laser power cycles The laser power control can make use of the power cycles which are saved in the laser control system. The laser output is controlled, depending on specific intervals. The individual laser power cycles are selected using the ramp cycle number parameter in the laser technology table.
  • Page 247 Softkeys: Actuate the Cycles on EEPROM softkey to read out the respective Cycles on laser power cycle from the working memory of the control system EEPROM onto an EEPROM and save it there. Actuate the Cycle number softkey to go directly to the cycle number Cycle parameter in order to, for example, repeat an entry.

  • Page 248: Welding Table

    Welding table The laser technology tables for welding are not global tables, but program-specific tables. The welding tables must be created by the user for each NC program. All parameters required for welding are stored in these tables. The table programmed in the TC_LASER_WELD_ON cycle is accessed when executing an NC program.
  • Page 249 • Table type: table for a CO or YAG laser. 1: CO laser - default setting. 2: YAG laser. • Laser output: output of the laser in watts with which the programmed machining will be carried out. The default value is 1 watt.
  • Page 250 Gases Fig. 35188en • Welding head Helium: flow rate in l/min. 0 = gas is inactive. <> 0 gas is active. When quantity regulation valves are utilized (optional), the flow rate must be entered. • Argon: flow rate in l/min. 0 = gas is inactive.
  • Page 251 • Workpiece Helium: flow rate in l/min. 0 = gas is inactive. <> 0 gas is active. When quantity regulation valves are utilized (optional), the flow rate must be entered. • Argon: flow rate in l/min. 0 = gas is inactive. <>...
  • Page 252 Softkeys: Press the Program name softkey to go to the "Program name" Prog. name selection field. Open the field using the TOGGLE key and select the desired table. Press the Tab. name softkey to go to the "Table name" selection Tab.

  • Page 253: Tube Section Technology Table

    Tube section technology table All tube section technology tables are program-specific tables. The table name can be selected by the user as desired. The tables are referred to as TPT together with a serial number in the ToPs 400 programming software. The table name must be written in quotation marks in brackets e.g.: ("TPT-1").
  • Page 254 Cutting around corners - tube section technology table Rectangular tubes have four corner radiuses of the same kind. Two steps which apply to all four corner radiuses are programmed in the tube section technology table on page 2, "Cutting around corners". Profile tubes can have different corner radiuses.
  • Page 255 Softkeys: Press the Program name softkey to go to the "Program name" Prog. name selection field. Open the field using the TOGGLE key and select the desired table. Press the Tab. name softkey to go to the "Table name" selection Tab.

  • Page 256: Production Summary Production Plan

    PRODUCTION Summary production plan The summary production plan permits the execution of several sheet programs one after the other without requiring that these be started individually at the control panel. The summary production plan needs to be applied at the system: it is used exclusively with machines that have pallet changers.
  • Page 257 Summary production plan Fig. 27812en • Sequence: shows the sequence number of the sheet job. The jobs are not necessarily processed in this order. The order of the jobs is determined by their acknowledgement by the operator at the start post and by the code of the loading location (see "Working with the production plan"...
  • Page 258 Softkeys: Press the Create sheet job softkey if you want to transfer an NC Creating program as a sheet job to the summary production plan. sheet job The "NC program management" menu appears on the screen. The program can be selected from the displayed overview list using the cursor keys.
  • Page 259 Single production plan Fig. 27843en • Sequence: shows the sequence number of the sheet job. • Status: the status of the sheet job will be displayed. − Free: the sheet job has been released for processing. − Blocked: the sheet job will not be taken into account during processing.

  • Page 260: Production Production Plan For Basic Machine

    PRODUCTION Production plan for basic machine The production plan for the basic machine permits the execution of several sheet programs one after the other without requiring that the associated NC programs be started and selected individually at the control panel (see Section "Working with the production plan of the basic machine").
  • Page 261 Production plan Fig. 39431en • Sequence: shows the sequence number of the sheet job. Free sheet jobs will be processed in accordance with this sequence. • Status: the status of the sheet job will be displayed. − Active: the sheet job is being processed. −...
  • Page 262 Softkeys: Press Create part job softkey to accept an NC program as a sheet Creating job in the production plan. sheet job The "NC program management" menu appears on the screen. The program can be selected from the displayed overview list using the cursor keys.

  • Page 263: Set-Up Activity

    SET-UP activity SET-UP – Switch elements With switch elements it is possible for the user to perform machine functions at the press of a button without having to know the respective NC functions. Only those switch elements can be actuated which are appropriate for the current operation situation and can be carried out safely.

  • Page 264: Switch Elements Of The Distance Control System

    Switch elements of the distance control system Switch elements for distance control system Fig. 39017en • Teach probe: press the switch element to work with the teach probe. The following apply when operating with the teach probe: The DIAS III distance control system is not active. It is not possible to ignite the laser.
  • Page 265 • Collision recognition: press the switch element when the reaction time of the distance control system is to be modified. The reaction time of the distance control system after a recognized collision will be influenced with this switch element until the triggering of FEED HOLD. The selected reaction time is self-holding.

  • Page 266: Switch Elements In General

    Switch elements in general General switch elements Fig. 39419en • He-Ne targeting laser: press the switch element to switch the He-Ne targeting laser on or off. • Gas change timer: switch the switch element to ON when different cutting gases are to be used for piercing and cutting. The residual gas can escape from the gas line during the applied delay of about 10 s.
  • Page 267 • Axis speeds: the speed currently active for the axis movement will be displayed. Reduced: teach panel is activated, axes travel with reduced speed. Normal: machining is activated, axes travel at maximum speed. Active: when switching between reduced and maximum axis speed.
  • Page 268 • Zero point memory: press the switch element to fill, edit, or delete the zero point memories G54, G55, G56, or G57 for individual axes or for all axes. The current axis positions (valid for WCS and MCS) can be adopted or edited manually. OFF: the default setting of this switch element is OFF.

  • Page 269: Service Switch Elements

    The axes return to their start positions after the end of the cycle. ½ Observe the start and end positions of the lubrication cycle. Note The lubrication cycle is configured by the customer after TRUMPF Service has started up the machine: take note of the start and end positions.
  • Page 270 • Adaptive telescope: the adaptive telescope has four levels for water pressure. The respective pressure stage is selected using the switch element. Prerequisite: "Laser service mode" must be active. • Releas. brakes w/o Z: press the switch element to release the brakes of the drive (except Z axis).

  • Page 271: Welding Switch Elements

    Welding switch elements Welding switch elements Fig. 27967 • Weld. head release: actuate this switch element if the welding head has been involved in a collision during machining. E-STOP is cancelled and the axes switched on. • Crossjet (optional): Actuate this switch element to switch the Crossjet on or off.

  • Page 272: Switch Elements For Maintenance

    Switch elements for maintenance Switch elements for maintenance Fig. 35186en • Reset lubricat. count.: press the switch element to reset the lubrication counter to zero. • No. of lubrications: the number of major lubrication cycles which have been carried out will be displayed. •...

  • Page 273: Left Pallet Changer Switch Elements (Optional)

    Left pallet changer switch elements (optional) Switch elements of the left pallet changer Fig. 27766en • X1 table loading position: Actuate this switch element if you wish to move the X1 table into loading position. The following statuses are possible: In loading position.

  • Page 274: Front Pallet Changer Switch Elements (Optional)

    Front pallet changer switch elements (optional) Front pallet changer switch elements Fig. 27767en • Table Y loading position: Actuate this switch element if you wish to move the Y table into loading position. The following statuses are possible: In loading position. In work position.
  • Page 275 • Y table work position: Actuate this switch element if you wish to move the Y table into work position. The following statuses are possible: In loading position. In work position. In motion. Not applied. • Y1 table work position: Actuate this switch element if you wish to move the Y1 table into work position.

  • Page 276: Right Pallet Changer Switch Elements (Optional)

    Right pallet changer switch elements (optional) Switch elements of the right pallet changer Fig. 27768en • X2 table loading position: Actuate this switch element if you wish to move the X2 table into loading position. The following statuses are possible: In loading position.

  • Page 277: Left Pallet Changer Manual Function Switch Elements (Optional)

    Left pallet changer manual function switch elements (optional) Left pallet changer manual function switch elements Fig. 27769en • Jog mode table X1: Actuate this switch element if you wish to move the X1 table with the JOG buttons. • Status table X1: The X1 table position is displayed. The follow- ing statuses are possible: In loading position.

  • Page 278: Front Pallet Changer Manual Function Switch Elements (Optional)

    Front pallet changer manual function switch elements (optional) Front pallet changer manual function switch elements Fig. 27770en • Jog mode table Y: Actuate this switch element if you wish to move the Y table with the JOG buttons. • Jog mode table Y1: Actuate this switch element if you wish to move the Y1 table with the JOG buttons.
  • Page 279 • Release brake, table Y: Actuate this switch element if you wish to move the Y table after a collision (axis switch actuation). default setting this switch element OFF. E-STOP must be active in order to release the brake. • Release brake, table Y1: Actuate this switch element if you wish to move the Y1 table after a collision (axis switch actuation).

  • Page 280: Right Pallet Changer Manual Function Switch Elements (Optional)

    Right pallet changer manual function switch elements (optional) Right pallet changer manual function switch elements Fig. 27771en • Jog mode table X2: Actuate this switch element if you wish to move the X2 table with the JOG buttons. • Status table X2: The X2 table position is displayed. The following statuses are possible: In loading position.

  • Page 281: Switch Elements For Suction Unit

    Switch elements for suction unit The applied default setting for the suction unit can be changed manually in setup mode by means of switch elements. The selected position of the vacuum flaps is retained after switching to automatic mode, provided the position of the flaps has not been programmed otherwise in the NC program with the TC_VACUUM cycle.

  • Page 282: Manually Movable Support Table Indexing Switch Elements (Optional)

    Manually movable support table indexing switch elements (optional) Electrical indexing There is an indexing bolt on both the left and right edges of each support table (left and right indexing areas). Only the two outer indexing bolts engage when separated support tables are coupled and moved into the working area of the machine.
  • Page 283 Indexing Fig. 30896en • Indexing active: actuate this switch element if you want to either index the table/tables or undo the indexing. This switch element is effective for all four indexing pins (left and right indexing areas). Not applied. This switch element is not effective in active two-station operation.
  • Page 284 • Right index active: actuate this switch element if you want to index the table in machining station 2 or undo the indexing. Not applied. This switch element does not work if two- station operation is deactivated (partition panel removed) and for machines without two-station operation.

  • Page 285: Front Safety Door Switch Elements For Electrically Driven Sliding Doors

    Front safety door switch elements for electrically driven sliding doors This switch element group is only available if electrically driven safety doors have been applied to the machine. The doors can be opened or closed either manually by means of switch elements or automatically from the NC program.
  • Page 286 • Safety door open: press switch element in order to open the safety door. This switch element has no effect if the safety door has been isolated. Closed. Drives OFF. In motion. Open. • Safety door closed: press switch element in order to close the safety door.

  • Page 287: Front Safety Door Switch Elements For Electrically Driven Lift Doors

    Front safety door switch elements for electrically driven lift doors This switch element group is only available if lift doors have been applied to the system. A maximum of three lift doors can be installed at the machine: • Left safety doors. •...

  • Page 288: Tlf Laser Intervention 1 Switch Elements

    TLF laser intervention 1 switch elements TLF laser intervention 1 switch elements Fig. 27968en • Switch elements active: actuate this switch element to set the switch elements to active before executing the switching functions. The switch elements remain active (even if the mask is changed) until this switch element is reset to OFF.

  • Page 289: Tlf Laser Intervention 2 Switch Elements

    TLF laser intervention 2 switch elements TLF laser intervention 2 switch elements Fig. 27764en • Switch elements active: actuate this switch element to set the switch elements to active before executing the switching functions. The switch elements remain active (even if the mask is changed) until this switch element is reset to OFF.
  • Page 290 • Pressure control: actuate this switch element to switch the pressure control on and off, provided the vacuum pump is running. Softkeys: Press the softkey to select an axis. X, Y, Z, B, C The axis marked in yellow can be moved in jog mode by means of JOG buttons.

  • Page 291: Set-Up - Jog Mode

    SET-UP - Jog mode The machine operates in JOG submode if jog mode is selected. In JOG mode it is possible to: • Move the NC axes manually. • Approach positions precisely. Jog mode Fig. 27765en • Operation mode: − Jog mode: the NC axis (highlighted in yellow) selected by pressing the corresponding softkey can be moved manually using the JOG buttons.

  • Page 292: Set-Up Mda

    SET-UP MDA Warning! The axes travel immediately to the first axis position programmed. Risk of collision between Z center sleeve/processing optics and fixture or workpiece resulting in considerable damage to property. ½ Observe the start position. ½ Do not carry out any uncontrolled movements. In the MDA submode (Manual Data Automatic), individual or several NC blocks can be created and immediately started: 1.
  • Page 293 • NC blocks: enter the program blocks to be executed in semiautomatic mode in the white field. • Program status: the selected program status is displayed in this field. Actions can be triggered or procedures blocked, depending on the current program status. Three different statuses can be displayed: −...

  • Page 294: Set-Up - Adjust Laser Beam

    SET-UP – Adjust laser beam In this menu, the laser is controlled by data blocks which are entered via the user interface. All parameters which have been edited are displayed after a short time on the left-hand side of the mask.
  • Page 295 Adjust laser beam - Parameters with SERVICE MODE OFF Fig. 35181en • Req. operation mode: select required operating mode: LPC normal, LPC analog, LPC cycles. • Required submode: select required submode: CW, PULSING F, PULSING T. • Duration: display. • Laser power −...
  • Page 296 Adjust laser beam - Parameters with SERVICE MODE ON Fig. 35181en • Req. operation mode: select required operating mode: align- ment on, alignment off. • Required submode: select required submode: CW, PULSING F, PULSING T Only the "PULSING F" operating submode can be selected in "Alignment on"...
  • Page 297 • Alignment ON Duration: − Enter the duration for igniting the beam using the pulse trigger switch. This value may not be greater than 600000 • Laser output: − PULSING F: enter value between 1% and 10% • Gating frequency: −...
  • Page 298 • Duration: display of duration for beam ON with active service mode, open beam trap and actuated pulse trigger switch. The beam is switched off automatically by the control system after this time has expired. • Laser power: displays the programmed laser output as a percentage of the rated laser output.

  • Page 299: Programming Activity

    PROGRAMMING activity NC Editor You can edit existing programs and create new NC programs in the NC Editor. The text must be entered via the ASCII keyboard. The cycles available can be displayed using the focus key. The call-up parameters can be entered directly into the selected cycle. To help you edit NC texts, you can use the softkeys and the integrated programming guide which provides constant access to information on functions and how to program them as well as...
  • Page 300 Softkeys: Press the Exit softkey of the editor to return to the last selection Exit frame. Press the Save softkey to save changes to the NC text. Save Press the Cut out softkey to cut text passages out of the NC text. Mark these text passages first by pressing the SHIFT and CURSOR keys simultaneously.

  • Page 301: Nc Program Management

    NC program management The "PROGRAMMING - NC program management " menu gives you an overview of all main programs stored in sections on the hard drive of the control system. If a main program (MP) contains subroutines (SR), these can be displayed by selecting the main program in question with the ENTER key.
  • Page 302 Syntax check: If NC programs are modified or split up, a "syntax check" is carried out automatically in the background. However, only the TRUMPF-specific components of the control system such as e.g. the laser technology tables are checked. The basic functionality of the Siemens control system is not checked.

  • Page 303: File Management

    File management In the "PROGRAMMING - File management" menu you can obtain an overview of the data management on the hard drive (C:\DH\ToPsmanu.dir) of the control system. Programs created by the programming software and transferred to the machine control system are stored in this directory as a master file. In addition, all network drives to which your control system is connected and the disk drive (A:) are displayed.
  • Page 304 Softkeys: Press the Find file softkey to search through a directory for a Find particular file. You need to know the exact program designation here file and enter it in the input field. Press the Split master file softkey to subdivide a master file from the Split programming system into main programs, subroutines and tables.

  • Page 305: Outputting Nc Programs From The Management System

    Outputting NC programs from the management system You can use this menu to re-create a master file from related main programs and subroutines, including all corresponding table information. You can also copy individual program sections as a file to the hard drive or to a diskette. This menu appears if you press the Output program softkey within the "PROGRAMMING - File management"...
  • Page 306 Softkeys: Press the Find program softkey if you want to search for a particular Find program. To do this, you need to know the exact program program designation and enter it in the input field. Press the Create master file softkey to re-create a master file from Create related main programs, subroutines and tables and to store it on the master file...

  • Page 307: Selecting Nc Programs

    Selecting NC programs This menu only appears if you press the Select program softkey from the "PRODUCTION - Single job" menu. The list of programs is identical to that shown in the "PROGRAMMING - NC program management" menu. Only the allocation of keys in the softkey bar is different.
  • Page 308 Softkeys: Press the Find program softkey if you want to search for a particular Find program. To do this, you need to know the exact program program designation and enter it in the input field. Press the Select program softkey if you wish to select an NC Select program in order to execute it.

  • Page 309: Tooling Activity

    Tooling activity Zero point offset The machine has 4 zero point memories in which a zero point correction can be entered. The zero point correction becomes effective after being transferred to the machine control system. The following convention is recommended: •...
  • Page 310 Softkeys: Press the Line softkey to select an axis. Line Press the Modify softkey to activate the input field. The value for the Modify selected axis is changed in the input field. Confirm the entry with the ENTER key. Press the Select function softkey to select a zero point memory. Select function Press the Adopt softkey to accept the zero point correction.

  • Page 311: Maintenance / Initial Start-Up Activity

    This way, the data can be restored if, due to certain circumstances, the database has been corrupted e.g. by a defective hard drive or similar. TRUMPF Customer Service must always be informed in such a case though, since data is only allowed to be restored by service technicians even if the data concerned is customized data.

  • Page 312: Maintenance / Initial Start-Up Display

    Softkeys: Press the Data group backup softkey to back up the data displayed Data group as source. backup This function may only be used by service technicians. Restore data group MAINTENANCE / INITIAL START-UP Display The desired language and measurement system (metric/inch) can be selected in the display menu.

  • Page 313: Maintenance / Initial Start-Up Maintenance Logbook

    MAINTENANCE / INITIAL START-UP Maintenance logbook The most important maintenance intervals at the laser are monitored in the maintenance logbook. The status of the individual maintenance points can be observed by means of a bar display. A system status message is issued for the waiting component when the respective maintenance interval expires.

  • Page 314: Diagnostics Activity

    DIAGNOSTICS activity DIAGNOSTICS Error diagnostics A list of active errors and messages generated when working at the machine is displayed in the error diagnostics. Furthermore, it is not only possible to query the error text via softkeys, but also the cause, effect, error location and measures for eliminating the error.

  • Page 315: Diagnostics I/O Diagnostics

    Press the Error location softkey to display the error location, the Error cause and any comments. location Press the End softkey to jump to the last line of the displayed list. DIAGNOSTICS I/O diagnostics All digital inputs and outputs of the basic machine, the laser and the automation components appear in the displayed mask.

  • Page 316: Diagnostics Remote Diagnostics

    Press the Start softkey to start remote diagnostics. Start Press the Menu softkey to receive written messages from (remote Menu PC) or to send them to (host PC) TRUMPF via "Dialog". Press the Exit softkey to quit remote diagnostics, i. e. to interrupt the Exit telephone connection.

  • Page 317: Diagnostics Laser

    The correcting variables of the RF generator in the lower right part can be modified in service mode. Note These values may only be modified by TRUMPF Customer Service or by specially trained technicians. Laser RF generator Fig.

  • Page 318: Laser Leak Test

    Laser leak test This menu is used to conduct a leak test for the laser. A description on how to conduct a leak test is contained in the operating procedures for "Operating the laser". Fig. 28437EN • System pressure: The current actual pressure is displayed in hPa.
  • Page 319 Softkeys: Press the Start leak test softkey to start the leak test. The leak test Start data is accepted by the control system ("actual value" of the control leak test system corresponds to the entered required value). The resonator pressure is reduced to the desired start pressure. The leak test begins once the start pressure has been attained (message in the comment line).

  • Page 320: Diagnostics Display Home Position

    DIAGNOSTICS Display home position Whether the active system components are in home position or not is displayed in this menu. The yellow and black home position symbol appears next to the corresponding system component if it is in home position. Fig.

  • Page 321: Integrated Mdc Activity (Optional)

    Integrated MDC activity (optional) 10.1 MDC message texts The "Integrated MDC" (Machine Data Collection) software automatically records all of your machine’s runtimes and downtimes. The integrated MDC uses both messages "Machine runs" and "Machine stationary". The data is stored in chronological order in a database and can be retrieved from there and evaluated.

  • Page 322: Mdc Creating And Modifying Message Texts

    10.2 MDC Creating and modifying message texts To create or modify your own message texts, select the 1 Activity - 7 MDC - 1 MDC message Texts function from the menu bar. The "List of MDC message texts" mask appears. You can see all available messages texts in a list.
  • Page 323 The display shows the following information for each message text: • Level: The message texts are subdivided into different levels with the four reason types making up level 1. New message texts must be assigned or subordinated to one reason type or to an existing message text.

  • Page 324: Mdc Displaying And Editing Machine Data

    10.3 MDC Displaying and editing machine data You can have all recorded interruptions of the machine runtime displayed and issued as a file in the "Edit machine data" function area. Beyond this, you can assign a cause (MDC message text) to each interruption here, as well as subdivide the interruptions into periods of time.
  • Page 325 You can see information on a selected data record in the line above the message window . You can see the time period for the listed messages as well as their amount in the line beneath the window. Since the size of the display window is limited, only some the messages can be displayed if their total size exceeds that of the window itself.

  • Page 326: Mdc Creating And Modifying Interruptions

    10.4 MDC Creating and modifying interruptions Each machine downtime should be assigned a reason in order to analyze machine operation precisely. For this purpose, you have to select a message ("Stationary") from the "Machine data collection" mask and then press the Create/ modify softkey. The "Create/modify MDC interruption"...

  • Page 327: Mdc Evaluating Machine Data

    Softkeys If you wish to create a new interruption, i.e. subdivide an existing Create interruption time interval, you must first select a message text from interrupt. the list for the new interruption and then press the "Create interrupt." softkey. A mask appears with the new message text and the recorded time interval.
  • Page 328 Evaluating machine data Fig. 31275EN To create an evaluation, you must first enter the desired period of time in the top line of the mask, as well as a designation for the evaluation (e.g. Evaluation KW12). Softkeys Actuate the "Create evaluation" softkey. The program then Create generates the corresponding evaluation and adds it to the list evaluation...

  • Page 329: Mdc Display Of The Times In A List

    10.6 MDC Display of the times in a list This menu is opened if you actuate the Display list softkey in the "Evaluating machine data" menu. Fig. 20064 The mask displays the duration of the evaluation in the first line. The following information on the evaluated data appears below it: •...

  • Page 330: Mdc Changing The Time

    Softkeys Actuate the Create file softkey in order to have the evaluation issued Create as a file just like you can see it on the screen. file The "auswert.txt" file is automatically created in the directory "C:\DH\TOPSMANU.DIR\MDC\" on your hard drive. Note: If a file with the name "auswert.txt"...

  • Page 331: Part 3: Operating The Machine

    Part 3: Operating the machine Safety information Press the FEED HOLD button first if a problem occurs while the program is running. The E-STOP impact button must be actuated if work on the machine is required because the malfunction is unable to be eliminated by means of the control panel.
  • Page 332 Activating online help for the programming manual: There are two ways of activating online help for programming on the user interface. Display its table of contents: by means of the "Programming guide" menu item in the "Help" main menu. Press FOCUS MENU. Select Help >...
  • Page 333 Activating the user’s guide: There are two ways of activating online help for operation on the user interface. Display its table of contents: by means of the "Operating guide" menu item in the "Help" main menu. Press FOCUS MENU. Select Help > Operating guide. Or press button 3 - 2.

  • Page 334: Machine Start-Up And Shutdown

    Machine start-up and shutdown Switching on the machine Gas supply Switch the gas supply on, opening helium last. Air supply Switch on the air supply. Switch on MAIN SWITCH. Wait until the control system is ready for operation. Unlock the E-STOP impact button if necessary. Press the LASER ON/OFF button.

  • Page 335: Switching Off The Machine

    Switching off the machine Prerequisite • No program is being executed. Press the LASER ON/OFF button. LASER The automatic shutdown cycle is started and the button flashes. The turbine is switched off and braked by the frequency converter (duration: approximately 1 minute). The laser is filled with laser gas and the pressure in the resonator raised to 1100 hPa.

  • Page 336: Switching Off The Machine In The Event Of Malfunctions/Emergencies

    Switching off the machine in the event of malfunctions/emergencies Triggering E-STOP Prerequisite • None Press E-STOP. The power supply of the machine is interrupted (the 24 V control voltage at the machine and laser is maintained). The laser beam is switched off.

  • Page 337: Eliminating Malfunctions

    Eliminating malfunctions Triggering FEED HOLD Prerequisite • None Press FEED HOLD. The button lights up. The laser beam is switched off. All motion stops. The cutting gas supply is interrupted. Acknowledging FEED HOLD Eliminate the malfunction. Press START. FEED HOLD is cancelled. The active NC program is resumed at the point of interruption.

  • Page 338: Cancelling E-Stop After Detecting A Collision (Optional For The Cutting Head)

    Cancelling E-STOP after detecting a collision (optional for the cutting head) If there is a collision in the workspace involving the cutting head, the predetermined breaking screws used to attach the cutting head to the flange of the B/C gearbox will be sheared off (this constitutes the predetermined breaking point).

  • Page 339: Releasing The X, Y, B And C Axis Drive Brakes

    3.5. Releasing the X, Y, B and C axis drive brakes Prerequisite • E-STOP is active. Select SET-UP > Switch elements > Service. Select "Releas. brakes w/o Z". Press TOGGLE. Press the ESTABLISH HOME POSITION button if it is flashing. Press ESTABLISH HOME POSITION.

  • Page 340: Releasing The Z Axis Drive Brake

    3.6. Releasing the Z axis drive brake The Z axis brake can only be released by means of a switch in the switch cabinet of the machine. OFF Brake closed ON Brake released Switch in the switch cabinet Fig. 31042 Caution As soon and as long as the switch is set to "ON", the Z axis travels downwards without being braked, but no further than...

  • Page 341: Executing A Program

    Executing a program Calling up and starting a program Prerequisite • The machine is ready for operation. • The laser is ready for operation. • The home position of the machine has been established. • An NC program is available in the program manager in split form.

  • Page 342: Stopping A Program During Machining

    Stopping a program during machining The machine can be stopped in order to carry out inspections. Prerequisite • A program is being executed. Press the FEED HOLD button. The FEED HOLD button lights up. The machine is no longer in motion.

  • Page 343: Operating In Marking Test Mode

    Cutting large/medium-sized/small contour LTT. This means that for LTT’s created by the user, the Marking LTT also needs to be created. All parameters are automatically available for LTT’s created by TRUMPF. Note: There is a higher priority on LASER test mode (in which program can be processed without the laser beam ignited –...

  • Page 344: Editing, Filling And Deleting The Zero Point Memories G54 To G57

    Press Continue. Continue The test run is started. The contour is engraved on the workpiece. Note Deselect by pressing RESET or by setting the "Test marking" switch element to OFF. Editing, filling and deleting the zero point memories G54 to G57 Four zero point memories are defined in the machine’s control system: G54, G55, G56, and G57.

  • Page 345: Editing A Zero Point Memory Manually

    Editing a zero point memory manually Prerequisite • The machine is ready for operation. Select Set-up >Switch elements > General select Production >Switch elements >General. Select "Zero point memory". Press TOGGLE. The display switches to ON. The "TLC zero point memory initialization"...

  • Page 346: Filling The Zero Point Memory For All Axes With The Current Axis Position

    Select the G54, G55, G56, or G57 zero point memory. Edit the axis positions manually in the "Default position" field. Press Adopt. Adopt The axis positions entered in the "Default position" field are transferred to the selected zero point memory: the "Default position" becomes the "Defined position"...
  • Page 347 Press Continue. Continue The "TLC zero point memories G54 G55 G56 G57" mask is displayed while the control system loads the current actual positions of the axes and the axis positions defined in the zero point memory. The "TLC zero point memory initial screen" mask is then opened. The current axis positions are displayed in the "Actual position ..."...

  • Page 348: Filling The Zero Point Memory For Individual Axes With The Current Axis Position

    Press Exit Abort. Exit The process is over. The dialog box is closed. Abort Note: the dialog is aborted if this softkey is pressed before the Adopt softkey is pressed. The "defined position" in the zero point memory remains intact. Filling the zero point memory for individual axes with the current axis position...
  • Page 349 Fig. 36068en Select the G54, G55, G56, or G57 zero point memory. Press Individual axes. Individual The "TLC zero point memory, individual axes" mask is opened. axes If needed: press Select round. Select ..Note: the Select ... softkey can be used to switch to and fro between linear and rotational axes.
  • Page 350 Select an axis or axis combination. Press Set ..Set ..The current axis position in the "Actual position ..." field for the selected axis or axis combination is written to the “Default position” field. Press Back. Back Note: the axis positions entered in the "Default position" field can be edited manually at any time.

  • Page 351: Deleting The Zero Point Memory For All Axes

    Deleting the zero point memory for all axes Prerequisite • The machine is ready for operation. Select Set-up >Switch elements > General select Production >Switch elements >General. Select "Zero point memory". Press TOGGLE. The display switches to ON. The "TLC zero point memory initialization"...
  • Page 352 Select the G54, G55, G56, or G57 zero point memory. Press All axes. All axes The "TLC zero point memory, all axes" mask is opened. Press Delete all. Delete all The display in the "Defined position" field changes. All axis positions are set to 0.

  • Page 353: Deleting The Zero Point Memory For Individual Axes

    Deleting the zero point memory for individual axes The zero point memories can be deleted for individual axes. There are different ways of doing this for rotational axes and linear axes. Rotational axes can only be selected individually, linear axes either individually or in X, Y, Z axis combination.
  • Page 354 Select the G54, G55, G56, or G57 zero point memory. Press Individual axes. Individual The "TLC zero point memory, individual axes" mask is opened. axes If needed: press Select round. Select ..Note: the Select ... softkey can be used to switch to and fro between linear and rotational axes.

  • Page 355: Working With The Summary Production Plan

    Working with the summary production plan The summary production plan permits the execution of several sheet programs one after the other without requiring that these be started individually at the control panel. The summary production plan needs to be applied at the system: it is used exclusively with machines that have pallet changers.
  • Page 356 TLC 1005 Left pallet changer (PCX1) Front pallet changer Right pallet changer (PCX2) (PCY1/PCY2) or (PCY) Start post for pallet changer 2+3 Start posts for pallet changer Start post for pallet changer System example Fig. 31104 Machining sequence The execution of the individual sheet jobs only corresponds to a certain degree to the sequence determined in the summary production plan.
  • Page 357 Example Summary production plan for a machine with PCY1/PCY2 pallet changer The code for the loading location consists, for example, of two digits if only the pallet changer PCY1/PCY2 has been applied to the machine. The start post of the PCY1 is assigned the code "10". The start post of the PWY2 receives the code "01".

  • Page 358: Creating A Summary Production Plan

    Creating a summary production plan Prerequisite • Summary production plan is applied at the system. • NC programs are in the NCU in split form. Select Operation > PRODUCTION > Single job. Press Production plan. Production plan Select Activity PRODUCTION > Production plan. Press Create sheet job Create sheet job...

  • Page 359: Starting A Summary Production Plan

    Starting a summary production plan Prerequisite • The machine and laser are ready for operation. • The home position of the machine has been established. • The summary production plan has been created. • The status has been defined for each sheet job. •...

  • Page 360: Ending A Summary Production Plan

    Ending a summary production plan Prerequisite • The NC program has been ended. Select Operation > PRODUCTION > Single job. Press Production plan. Production plan Select Activity PRODUCTION >Production plan. Press Production Start / Stop. Production The execution of the summary production plan is ended. Start / Stop 4-200 Operation...

  • Page 361: Processing With The Production Plans -Basic Machine

    Processing with the production plans - basic machine The production plan for the basic machine permits the execution of several sheet programs one after the other without needing to select and start the associated NC programs individually at the control panel. Note: If a pallet changer is applied at the unit, then the summary production plan is in effect instead of the production plan.

  • Page 362: Creating A Production Plan

    Creating a production plan Prerequisite • Production plan is applied at the system. • NC programs are in the NCU in split form. Select Operation > PRODUCTION > Single job. Press Production plan. Production plan Select Activity PRODUCTION > Production plan. Press Create sheet job.

  • Page 363: Starting Production Plans

    Starting production plans Prerequisite • The machine and laser are ready for operation. • The home position of the machine has been established. • The production plan must have been created. • The status of each sheet job has been defined as "free". •...

  • Page 364: Ending Production Plans

    Ending production plans Prerequisite • No processing program is active. Select Operation > PRODUCTION > Single job. Press Production plan. Production plan Select Activity PRODUCTION >Production plan. Press Production Start/Stop. Production The execution of the production plan is ended. Start/Stop 4-204 Operation B337EN4_8...

  • Page 365: Moving The Axes In Jog Mode

    Moving the axes in jog mode Prerequisite • No FEED HOLD is active. • The home position of the machine has been established. • There is no NC program running. • The feed rate potentiometer is set to > 0%. Select the activity field SET-UP >...

  • Page 366: Undoing Electrical Indexing

    10.2 Undoing electrical indexing Prerequisite • E-STOP is not active. Select Operation >Set-up > Switch elements > Indexing. Select "Indexing active". Press TOGGLE. Set the switch element to INACTIVE. The indexing is undone. The tables can be pushed out of the working area of the machine.

  • Page 367: Optional: Driving Pallet Changers

    Optional: Driving pallet changers The machine can be equipped with a pallet changer. The tables can be moved either manually using switch elements or automatically by means of the machining program. Different versions of the pallet changer can be installed at and applied to the machine.

  • Page 368: Coupling Pallets

    11.1 Coupling pallets Prerequisite • E-STOP is not active. Select SET-UP > Switch elements > Pallet changer ..Set "Couple pallets" to "Coupled". Press TOGGLE. The pallets are coupled. The mechanical coupling pin locks into place. 11.2 Separating pallets Prerequisite •...

  • Page 369: Moving Pallets In Manual Mode

    11.3 Moving pallets in manual mode Prerequisite • E-STOP is not active. Select SET-UP > Jog mode. Press MOVE PALLET INTO LOADING POSITION or MOVE PALLET INTO WORK POSITION. The pallet moves as long as the button is pressed down and stops automatically in its final position.

  • Page 370: Moving The Pallet After Actuating The Axis Switch (After A Collision)

    11.5 Moving the pallet after actuating the axis switch (after a collision) Prerequisite • E-STOP is active. SET-UP > Switch elements > Pallet changer manual functions. Set "Release table brake ..." to On. Press TOGGLE. Electrically driven safety doors The electrically driven safety doors are available in different versions: •...

  • Page 371: Opening The Lift Door

    12.1 Opening the lift door Caution The lift doors do not have a viewing window. It is not possible to identify obstacles within the danger zone. ½ Before opening the door, the operator must make sure that nobody is within the danger zone and that a collision with the pallet changer is not possible.

  • Page 372: Referencing The Safety Door

    12.3 Referencing the safety door Referencing The electrically driven loading doors must be referenced. The (calibration run) distance between the two final positions is measured during the referencing run. The referencing run is necessary: • After the MAIN SWITCH has been switched on. •...

  • Page 373: Referencing The Safety Door

    12.4 Referencing the safety door The safety door can be opened completely or partially according to the position of the selector switch. Prerequisite • Safety door is referenced. At the safety cabin: press OPEN. The safety door is opened. Select SET-UP > Switch elements > Safety doors ..Press "Open safety door".

  • Page 374: Releasing The Safety Door After A Collision

    12.6 Releasing the safety door after a collision All door leafs come to a halt if a door leaf collides with an obstacle in the travel area while it is being opened or closed. The "Release front door" switch element switches to "Collision! Release" status (flashes).
  • Page 375 Press E-STOP. The door leafs are undocked from the drive system. They can now be shifted by hand. Unlock the E-STOP button. Select SET-UP > Switch elements > Safety door s..Press "Release front door". Press TOGGLE. The display switches to active. All door leafs move in parallel, but not simultaneously, first to the right (open) and then to the left (closed).

  • Page 376: Calling Up A Lubrication Cycle

    The axes return to their start positions after the end of the cycle. ½ Observe the start and end positions of the lubrication cycle. Note The lubrication cycle is configured by the customer after TRUMPF Service has started up the machine: take note of the start and end positions.

  • Page 377: Starting A Lubrication Cycle

    13.1 Starting a lubrication cycle Prerequisite • The machine is ready for operation. • The home position of the machine has been established. • The lubricant well has been filled up. Note: The safety door of machines with two-station operation has to be closed before starting the lubrication cycle.

  • Page 378: Starting The Z Axis Lubrication Cycle

    Fig. 36072en Check whether there is any risk of collision. If not: Continue Press Continue. The lubrication cycle is started from the current axis position. The axes return to their initial positions after the end of the cycle. Note: A display dialog box appears on the user interface during the lubrication cycle.

  • Page 379: Operating The Laser

    All work and settings which have to be carried out with the laser in service mode may only be carried out by specially trained service personnel: • TRUMPF service personnel. • Service personnel of the customer who have received intensive laser-specific training and have been given instructions on safety procedures.

  • Page 380: Switching Off The Laser

    14.2 Switching off the laser Press the LASER ON/OFF button. LASER The automatic shutdown cycle is started (button flashes). The turbine is switched off and braked by the frequency converter (duration: approximately 1 minute). The laser is filled with laser gas and the pressure in the resonator raised to 1100 hPa.

  • Page 381: Switching Off The Laser Beam

    14.4 Switching off the laser beam Press the BEAM ON/OFF button. The lamp in the button goes out. 14.5 Opening the beam trap Prerequisite • SERVICE MODE key switch is set to "ON". • The laser beam is OFF. Press the OPEN/CLOSE BEAM TRAP button. The button is lit up if the beam trap is open.

  • Page 382: Working In Laser Test Mode

    14.7 Working in laser test mode There are two ways of operating in test mode: • A program can be simulated without igniting the laser beam and without cutting gas. • If machining is interrupted, the point of interruption can be approached in test mode and then test mode deselected and machining resumed after reselecting the program.

  • Page 383: Setting The Laser Mode

    14.9 Setting the laser mode Prerequisite • SERVICE MODE key switch is set to "ON". Select the "SET-UP - Adjust laser beam" activity field. Press Submode softkey. Submode The selection of the laser submode depends on the selected laser operation mode. The selected laser submode is highlighted in blue. 14.10 Setting the laser power Prerequisite...

  • Page 384: Carrying Out A Leakage Test

    14.11Carrying out a leakage test Prerequisite • Laser off. • The resonator is in idle mode. Select the "DIAGNOSTICS - Laser - Leakage test" activity field. Use the focus key to select the "Start pressure" display field. Use the keyboard to enter the start pressure. 1 2 3 Use the focus key to select the "Measuring time"...

  • Page 385: Diagnostic Functions

    Diagnostic functions 15.1 Error diagnostics With the error diagnostics feature it is possible to examine the cause, effect and location of errors indicated by messages generated during machine operations. Furthermore measures for eliminating errors are displayed. Select the "DIAGNOSTICS - Fault diagnostics" activity field. An overview list of all current error messages is displayed.

  • Page 386: Displaying Inputs And Outputs Of The Machine And Laser

    15.2 Displaying inputs and outputs of the machine and laser Select the "DIAGNOSTICS - I/O Diagnostics" activity field. Fig. 28434en Select Basic machine or Laser from the selection field. All inputs and outputs appear on the displayed mask. Example: You want to check whether the 2nd bit of input E33 has been set. Keep on pressing the buttons until you reach the green bar in <<...

  • Page 387: Querying The Software Version

    The remote diagnostics software pcANYWHERE is available. By activating the remote diagnostics at the control system, it is possible for a TRUMPF engineer to operate the control system via the telephone line and, in this way, locate and possibly solve any arising problems.

  • Page 388: Managing Master Files

    Managing master files 16.1 Uploading an NC program from the disk drive An NC program is stored as a master file on a 3.5" diskette and is to be split up and loaded into the program manager of the control system before being executed at the machine.

  • Page 389: Uploading An Nc Program From The Hard Disk

    16.2 Uploading an NC program from the hard disk An NC program is stored as master file on the hard disk in the directory C:\DH\TOPSMANU.DIR and is to be split up and transferred to the program manager of the control system in order to be executed at the machine.

  • Page 390: Outputting An Nc Program To The Disk Drive

    16.3 Outputting an NC program to the disk drive An NC program is split up into main programs, subroutines and tables in the program manager of the control system and is to be saved as a master file to a 3.5" diskette. Select the "PROGRAMMING - File management"...

  • Page 391: Outputting An Nc Program On The Hard Disk Drive

    16.4 Outputting an NC program on the hard disk drive An NC program is in the program manager of the control system, split up into main programs, subroutines and tables, and is to be archived master file hard disk drive "C:\DH\TOPSMANU.DIR".

  • Page 392: Outputting A Program Part Onto The Disk Drive

    16.5 Outputting a program part onto the disk drive A program part (main program or subroutine) is to be saved to a 3.5" diskette. Select the "PROGRAMMING - File management" activity field. Press the Output program softkey. Output program Select the desired program part (main program or subroutine) using the CURSOR keys.

  • Page 393: Deleting Nc Programs From The Program Manager

    16.6 Deleting NC programs from the program manager An NC program is stored in the program manager of the control system in split form and is to be deleted together with all program parts and table entries. Select the "PROGRAMMING - NC program management" activity field.

  • Page 394: Managing Nc Programs

    Managing NC programs 17.1 Displaying NC text The NC text of a program part (main program or subroutine) is to be displayed in the NC Editor. Prerequisite • The NC program is stored in the program manager of the control system, split up into main programs, subroutines and table entries.

  • Page 395: Editing Nc Text

    17.2 Editing NC text Searching for a block in the NC text The program block with number N100 is to be found in the NC program. Prerequisite • The NC text is displayed in the editor. Press the Search/Replace softkey. Search/ Enter N100 in the input field.

  • Page 396: Searching For And Replacing A Function In The Nc Text

    Searching for and replacing a function in the NC text The function G00 is to be found in the NC text and replaced by the function G01. Prerequisite • The NC text is displayed in the editor. Press the Search/Replace softkey. Search/ Enter G00 into the input box.

  • Page 397: Copying And Inserting Text Passages

    Copying and inserting text passages Several lines of the NC text are to be copied and inserted elsewhere in the NC text. Prerequisite • The NC text is displayed in the editor. Position the cursor bar at the start of the block at which you wish to begin your selection.

  • Page 398: Deleting Text Passages

    Deleting text passages A block, word or character is to be deleted from the NC text. Prerequisite • The NC text is displayed in the editor. Position the cursor bar at the start of the text passage you want to delete.

  • Page 399: Editing Tables Based On An Nc Text

    Editing tables based on an NC text The programming of machine sequences or technology tables can be subsequently changed in the NC text, usually by editing table parameters: • Laser technology (TC_LASER_ON). The table parameters for the active program can also be modified while the program is executed.

  • Page 400: Acknowledging Maintenance

    Acknowledging maintenance If a message is issued by the control system, indicating that one of the monitored maintenance tasks has to be performed, the maintenance task has to be acknowledged after it has been carried out, as follows. Select the MAINTENANCE/START-UP > Maintenance logbook activity.

  • Page 401: Operating The Integrated Mdr

    Operating the integrated MDR All machine runtimes and downtimes are automatically recorded by the integrated machine data register (MDR). The recorded downtimes (interruptions) can be assigned an interruption cause in the form of a message text. Each message text must be assigned to one of the basic types of causes.

  • Page 402: Assigning A Message Text

    20.2 Assigning a message text In order for the downtimes of the machine to be evaluated properly, each downtime must be assigned an interruption cause (message text). Select Operation > MDR > Data. The "Machine data collection" mask is opened. A list is displayed of all message texts during the entered period of time.

  • Page 403: Splitting Up An Interruption Period

    20.3 Splitting up an interruption period A downtime period can be split up into several time intervals and each time interval assigned an interruption cause (message text). Select Operation > MDR > Data. Select an interruption ("Stationary" message) of which the time interval is to be split up.

  • Page 404: Evaluating Machine Data

    20.4 Evaluating machine data The list of all downtimes during a given period of time can be displayed and saved as a file. Select Operation > MDR > Evaluation. The "Evaluation of Machine Data" mask is opened. Enter the period of time in the "From" and "To" input fields. Enter the title in the "Comments"...

  • Page 405: Evaluating The Odc Interface

    Evaluating the ODC interface The Operating Data Collection (referred to as ODC in the following) allows the user to keep a log of the following operation and machine data during machining: • Date • Time • Main program name. • Reference text.

  • Page 406: Opening A Log File In Ms Excel

    21.2 Opening a LOG file in MS Excel The saved operation data can also be evaluated by means of a spreadsheet program such as MS EXCEL. 1. Open the LOG file in MS Excel. Text wizard - step 1 appears. 2.

  • Page 407: Carrying Out A Back Up Of The Pcu 50

    Insert empty ZIP disk. 2. Switch on the MAIN SWITCH. Go at once to the control panel. The control system starts up. When the following image appears: Fig. 36628 3. With the <Cursor>, select TRUMPF Service Menu, confirm with <Enter>. 4-247 Operation B337EN4_8...
  • Page 408 Fig. 36634 4. Select Backup to ZIP: press <4>. Fig. 36630 5. Press <Enter>. 4-248 Operation B337EN4_8...
  • Page 409 Fig. 36626 6. Enter file name, press <Enter>. Fig. 36627 7. Press <Y>. Backup starts. 4-249 Operation B337EN4_8...
  • Page 410 Fig. 36631 Note Backup takes approximately 30 to 40 minutes. When the memory capacity of the first ZIP disk has been reached, the lower display field will start flashing. 8. Insert second ZIP disk. When the backup has been completed, the following image will appear: Fig.
  • Page 411 Fig. 36633 10. Press <Enter>. When the following image appears: Fig. 36634 11. Switch off MAIN SWITCH in order to separate the ZIP drive from the control system and to delete temporary files. 12. Separate ZIP drive from the parallel interface. After this, the machine can be switched back on again.
  • Page 412 4-252 Operation B337EN4_8...
  • Page 414 Chapter 5 Setting work Safety information............5-4 Overview of setting work ..........5-5 Checking and setting B and C axes ......5-6 Checking C axis and setting reference offset value..5-7 Checking the B axis and setting the reference offset value ............... 5-9 Selecting processing optics ........
  • Page 415 Determining and setting the focus position ....5-25 Adjusting the setting on the cutting head....5-29 Determining focus position f=0 ......... 5-30 Correcting focus position .......... 5-32 Adjustment work on the welding head ...... 5-33 Installing the welding head..........5-33 Centering the beam............
  • Page 416 Setting the rotary axis (optional) ........ 5-90 15.1 Shifting the rotational axis horizontally in X direction................5-90 15.2 Adjusting the rotational axis in Z direction ..... 5-91 15.3 Swivelling the rotational axis by 90°....... 5-92 Setting the back stop (optional) ......... 5-93 16.1 Shifting the rotational axis horizontally in X direction................

  • Page 417: Safety Information

    Safety information The following listed setting work may only be carried out by specially trained service personnel. Setting work Service Press Required Max. Max. beam submode pulse operating beam power key switch trigger mode: operating switch Alignment time Alignment ON 600 s Alignment OFF 25 s...

  • Page 418: Overview Of Setting Work

    Overview of setting work The setting work listed in the following may be carried out by the operator. All work is executed in normal mode of the machine. The safety devices of the machine are active. The service programs listed here are stored on the hard disk of the PCU 50 at the operator’s panel under: C:\DH\TOPSMANU.DIR\SERVICE.PRG\CUSTOMER Valid:...

  • Page 419: Checking And Setting B And C Axes

    Setting work Complete file When? Welding head Aligning the beam centrally to CP_TAPESHOT.LST After cleaning or replacing the the nozzle parabolic mirror After adjusting the mode or the beam Determining the focus position CP_FOCUS_WELD.LST After cleaning or replacing the offset parabolic mirror After adjusting the mode or the beam...

  • Page 420: Checking C Axis And Setting Reference Offset Value

    Checking C axis and setting reference offset value Prerequisite • The cutting or welding head has been fully installed. Additional equipment, tools, material • Dial gauge and measuring probe with stand. • SW4, SW5 hexagon socket keys. C axis reference area C axis reference area Dial gauge C axis reference area...
  • Page 421 Setting the C axis The C axis is corrected by the software in the machine data. The position of the C axis is not changed mechanically. 1. Select >Operation >Set-up >MDA. 2. Enter C0. 3. Press Start. The C axis travels to 0. 4.

  • Page 422: Checking The B Axis And Setting The Reference Offset Value

    Checking the B axis and setting the reference offset value Prerequisite • The cutting or welding head has been fully installed. • The C axis has been checked and set. Additional equipment, tools, material • Dial gauge and measuring probe with stand. •...
  • Page 423 Welding head reference area Reference area B axis reference area Fig. 32420 Checking the B axis 1. Select >Operation >Set-up >MDA. 2. Enter B0. 3. Press Start. The B axis travels to 0. 4. Install the measuring probe and align it to the reference area. 5.
  • Page 424 Setting the B axis The B axis is set mechanically. Securing screw and clamping screw for friction clutch Rear view of the B/C angular gear Fig. 32552 1. Unscrew the securing screw (SW4). 2. Move the B axis in jog mode until the BS mark corresponds to the reference mark on the B/C angular gear.
  • Page 425 0° 0° BS Mark 0° 0° marker 0° reference marker B and C axis reference mark Fig. 32547 9. Move the B axis in jog mode until the BS mark corresponds to the 0° reference marker again. 10. Tighten the slipping clutch clamping screw hand-tight. Screw in the securing screw.

  • Page 426: Selecting Processing Optics

    Selecting processing optics Each time the processing optics are replaced, the control system must be notified which processing optics are active, in order for the corresponding joint offset values to be entered in the machine parameters. The processing optics are selected interactively. Note The joint offset values can be edited in the selection dialog as required.

  • Page 427: Selecting The Cutting Head

    Selecting the cutting head Prerequisite • The cutting head is fully installed. • The joint offset values have been determined and saved in the data management. 1. Select >Operation >Set-up > Service. 2. Set the "Head change" switch element to ACTIVE. The selection dialog is started.
  • Page 428 8. Press Continue. The "Parameters for cutting head" mask opens. The current joint offset values for the selected processing optics and the AutoLas Plus characteristic curve belonging to the optics are displayed. "Parameters for cutting head" mask Fig. 36075en Note The Axis joint offset fields will be retained in the event of a software update.

  • Page 429: Selecting The Welding Head

    Note The Back softkey can be used to return to the previous mask. The Cancel softkey is used to cancel the dialog. The machine data remain unchanged. 10. Press Continue. The joint offset is transferred to the machine data and is immediately effective in the control system (NCU).
  • Page 430 4. Press TOGGLE The selection is confirmed. 5. Press Continue. The "Parameters for the processing optics" mask opens. 6. Select Focal length. 7. Press Continue. The "Welding head parameters" mask is opened. The current joint offset values for the selected processing optics as well as the current focus position offset and the AutoLas Plus characteristic curve...
  • Page 431 The "Welding head parameters" mask is opened. Fig. 38790en Note The Back softkey can be used to return to the previous mask. The Cancel softkey is used to cancel the dialog. The machine data remain unchanged. 10. Press Continue. The joint offset is transferred to the machine data and is immediately effective in the control system (NCU).

  • Page 432: Cutting Head Setting Work

    Cutting head setting work Unassigned Cooling water supply connection Cutting gas connection Beam guideway ventilation Cooling water return connection connection Distance control system Cutting insert connection Sensor body Measuring probe connection 10 Nozzle Cutting head 7.5" Fig. 32589 5-19 Cutting head setting work B337EN05.DOC...

  • Page 433: Dismantling The Cutting Head

    Dismantling the cutting head 1. Move the Z center sleeve into a good changing position. 2. Select >Operation >Set-up >MDA. 3. Enter B0 C0. 4. Press Start. The B and C axes travel to 0. 5. Press FEED HOLD. 6. Unscrew connection for height regulation (distance control system), turn the bayonet catch to the left.

  • Page 434: Centering The Beam

    Centering the beam The beam must be re-centered every time after the mode or beam has been adjusted or after cleaning or changing the focusing lens. Only centric beam emission through the nozzle can guarantee satisfactory cutting results regardless of the direction. At the same time, it is guaranteed that the nozzle wall will not reflect the beam and that the cutting gas flow will be directed evenly around the focus spot.
  • Page 435 Installing the setting device The setting device (see Fig. 23177) is mounted and fastened onto the cutting head’s cutting insert from below. The contact surfaces must be clean. The device may not be tilted. 1. Unscrew the adjusting screws (1) and dial gauges (2) from the device up to the red marker (8).
  • Page 436 Localizing the beam The CP_TAPESHOT.LST service program is used to trigger a laser pulse. 1. Remove sensor body connection. Remove the protective plug from the cutting insert. Mount the setting device. 4. Stick adhesive strips onto the nozzle orifice. 5. Position cutting head in the center of the workspace in jog mode.
  • Page 437 Adjusting the beam The sensor body (7) is attached to a slide (+1.5 mm path movement in X and Y direction). The sensor body and slide are fixed with the clamping screws (6). The sensor body and nozzle are connected rigidly. The beam is adjusted by moving the sensor body.

  • Page 438: Determining And Setting The Focus Position

    1. Move the sensor body using the adjusting screws (1). The adjustment value can be read off the opposite dial gauge (2). 2. Trigger the laser pulse again and, if necessary, correct the beam. Repeat this procedure until the beam is centered. Use a new adhesive strip each time.
  • Page 439 Reference value Every lens is different in its geometrical and optical properties. That is why the reference value must be determined for each cutting head in combination with the beam guideway of the machine. The reference value is the value by which the permanently defined setting value on the scale has to be adjusted.
  • Page 440 AutoLas Plus function The AutoLas Plus mirror serves to compensate the focus shift and the program-controlled setting of the focus position. The surface of the AutoLas Plus mirror is intentionally reshaped by the pressure of the cooling water. As a result, the angle of divergence of the laser beam is adjusted in such a way that it is possible to shift the focus systematically upwards or downwards during machining.
  • Page 441 7,5" 5" Auto focus mirror Sheet surface Lens Recommended values for the automatic adjustment Fig. 23180 range Exceeding the automatic For technological reasons it may be necessary to work with a AutoLas Plus setting which is outside the AutoLas Plus automatic adjustment range setting range.

  • Page 442: Adjusting The Setting On The Cutting Head

    Adjusting the setting on the cutting head The setting is set on the cutting head by using the focal adjustment screw. You can feel the focus adjustment screw snapping while it is turned. Each time it snaps the height is adjusted by 0.1 mm. Example: The setting dimension in the laser technology table is 1.1 mm.

  • Page 443: Determining Focus Position F=0

    Determining focus position f=0 The program cuts a reference part out of the sheet with slats of equal size. The individual slats are cut consecutively, each with a different focus position, resulting in the kerf between the slats being changed continuously. The numerical value engraved for each gap defines the adjustment value by which the fixed setting value (-3 mm or -5 mm) has to be corrected on the focus adjustment screw.
  • Page 444 Prerequisite • The cutting head has been fully installed and selected via the head change dialog. • The beam is centered. • The DIAS characteristic curve has been recorded. • Setting value on the scale is set to -3 mm or -5 mm. •...

  • Page 445: Correcting Focus Position

    Correcting focus position 1. Shift the focus position upwards or downwards by this calculated adjustment value, e.g.: Adjustment value = +0.4: Turn the focus adjustment screw – to shift the focus position 0.4 mm upwards. Adjustment value = -1.0: Turn the focus adjustment screw –...

  • Page 446: Adjustment Work On The Welding Head

    Adjustment work on the welding head Installing the welding head Welding head identification Crossjet connection connector Cooling water supply connection Welding gas connection TSD seam sensor system or Cooling water return connection welding wire feed connection Welding wire feed driving motor Welding nozzle electrical connection Installing the welding head...

  • Page 447: Centering The Beam

    7. Slip the welding head onto the B/C angular gear and tighten the screws hand-tight. 8. Install the welding head identification connector. Connect the welding gas, Crossjet and cooling water. 9. Select a welding head (refer to the sections "Selecting the processing optics", "Selecting the welding head").
  • Page 448 Adjusting the beam The beam needs always to be first adjusted in Y direction. The beam in Y direction is adjusted by inserting spacer washers of the appropriate thickness between the mirror carrier and housing. Spacer washers of different thicknesses belong to the standard equipment of the machine.
  • Page 449 Adjust the beam in Y direction: Remove the fixing screws from the mirror carrier. – Carefully pull out the mirror carrier in a straight line. – Insert spacer washers of the appropriate thickness. – Insert mirror carriers and remove any leaking cooling –...

  • Page 450: Determining And Setting The Focus Position

    Determining and setting the focus position The focus position is the vertical position of the focus point in relation to the sheet surface. The exact position of the focus point is important for good welding results. As a rule, when welding, the focus point f=0 lies on the sheet surface, which corresponds to a nozzle distance of 15 mm.

  • Page 451: Utility Program Cp_Focus_Weld

    Utility program CP_FOCUS_WELD Determining the focus The focus position of f=0 is determined using the utility program CP_FOCUS_WELD. The program makes a general distinction position between approximate and fine-calibration searches. • Only approximate searches are offered and performed with machines lacking AutoLas Plus. Approximate search means: the actual focus position of f=0 is determined, together with the Deviation from nominal dimension.
  • Page 452 Welding table 1111 The utility program CP_FOCUS_WELD works with the welding table 1111. The welding table is designed for laser output 5000 W, St37 and sheet thickness 4 mm. The parameters programmed in the welding table are preset Recommended values that can be edited by the user as needed.

  • Page 453: Setting The Welding Head To The Nominal Dimension

    Setting the welding head to the nominal dimension To determine the actual focus position, it is first necessary to set the welding nozzle to a defined dimension: the nominal dimension. Differences are made, depending on the focal length. Note When the nozzle is shifted mechanically, the joint offset of the Z axis (tool length) will always need to be redetermined afterwards: see Section 7.2 "Determining joint offset Z axis (tool length)".

  • Page 454: Focus Search With Machines Without Autolas Plus

    Focus search with machines without AutoLas Plus Focus search Only an approximate search is carried out on machines that do not have AutoLas Plus. The Deviation from nominal dimension is determined. The length of the welding nozzle is adjusted to the new nominal dimension, after which a monitoring of the results of the approximate search is carried out.
  • Page 455 9. Select >Operation >Production >General welding table. 10. Select Table 1111. Edit the parameters if necessary. 11. Select the program CP_FOCUS_WELD. 12. Press Select program. A dialog box is opened. "Focus search for welding heads" mask Fig. 38777en 13. Select Start the focus search for the current welding optics. 14.
  • Page 456 Analyze welding seam. 17. Check weld root on the underside of the sheet, determine Z position for focus position of f=0. The focus position of f=0 is reached when the welding root on the bottom of the sheet can be clearly seen with full penetration welding.
  • Page 457 Actual focus position Nominal focus position Example Fig. 38700 19. Enter the deviation from the nominal dimension in the mask. "Input of deviation from nominal dimension Fig. 38778en determined" mask. 20. Press Apply value. 21. Press Continue. 22. Press Close. The approximate search is ended.
  • Page 458 Correcting the welding nozzle For welding heads with a focal length of f = 150 mm: ½ Screw sleeve into the welding head with corrected nominal dimension. Note An array of sleeves of different lengths belongs with the welding head with a focal length of f=150 mm. The difference between actual and nominal focus position is balanced out by utilizing a sleeve with corrected nominal dimension.
  • Page 459 Starting results check A weld seam 450 mm in length is welded in order to test whether the focus point remains constant over longer stretches. Prerequisite • Focus position of f=0 is determined. • Length of the welding nozzle is corrected. •...

  • Page 460: Focus Search With Machines With Autolas Plus

    Focus search with machines with AutoLas Plus AutoLas Plus characteristic Each welding head is assigned an AutoLas Plus characteristic curve: curve Characteristic curve Welding head f = 150 mm f = 200 mm f = 270 mm customized AutoLas Plus characteristic curve of the welding head Tab.
  • Page 461 Starting the approximate The focus position f=0 is determined in the welding-through process. The Deviation from nominal dimension is determined. search The CP_FOCUS_WELD program is used to weld eleven 40 mm welding seams, each with a different focus position. After each weld seam, the nozzle distance is increased by 1 mm.
  • Page 462 12. Press Select program. A dialog box is opened. "Focus search for welding heads" mask Fig. 38777en 13. Select Start the focus search for the current welding optics. 14. Press Continue. 15. Press >> following page. 16. Press Start approximate search. Program starts from the current axis position: 11 welding seams of 40 mm length each are welded.
  • Page 463 Analyze welding seam. 17. Check weld root on the underside of the sheet, determine Z position for focus position of f=0. The focus position of f=0 is reached when the welding root on the bottom of the sheet can be clearly seen with full penetration welding.
  • Page 464 Actual focus position Nominal focus position Example Fig. 38700 19. Enter the deviation from the nominal dimension in the mask. "Input of deviation from nominal dimension Fig. 38778en determined" mask. 20. Press Apply value. 21. Press Continue. 22. Press Close. The approximate search is ended.
  • Page 465 Correcting the welding nozzle For welding heads with a focal length of f = 150 mm: ½ Screw sleeve with the corrected nominal dimension into the welding head. Note An array of sleeves of different lengths belongs with the welding head with a focal length of f=150 mm.
  • Page 466 Start monitoring results after A weld seam 450 mm in length is welded in order to test whether the focus point remains constant over longer stretches. approximate search Prerequisite • Focus position of f=0 is determined. • Length of the welding nozzle is corrected. •...
  • Page 467 Starting fine search (without The focus position – the parameter Focus position offset – is determined once with maximum laser output. power-dependent focus shift) Prerequisite • Welding head is completely mounted and selected. • The beam is centered. • Approximate search and results check have been carried out. •...
  • Page 468 "Focus search for welding heads" mask Fig. 38781en 9. Select Start the focus search for the current welding optics. 10. Press Continue. 11. Press >> following page. 12. Press Start fine search. 13. Press Prepare. NC program is terminated. 14. Press START. Program starts from the current axis position: 11 welding seams of 40 mm length each are welded.
  • Page 469 Foc Off +5 mm Start position Example: focus position reference part Fig. 38699 17. Determine focus position offset and enter into the dialog. Note The focus position offset is the amount by which the control system uses software to pan the AutoLas Plus characteristic curve.
  • Page 470 Start monitoring results after The reference part is welded once again with 11 welding seams, each with a respectively different focus position at maximum laser fine search output. Prerequisite • Focus position of f=0 is determined. • Focus position offset is entered. •...
  • Page 471 Starting fine search with The focus position is determined twice, once at maximum laser output and once with minimum laser output. The control system power-dependent focus shift calculates the Power-dependent focus shift from the difference between the two values which have been determined. First the focus position offset is determined at maximum laser output.
  • Page 472 5. Select >Operation >Production >General welding table. 6. Select Table 1111. Edit the parameters if necessary. Program maximum laser output. 7. Select the program CP_FOCUS_WELD. 8. Press Select program. A dialog box is opened. "Focus search for welding heads" mask Fig.
  • Page 473 Evaluate the welding seams 17. Check weld root on the underside of the sheet, determine focus position of f=0. The focus position of f=0 is reached when the welding root on the bottom of the sheet can be clearly seen with full penetration welding.
  • Page 474 19. Press Apply value. The focus position offset is stored in the control system. Display dialog opens. 20. Press Prepare. NC program is terminated. Starting fine search with 21. Pan the sheet or establish new start position. Position welding head with 15 mm nozzle distance. minimum laser output 22.
  • Page 475 29. Press Adopt values. The control system calculates the power-dependent focus shift from the focus position offset, which was determined at maximum and minimum laser output. Display dialog opens. "Entering the established power-dependent focus Fig. 38799en shift" mask. 30. Press Continue. The fine search is ended.
  • Page 476 Start monitoring results after The reference part is welded twice again with 11 welding seams, each with a respectively different focus position; first at maximum fine search laser output and then with minimum laser output. Prerequisite • Power-dependent focus shift is determined. •...
  • Page 477 Foc Off +5 mm Foc Off +5 mm with maximum laser output with minimum laser output Start position Reference parts Focus position Results check Fig. 38787 The focus search is ended when the best welding root on the underside of the sheet is at focus position = 0 mm for both reference parts.

  • Page 478: Determining The Joint Offset

    Determining the joint offset Joint offset The offset value for the X, Y and Z axes between the beam center of the pivot B/C angular gear and the beam center of the focus point (tool center point) is referred to as the joint offset. Pivot B/C angular gear joint offset X axis (X “fixed“) Focus point...
  • Page 479 Theoretical joint offset (recommended value): Processing optics Joint offset Joint offset Joint offset X axis in [mm] Y axis in [mm] Z axis in [mm] Cutting head 3.75" Cutting head 5" Cutting head 7.5" Welding head f = 150 mm Welding head f = 200 mm Welding head f = 270 mm Theoretical joint offset...

  • Page 480: Determine Link Offset Of X And Y Axis

    Determine link offset of X and Y axis The joint offset for the X and Y axes is determined using the CP_OFFSET_CUT program (for cutting heads) CP_OFFSET_WELD program (for welding heads) automatically saved in joint offset dimension data management when it is adopted. Determining the joint offset for cutting head The service program CP_OFFSET_CUT.LST is used to cut a sample.
  • Page 481 Prerequisite • B and C axes are set exactly. • The cutting head is fully installed. • The beam is centered. • The focus position has been determined and set. • The DIAS characteristic curve has been recorded. Additional equipment, tools, material •...

  • Page 482: Determining The Joint Offset For The Welding Head

    Determining the joint offset for the welding head The service program CP_OFFSET_WELD.LST is used to engrave pairs of lines on a sample part. For this, the C axis is once in position C0 and once in position C180. The joint offset is then determined precisely once the lines of a pair of lines form a continuous line without any offset after the fine evaluation has been completed.
  • Page 483 Additional equipment, tools, material • Slip gauge 15 mm. • A flat, oil-free, 2 mm thick sheet, ca. 500 mm x 500 mm, mild steel. • Measuring magnifier (10 to 20 times enlargement). • CP_OFFSET_WELD.LST service program. Evaluating the pairs of lines The pairs of lines are first evaluated roughly and then precisely.

  • Page 484: Determining Link Offset Of Z Axis (Tool Length)

    Evaluating the pairs of lines 1. Evaluate the pairs of lines for the X and Y direction: precisely Select the pair of lines which coincide precisely. – Enter the corresponding engraved numerical value in the – mask. 2. Press Adopt. The determined joint offset values are saved to the data management.
  • Page 485 Prerequisite • B and C axes are set exactly. • The processing optics are fully installed. • The beam is centered. • The focus position has been determined and set. • For cutting head: distance control system characteristic curve has been recorded. Additional equipment, tools, material •...
  • Page 486 Transferring the joint offset The joint offset for the Z axis must be entered manually in the dialog box. to the data management 1. Select >Operation >Set-up > Service again. 2. Set the "Head change" switch element to ACTIVE. The selection dialog is started. 3.

  • Page 487: Changing The Gas And Air Connections At The Z Center Sleeve

    Changing the gas and air connections at the Z center sleeve The gas and air connections at the Z center sleeve have to be changed in order to change machining from welding to cutting or vice versa. Welding Cutting Crossjet connection Beam guideway ventilation Welding gas connection connection...

  • Page 488: Recording The Dias Characteristic Curve

    Recording the DIAS characteristic curve The cutting head is equipped with the DIAS distance control system. The distance control system uses a characteristic curve. The characteristic curve has to be recorded again: • After switching on the machine. • After changing the cutting head or nozzle. •...

  • Page 489: Checking And Setting The Crossjet

    Checking and setting the Crossjet Dirt or slag particles can enter the beam guideway during welding and dirty the parabolic mirror in the welding head. This is why air is blown permanently through the nozzle of the welding head during machining.

  • Page 490: Setting The Flow Rate Of The Welding Gas

    Setting the flow rate of the welding Setting the flow rate The flow rate must be set at the welding gas flowmeter at the instrument panel prior to welding. The welding gas and correct flow rate are selected according to the welding job. Material Flow rate [l/min] Helium...

  • Page 491: Switching Over The Welding Gas

    Switching over the welding gas Switching over the welding A maximum of 5 welding gases can be installed at the machine. A welding gas unit is installed at the instrument panel for each of the welding gases helium (He), argon (Ar) and nitrogen (N ).

  • Page 492: Measuring Probe (Optional)

    Measuring probe (optional) 13.1 Installing the measuring probe The cutting head or welding head can be equipped with a precision measuring probe (Renishaw measuring probe). The tactile measuring probe (multi-axis microswitch) is slipped onto the prepared processing optics and fixed at an offset of 120° to the nozzle.

  • Page 493: Selecting Measuring Probe

    Prerequisite Processing optics have been installed and set up. 1. Select >Operation >Set-up >MDA. 2. Enter B0 C0. 3. Press Start. The B and C axes travel to position 0. 4. Move the Z axis to an approximate distance of 5 - 10 mm to the nozzle.
  • Page 494 1. Select >Set-up >Switch element group Service. 2. Press "Measurement functions". Selection dialog opens. Select Measurement function Fig. 38095en 3. Select measuring probe mode. 4. Press Continue. Selecting measuring probe Fig. 38096en 5. Select measuring probe. 6. Press Continue. 5-81 Measuring probe (optional) B337EN05.DOC...
  • Page 495 Joint offset measuring probe Fig. 38097en Note Joint offset Z = length of the measuring probe. The last joint offset values detected are displayed. If no joint offset has yet been determined for the measuring probe, then the default values for the respective measuring probe will be displayed.

  • Page 496: Calibrating The Measuring Probe

    A measuring device is available. Additional equipment, tools, material • Utility program CP_TOUCH_PROBE.LST. • Measurement device: The reference sphere does not belong to the scope of delivery of the measuring probe. It can be acquired at TRUMPF. 5-83 Measuring probe (optional) B337EN05.DOC...
  • Page 497 Measurement feature: reference sphere Fig. 31871 1. Position the reference sphere in the working area. 2. Select >Operation >Set-up >MDA. 3. Enter B-120 C0. 4. Press Start. 5. Position the Z axis about 2 mm over the center of the sphere. 6.
  • Page 498 Measuring points on the reference sphere Fig. 31882 Each measurement begins and ends at the top, at the center of the sphere. The measurement is carried out four times in different B and C axis positions: B = -120 and C = 0. –...

  • Page 499: Welding Wire Feed (Optional)

    Welding wire feed (optional) 14.1 Inserting welding wire Welding wire feed is an option for welding applications with supplementary wire. The coil at the Z axis and the drive at the welding head can be removed. Prerequisite • The welding head and Z center sleeve are equipped with the components for welding wire feed.
  • Page 500 If the welding wire is bent: 1. Undo the clamping screw. 2. Adjust the form roller until the welding wire is straight. 3. Retighten the clamping screw. 4. Screw in the hose at the connection. Inserting the welding wire in the drive Drive motor Clamp lever Hose connection...
  • Page 501 Aligning the welding wire The position of the welding-wire tip is decisive for the welding result: • If the welding wire protrudes beyond the focus, the laser beam burns the welding wire. • If the welding wire is too far back, it is not in the welding seam. Fixing screw (2x) Welding wire nozzle Holder...
  • Page 502 Changing the welding wire The welding wire feed is designed for steel or aluminum wire with ∅ 0.8 mm, 1.0 mm or 1.2 mm. diameter Note The form rollers in the roller box, the guide roller at the welding wire drive and the welding wire nozzle all depend on the diameter of the welding wire.

  • Page 503: Setting The Rotary Axis (Optional)

    Setting the rotary axis (optional) 15.1 Shifting the rotational axis horizontally in X direction The rotary axis can be shifted horizontally about 1200 mm parallel to the X axis. Auxiliary equipment • 10 mm Allen wrench. Note We recommended marking the defined initial position before shifting the rotational axis, by using a fixed stop, for example.

  • Page 504: Adjusting The Rotational Axis In Z Direction

    15.2 Adjusting the rotational axis in Z direction The rotary axis can be adjusted vertically 200 mm parallel to the X axis. Auxiliary equipment • 10 mm Allen wrench. Note A tape measure has been applied to the rotary table for position- ing.

  • Page 505: Swivelling The Rotational Axis By 90

    15.3 Swivelling the rotational axis by 90° The rotary axis can be swung by 90° parallel to the X axis. Auxiliary equipment • 10 mm Allen wrench. (5x) Hand wheel for swinging Clamping screw (M12 socket head screw) Swinging the rotary axis Fig.

  • Page 506: Setting The Back Stop (Optional)

    Setting the back stop (optional) 16.1 Shifting the rotational axis horizontally in X direction The back stop can be shifted manually on guide rails on the machine body and positioned in the workspace as desired. Auxiliary equipment • 10 mm Allen wrench. Clamping screw (M12 socket head screw) Back stop...

  • Page 507: Further Service Programs

    Further service programs There are further service programs available to the user in addition to the service programs listed under section 1, "Overview of setting work". They are saved on the hard disk of the PCU 50 under: C:\DH\TOPSMANU.DIR\SERVICE.PRG\CUSTOMER Program overview Master file name For what purpose? CP_SRV_TAB_SET.LST...
  • Page 508 Prerequisite • Master file is split. Additional equipment, tools, material • Utility program CP_SRV_TAB_SET.LST. Note An LTT is effective only in the allocated utility program for the respective processing optics. The setting in the utility program is self-holding. 1. Select program CP_SRV_TAB_SET. 2.

  • Page 509: Performing Parting Cuts

    17.3 Performing parting cuts Performing parting cuts The service program CP_TRIM_OFF.LST performs parting cuts in the X or Y direction. Parting cuts are performed: • To separate a sheet. • To separate a sheet skeleton from a sheet. Prerequisite • The machine is equipped for laser cutting.

  • Page 510: Cutting Support Slats

    17.4 Cutting support slats Cutting support slats The program only cuts one support slat at a time. The workpiece zero point is automatically set to the start position. 1621 Start position Standard support slats with short slit Fig. 32548 1621 Start position Support slats with long slit Fig.
  • Page 511 1. Position the cutting head over the sheet. 2. Select >Operation >Set-up >MDA. 3. Enter B0 C0. 4. Press Start. The B and C axes travel to 0. 5. Select >Operation > Production > Single job. 6. Select program AUF_ST or AUF_QU. Note The laser technology table is designed for the TLF 4000 laser and St.1203 mild steel.

  • Page 512: Cutting Sacrificial Plates

    17.5 Cutting sacrificial plates Cutting sacrificial plates Sacrificial plates are loaded in the drawers of the support table for cutting in order to protect the drawers against wear. The sacrificial plates should be replaced when they show signs of wear. ±...
  • Page 513 ± ± Sacrificial plate 2 Fig. 39487 Prerequisite • The machine is equipped for laser cutting. • The cutting optics have been installed, set up and selected. • Master file is split. Additional equipment, tools, material • Utility program CP_93918_445_120_SACRIFIC.LST for sacrifi- cial plate 1.
  • Page 514 Number of sacrificial plates required Machine table Table size Master file: Master file: in X direction CP_93918_445_120_SAC CP_S99762_438_120_SA RIFIC.LST CRIFIC.LST Working height 700 mm 1500 mm 2000 mm 3000 mm 3000 mm divided 4000 mm divided Working height 550 mm 3000 mm 3000 mm divided 4000 mm divided...
  • Page 515 5-102 Further service programs B337EN05.DOC...
  • Page 517 Chapter 6 Machine maintenance General guidelines ............6-3 Maintenance overview ........... 6-4 System lubrication ............6-7 Explanation of the symbols used in the lubrication diagram ............6-7 Lubrication chart............... 6-8 Lubricant table..............6-9 Notes for lubrication chart ..........6-10 Maintenance of mechanical components....6-19 Maintenance on basic machine........
  • Page 518 Maintenance of optical components......6-44 General guidelines and additional equipment ....6-44 Maintenance of optical components....... 6-47 Maintenance of electrical components ...... 6-64 Safety information ............. 6-64 Safety cabin maintenance ........... 6-69 Maintenance of seam sensor system (optional) ..6-70 Maintenance of air-conditioning doors......

  • Page 519: General Guidelines

    General guidelines Correct maintenance is a prerequisite for maintaining the quality of the machine. This avoids operational errors and their conse- quences. Danger Risk of fatal injury during maintenance work when the machine is switched on! ½ When not expressly instructed otherwise: Switch off the MAIN SWITCH.

  • Page 520: Maintenance Overview

    Maintenance overview Sorted by maintenance interval: Maintenance point Procedure Interval (h) Page Support table support slats Clean Clean gas outlet Inspection Dust container Check capacity and replace Safety cabin viewing window Inspection Protective glass seam sensor system Cleaning and TSD 2 replacement Guide rails for rotary axis and back stop Clean and oil...
  • Page 521 Maintenance point Procedure Interval (h) Page Filter for beam guideway ventilation in Check and replace cutting head Filter for cutting gas conduit in cutting Check and replace head Beam guideway pressure Check and adjust Full flow filter and AutoLas Plus water Inspection filter in the cooling circuit Bypass filter in cooling water circuit,...
  • Page 522 Maintenance point Procedure Interval (h) Page X axis gearbox Change oil 5000 Y axis gearbox Change oil 5000 Z axis gearbox Change oil 5000 Rotary axis gearbox (optional) Change oil 5000 B and C axis motor intermediate gear Lubricate 5000 Compressed air supply prefilter Replace filter cartridge 5000...

  • Page 523: System Lubrication

    System lubrication Explanation of the symbols used in the lubrication diagram LE GE ND OF S YMB OLS Check oil level and Lubrication intervals in replenis h to level operating hours mark, if neces s ary S ee operator’s manual for Check oil level information on lubrication points and neces s ary action...

  • Page 524: Lubrication Chart

    Lubrication chart 5000 2000 Lubrication diagram Fig. 31761 Machine maintenance B337EN06.doc...

  • Page 525: Lubricant Table

    The lubricant table contains a list of approved lubricants. We recommend using the itemized lubricants or verifiable equivalents from other mineral oil companies. No. Maintenance Amount Recommended DIN 51502 Viscosity TRUMPF point (liters) lubricant identifi- Consis- part No. (see Fig. 31761)

  • Page 526: Notes For Lubrication Chart

    Notes for lubrication chart Maintenance point no. Interval Maintenance note operating Procedure hours 5000 Change oil X axis gearbox Drain oil: Fig. 31719 1. Open oil filler plug and oil drain plug. 2. Drain the oil while it is at working temperature. Refill with oil: 1.
  • Page 527 Maintenance point no. Interval Maintenance note operating Procedure hours 5000 Change oil Y axis gearbox Drain oil: Fig. 31722 1. Open oil filler plug and oil drain plug. (The oil filler plug is located on the opposite, rear side of the gearbox.) 2.
  • Page 528 Maintenance point no. Interval Maintenance note operating Procedure hours 5000 Change oil Z axis gearbox Drain oil: Fig. 31766 1. Open oil filler plug and oil drain plug. Fig. 31767 2. Drain the oil while it is at working temperature Refill with oil: 1.
  • Page 529 Maintenance point no. Interval Maintenance note operating Procedure hours 5000 Change oil Rotary axis gearbox Drain oil: (A axis) 1. Open oil filler plug and oil drain plug. Fig. 31718 2. Drain the oil while it is at working temperature Refill with oil: 1.
  • Page 530 Maintenance point no. Interval Maintenance note operating Procedure hours 2000 Lubricate ½ Fill grease nipples (4 each) on the rear sides of the Bearing frames on bearing frames with a grease gun until the grease rotary axis and on comes out on the bearing frames. back stop Rotary axis height adjustment...
  • Page 531 If topping up is required, use a synthetic grease as per the lubricant table. If grease is leaking out from the underside of the gearbox, TRUMPF customer service must be called in. Drive motors...
  • Page 532 Maintenance point no. Interval Maintenance note operating Procedure hours 5000 Lubricate B and C axis motor 1. Remove the casing on the Z center sleeve. intermediate gears 2. Fill the grease nipples (2) using a grease gun. Fig. 22963 Drive motors Lubricating heads B and C axis motor intermediate gears Fig.
  • Page 533 Maintenance point no. Interval Maintenance note operating Procedure hours When Filling the low-viscosity grease reservoir message Central lubrication The central lubrication supplies the pinions of the X, Y, and appears Z drives and the guide bearings of the axes with low- Fig.
  • Page 534 Maintenance point no. Interval Maintenance note operating Procedure hours The lubricating pressure at the pressure gauge must be at least 30 bar. The lubricating pressure is automatically checked during the active lubrication cycle via the pressure switch. The lubrication cycle stops if the pressure is less than 30 bar.

  • Page 535: Maintenance Of Mechanical Components

    Maintenance of mechanical components Maintenance on basic machine Maintenance points Fig. 31721 6-19 Machine maintenance B337EN06.doc...
  • Page 536 Maintenance point no. Interval Maintenance note (see Fig.31721) operating Procedure hours 10, 11, 12 2000 Checking and oiling Racks of X, Y, and Z 1. Clean the racks with a brush and spindle oil. axes 2. Afterwards, cover the points which have been cleaned with a thin film of oil.
  • Page 537 Maintenance point no. Interval Maintenance note (see Fig.31721) operating Procedure hours Clean Drawers and sacrificial Note: observe the safety information in the Safety chapter. Make sure you do not stir up any dust while cleaning. Use a plates in the support vacuum cleaner with an activated carbon filter.
  • Page 538 Maintenance point no. Interval Maintenance note (see Fig.31721) operating Procedure hours Clean Cleaning the basic Note: observe the safety information in the Safety chapter. Make sure you do not stir up any dust while cleaning. Use a table vacuum cleaner with an activated carbon filter. Fig.

  • Page 539: Maintenance Of Compact Dust Extractor

    Maintenance of compact dust extractor Warning Danger from residual dust. For all maintenance work during which the user comes into contact with residual dust, the following safety precautions are to be observed: ½ Wear dust mask of filter class P3. ½...
  • Page 540 Maintenance point No. Interval Maintenance note operating Procedure hours Clean gas outlet Spark arrester Clean gas space Oversized material collector Filter inserts drawer Seal for filter inserts Dust discharge mixer tube and Dust container precoating unit mixer tube (disposable container) Compact dust extractor maintenance point Fig.
  • Page 541 Maintenance point no. Interval Maintenance note (see Fig.27736) operating Procedure hours Inspection Dust may emanate from the clean gas outlet for the Clean gas outlet following reasons: Worn out, crushed, or torn filter seal. Damage to filter inserts. ½ Replace gaskets and/or filter inserts (see operation and maintenance manual for the filtering installation).
  • Page 542 Maintenance point no. Interval Maintenance note operating Procedure (see Fig. 27736) hours Check capacity and replace Dust container When installing the dust container, make sure the hose connections on the container and on the cover are attached (Hoobock-Fass steel) properly and the cover of the container is closed tightly. Fig.
  • Page 543 Maintenance point no. Interval Maintenance note (see Fig.27736) operating Procedure hours Inspection and, if needed, cleaning Spark arrester 1. Switch off the MAIN SWITCH. 2. Open the lower door and the inspection door. Fig. 27732 3. Remove the cartridge. Check for deposits and, if needed, sweep and vacuum-clean its upper and lower sides.
  • Page 544 Maintenance point No. Interval Maintenance note operating Procedure (see Fig. 27736) hours Check and clean Check both spiral hoses and clean as needed. Spiral hoses for dust discharge and 1. Switch off the MAIN SWITCH. precoating device 2. Open the lower door. Fig.
  • Page 545 Maintenance point No. Interval Maintenance note operating Procedure hours Note For filtering installations with a CO fire extinguishing device (optional), the following maintenance work is also required. For a description of this maintenance work see "Filtering installation operating and maintenance manual", "Documentation for CO extinguisher for filter".

  • Page 546: Maintenance Of Pneumatic Components And Filters

    Maintenance of pneumatic components and filters Instrument panel Fig. 39484 6-30 Machine maintenance B337EN06.doc...
  • Page 547 Compressed air gauge for Main filter for compressed air Beam guideway ventilation operating pressure disposable filter Compressed air gauge Activated carbon filter for Collecting tank Beam guideway ventilation Beam guideway ventilation condensate precipitation Prefilter for compressed air Crossjet activated carbon filter Beam guideway ventilation DFU Instrument panel maintenance points Caption Fig.
  • Page 548 Maintenance point no. Interval Maintenance note operating Procedure (see Fig. no. 39484) hours Check and replace 1. Shut off compressed air. Compressed air supply main filter 2. Undo nut. 3. Loosen filter, remove filter cartridge. 4. If the filter cartridge is smeared with oil, replace it. The filter cartridge may only be very slightly oily! 5.
  • Page 549 Maintenance point no. Interval Maintenance note operating Procedure (see Fig. no. 31768) hours Check and replace ½ If the filter is clearly dirty, replace filter insert. Disposable filter in beam guideway ventilation Inspection ½ Check container and empty as needed. Condensate precipitation collecting tank...
  • Page 550 Maintenance point no. Interval Maintenance note operating Procedure (see Fig. no. 31768) hours When Ventilating the sealing gas conduit message Sealing gas conduit on The emergency sealing gas supply is used to maintain the appears function of the rotation transmission (of gas/water) on the instrument panel Z center sleeve in the event of long machine downtimes and Fig.
  • Page 551 Maintenance point no. Interval Maintenance note operating Procedure hours Sealing gas conduit on When Emptying water from the sealing gas conduit message Z center sleeve 1. Remove the plugs (1) on the Z center sleeve. Allow air appears to escape until water stops leaking out. Fig.

  • Page 552: Maintenance On Basic Machine

    Maintenance on basic machine Maintenance point no. Interval Maintenance note operating Procedure hours Check and replace ½ If the filter is clearly dirty, replace filter insert. Beam guideway ventilation filter on cutting head Fig. 22971 Check and replace ½ If the filter is clearly dirty, replace filter insert. Filter in cutting gas conduit on cutting Note: ensure that the filter insert is installed the right way...
  • Page 553 Maintenance point no. Interval Maintenance note operating Procedure hours Inspection The beam guideway is permanently ventilated with flow Beam guideway pressure to keep dirt particles from settling onto optical pressure components. The flow pressure has been set at factory via a Fig.
  • Page 554 Maintenance point no. Interval Maintenance note operating Procedure hours Beam guideway Adjusting the pressure pressure necessary ½ Open laser cap. Fig. 39810 If the pressure differential is less than 0.4 ± 0.1 mbar then the pressure in the beam guideway is too low. ½...
  • Page 555 Maintenance point no. Interval Maintenance note operating Procedure hours Check and replace Full flow filter and The laser beam must be switched off. AutoLas Plus water 1. Close stopcocks (1) on full flow filter (2). filter in the cooling 2. Unscrew filter container on full flow filter (2) and on circuit AutoLas Plus water filter (3) and check filter insert for Fig.
  • Page 556 Maintenance point no. Interval Maintenance note operating Procedure hours Stopcock (2 x) AutoLas Plus water filter Full flow filter Water filter Fig. 22977 6-40 Machine maintenance B337EN06.doc...
  • Page 557 Maintenance point no. Interval Maintenance note operating Procedure hours Check and clean Bypass filter in the The laser beam must be switched off. cooling water circuit of 1. Remove panelling on the rear side of the Y extension the AutoLas Plus arm.
  • Page 558 Maintenance point no. Interval Maintenance note operating Procedure hours Inspection Adaptive telescope The laser beam must be switched off. filter 1. Remove panelling. Fig. 31725 2. Pull off filter housing and open. 3. Clean filter screen. If the filter screen is damaged, it must be replaced.

  • Page 559: Maintenance For Laserpac

    Maintenance for Laserpac Laserpac is a fitting on machines with high laser power and/or a long beam path. The Laserpac has the task of filtering dust, oil and out of the compressed air used to ventilate the beam guideway. Note For description of the maintenance work and maintenance intervals, see: "Operator’s manual preparation unit Laserpac LP 0072".

  • Page 560: Maintenance Of Optical Components

    Maintenance of optical components General guidelines and additional equipment Warning Invisible, high-energy laser radiation! Danger can arise from both direct and reflected laser radiation. Severe skin burns and injuries to eyes can occur. Resulting in damage to eyesight or even complete blindness. All maintenance work on optical components must only be carried out when the machine has been switched off: ½...
  • Page 561 Cleaning the copper beam Coated and uncoated copper mirrors are cleaned in the same way. bending mirror If the mirror surface is damaged, e.g. by deep scratches or scorched areas, the mirror must be replaced. Dirty or scratched optics result in loss of performance. 1.
  • Page 562 Lens cleaning paper (Kodak) (TRUMPF part no. 086452). • Aluminum foil. • Lint-free base cloth and gloves. • Pure cotton wool (TRUMPF Mat. No. 096 751 must not contain viscose as this scratches copper • Wenol. • Topol 2 metal polish (TRUMPF part no. 240 568) •...

  • Page 563: Maintenance Of Optical Components

    Maintenance of optical components Beam guideway with TLF lasers of the small construction type 57 59 Lens cutting head Beam bending mirror (Cu) for Adaptive telescopic mirror (Cu) X/Y axis Beam bending mirror (Si) for Beam bending mirror (Si) for Phase shifter (Si) cutting head X/Y axis...
  • Page 564 Beam guideway large-series TLF lasers Lens cutting head Beam bending mirror (Cu) for Beam bending mirror (Cu) Y/Z axis Beam bending mirror (Si) for Beam bending mirror (Cu) for laser/machine cutting head X/Y axis AutoLas Plus mirror (Cu) Beam guideway TLF lasers of the large construction type Fig.
  • Page 565 Maintenance point no. Interval Maintenance note operating Procedure hours Check, clean, replace The lens must be cleaned even in the case of only minimal Lens in the cutting contamination. The lens must be replaced if it is damaged. head ½ Remove the cutting head, if necessary. Fig.
  • Page 566 Maintenance point no. Interval Maintenance note operating Procedure hours Fig. 31715 Removing lens Warning Danger of poisoning from zinc selenide (ZnSe) lens! ½ Do not eat or drink anything while cleaning the lens. ½ Wash your hands after contact with the lens. ½...
  • Page 567 Maintenance point Interval Maintenance note operating Procedure hours Cleaning lens 1. Place the lens on the lens holder and blow off with bellows. 2. Preclean the lens with acetone and remove coarse dirt. 3. Shake Topol 2. Moisten a pad of surgical cotton thoroughly with Topol 2.
  • Page 568 Maintenance point Interval Maintenance note operating Procedure hours Fig. 32123 Inserting lens in the lens adapter 1. Clean the lens support area in the threaded sleeve using cleaning paper moistened with acetone. 2. Blow off lens, lens adapter and threaded sleeve using bellows.
  • Page 569 Maintenance point Interval Maintenance note operating Procedure hours Fig. 31716 5. Carefully set the lens adapter onto the threaded sleeve. Screw the threaded sleeve in until it aligns evenly with the lens adapter, without protruding. Do not screw in the threaded sleeve too tightly.
  • Page 570 Maintenance point Interval Maintenance note operating Procedure hours Mounting lens adapter 1. Screw the lens adapter into the correct position in the housing. The focus adjustment screw must be screwed in so far that none of its thread is visible. 2.
  • Page 571 Maintenance point Interval Maintenance note operating Procedure hours Clean necessary Parabolic mirror in Note: The focusing lens must be cleaned even in the case of minimal contamination. The parabolic mirror in the laser the welding head welding head is coated with molybdenum. The surface of the Fig.
  • Page 572 Maintenance point Interval Maintenance note operating Procedure hours Dismantling parabolic mirror Note: The water connection must be slightly loosened so that the O-ring inside is not damaged. 1. Turn the welding head to B90 so that cooling water does not enter the interior of the welding head after the mirror mount has been opened.
  • Page 573 Maintenance point no. Interval Maintenance note operating Procedure hours Inspection 1000 ½ Check mirror for contamination or damage. Cutting head Clean deflection mirror (fixed/Si-coated) 1. Remove cooling water connections on the Z center necessary sleeve. Remove the cutting head if necessary. Fig.
  • Page 574 Maintenance point no. Interval Maintenance note operating Procedure hours 1000 Inspection ½ Check mirror for contamination or damage. AutoLas Plus mirror (adaptive mirror/Cu) Clean necessary Fig. 36763 1. 1. Select >Operation > Production > Switch elements TLF laser Status. 2. Set "cooling unit" switch element to OFF. 3.
  • Page 575 Maintenance point no. Interval Maintenance note operating Procedure hours 1(2x) 2(4x) Water connection Mirror Fixing screws AutoLas Plus mirror Fig. 36763 6-59 Machine maintenance B337EN06.doc...
  • Page 576 Maintenance point Interval Maintenance note operating Procedure hours Inspection 1000 ½ Check mirror for contamination or damage. Z/C axes deflection mirror Clean (adjustable/Cu) necessary 1. If there is a cover, remove it. 2. Undo the cap screws (1) on the deflection mirror. X/Y axis deflection 3.
  • Page 577 Maintenance point no. Interval Maintenance note operating Procedure hours Inspection 57, 58 1000 ½ Check mirror for contamination or damage. Deflection mirror Clean (fixed/Si-coated) ½ Remove cover. necessary Deflection mirror (57 and 58): 1. Undo the cap screws on the deflection mirror. Adaptive telescope 2.
  • Page 578 Maintenance point no. Interval Maintenance note operating Procedure hours Adaptive telescope (59): 1. Undo the cap screws on the cooling element. 2. Carefully draw out the cooling element. 3. Blow the mirror clean using oil-free compressed air or nitrogen. 4. Clean the mirror surface with lens cleaning paper and acetone.
  • Page 579 Maintenance point no. Interval Maintenance note operating Procedure hours 1000 Inspection ½ Check mirror for contamination or damage. Deflection mirror (fixed/ Clean Cu-coated in TLF necessary 1. Open small laser hood. 4000/ 2. Undo the cap screws (1) on the deflection mirror. Si-coated in TLF 5000) Fig.

  • Page 580: Maintenance Of Electrical Components

    Maintenance of electrical components Safety information Danger All components in the switch cabinet which have not been de- energized continue to carry a charge for four minutes after MAIN SWITCH OFF! Risk of fatal injury! ½ Maintenance work on the electrical system may only be performed once the machinery has been switched off and is dead (except when replacing MMC batteries).
  • Page 581 Maintenance point no. Interval Maintenance note operating Procedure hours 2000 Inspection ½ Connectors and screw- Make sure the connectors are in perfect condition. type connections in the switch cabinet Clean ½ Switch cabinet fan Use compressed air to blow out the outer cooling circuit fan.
  • Page 582 Maintenance point no. Interval Maintenance note operating Procedure hours Every 3 Battery replacement years NC-CPU battery/fan in Caution, loss of data! starting the machine switch The battery must be replaced within 15 minutes to avoid from cabinet loss of data! Siemens’...
  • Page 583 Maintenance point no. Interval Maintenance note operating Procedure hours Every Battery replacement 3 years MMC buffer battery Caution, loss of data! starting in control panel The battery may only be replaced when the machine from Part no.: 0143467 control system is switched on. If the battery is changed Siemens’...
  • Page 584 Maintenance Interval Maintenance note point no. operating Procedure hours 2000 h Clean Air conditioning Note: it is not permitted to change the settings. unit control 1. Switch off the MAIN SWITCH. panel 2. Remove the protective cover. Fig. 39439 3. Remove panelling. 4.

  • Page 585: Safety Cabin Maintenance

    ½ Replace the viewing window if 1 mm deep pits or holes are discovered during inspection. ½ Operation of the machine is only permitted after the defective window has been replaced. Note: TRUMPF customer service must be called in to replace the viewing window. 6-69 Machine maintenance...

  • Page 586: Maintenance Of Seam Sensor System (Optional)

    Maintenance of seam sensor system (optional) Maintenance point no. Interval Maintenance note operating Procedure hours Cleaning orReplacement Protection glass, seam Note: The protective glass must be cleaned daily. It must be replaced if it is scratched or broken. The seam sensor system sensor system can only function with precision when the protective glass is in a perfect and clean condition.

  • Page 587: Maintenance Of Air-Conditioning Doors

    Maintenance of air-conditioning doors Maintenance point no. Interval Maintenance note operating Procedure hours 2000 Clean Air-conditioning doors, To avoid loss of cooling power, the inner space of the air- machine switch cabinet conditioning door must be cleaned. and laser switch 1.
  • Page 588 Maintenance point no. Interval Maintenance note operating Procedure hours 1. Clean the inside area, condenser fins, external fans, compressor and transformer with a vacuum cleaner. 2. Clean the fins with compressed air. Remove stubborn, oil impregnated dirt using spirit. 3. Screw air guiding plate down and mount the hood. Air-conditioning door Fig.
  • Page 590 Chapter 7 Maintenance of laser Maintenance overview ........... 7-3 Maintenance intervals ............7-4 Vacuum pump ..............7-5 Auxiliary tools and materials ..........7-5 Maintenance work ............7-6 Compressed air filter unit ..........7-7 Laser control ..............7-7 Cooling unit ..............7-8 Auxiliary tools and materials ..........
  • Page 591 RF generator..............7-18 Notes on safety .............. 7-18 Auxiliary tools and materials .......... 7-19 Construction of RF generator......... 7-19 Short-circuiting residual voltage........7-20 Tube output stage ............. 7-21 HV power supply unit ..........7-24 Maintenance work ............7-26 Operating steps during maintenance work ....7-37 Opening the vacuum system .........

  • Page 592: Maintenance Overview

    Maintenance overview The control system indicates pending maintenance by showing the Maintenance marker maintenance symbol and a corresponding note on the user interface. Operating hours In the table "Maintenance intervals", Interval (h) = operating hours. Execute calendar-dependent intervals (e.g. the specifications Calendar-dependent "5 years", "after 6 months") after the elapsed period of time, even if intervals...

  • Page 593: Maintenance Intervals

    Maintenance intervals Interval Module Maintenance point Activity field Who? Pag Cooling unit Water tank Check water level Cooling unit Cooling unit Replace or clean filter mats 1000 RF generator Fans Check for operation noises 1000 RF generator Output stage Check sacrificial anodes and Teflon hoses 1000...

  • Page 594: Vacuum Pump

    Open and close laser cap Lock for small cap Locks for large cap Laser caps Fig. 29826 Open laser caps using the following the procedure: • Open lock for small cap (1). • Fold small cap forwards. • Open both locks for large cap (2). •...

  • Page 595: Maintenance Work

    Maintenance work Maintenance point Interval / Maintenance information Operating hours 10 000 h Replace pump Vacuum pump (Hyco) Change vacuum pump for modifications. The use of a conversion kit with an outdated vacuum pump (mat. no. 0946052) is recommended. • The interval for pump replacement can be checked at the operating hours display on the control system.

  • Page 596: Compressed Air Filter Unit

    Compressed air filter unit For maintenance of the compressed air filter unit, see Chapter "Machine Maintenance". Laser control Note: The TASC 3 control system is maintenance free. Maintenance of laser B337EN07.doc...

  • Page 597: Cooling Unit

    Cooling unit Auxiliary tools and materials The listed maintenance work refers to the standard cooling unit. Maintenance intervals If a different cooling unit is used, use the maintenance intervals water-cooled listed here as a guideline. Detailed information can be found in the air cooling unit supplied instruction manual for the respective cooling unit.
  • Page 598 Detailed information on maintenance can be found in the supplied Maintenance intervals instruction manual. evaporative cooling Components Interval Procedure Metering device 100 h Check filling level Circulation water 100 h Check for contamination and algae KK1 / KK2 500 h Conductivity measurement water cycles Suction grids...
  • Page 599 Filling volumes and Copper cooling Aluminium cooling conductivity circuit circuit KK1 Cu KK2 Al Tank volumes 55 (65)* l 320 (450)* l 85 (95)* l 350 (480)* l Total water volumes Conductivity for freshly max. 10 µS/cm max. 10 µS/cm filled water Conductivity limit 200 µS/cm...

  • Page 600: Maintenance Work

    Maintenance work Maintenance point Interval / Maintenance information Operating hours Water tank 100 h Check water level Cooling unit display Cu (TLF 4000t) display Al Cooling unit Fig. 24028 • Read water level on the display. If the water level does not correspond with the marking: •...
  • Page 601 Maintenance point Interval / Maintenance information Operating hours Cooling unit 100 h Replace or clean filter mats The maintenance interval is determined by the quality and cleanliness of the cooling unit’s surrounding air. This means that the maintenance interval after the first inspection (100 hours) is determined by the user through regular checks.
  • Page 602 Maintenance point Interval / Maintenance information Operating hours Water tank after Measure conductivity, three months add cooling water additive Conditional on the diminishing effect of the biocide Nalco 2594, this must be topped up in the copper and aluminum cooling circuit as for a water exchange.
  • Page 603 Maintenance point Interval / Maintenance information Operating hours Filter in Al-water circulation After 3 months Replacing the filter The filter consolidates impurities in the aluminium circuit. Hold it as straight as possible when removing the filter housing full of water. The system can continue to be operated whilst the filter is being changed.
  • Page 604 Maintenance point Interval / Maintenance information Operating hours Strainer in Cu-water circulation 3 months clean the strainer (KK1CU) The strainer consolidates impurities in the copper-cooling circuit. Cooling unit only for the TLF 4000/5000 • Switch system off. • Remove front right cover at the cooling unit. Strainer Strainer for copper circuit Fig.
  • Page 605 Maintenance point Interval / Maintenance information Operating hours Cooling unit 6 months Replacing the cooling water The cooling water at the cooling unit must be replaced in one (only KK2 Al) or two (KK1 Cu and KK2 Al) cooling water tanks, depending on the laser type.
  • Page 606 Maintenance point Interval / Maintenance information Operating hours Caution Cooling water additives have a caustic effect on skin and eyes. Wear safety glasses and protective gloves when working with cooling water additives. Observe instructions on products and product packaging. Notices regarding the filling amounts are also located on the water tank of the beam generator cooling unit.

  • Page 607: Rf Generator

    RF generator Notes on safety When the generator is operated in accordance with the instructions, it presents no danger to persons through the radiation of high-frequency fields. Constructive measures ensure the observance of CE guidelines (EMC guideline with limits for radiation values according to EN 55011).

  • Page 608: Auxiliary Tools And Materials

    Auxiliary tools and materials Components Inter- Task Material Mat. no. Mat. no. val (h) IS18/IS22 IS36/IS44 Fans 1000 Check fans for – – – operation noises Reactive anodes 1000 Check Reactive anode 0087596 0922660 reactive anodes Gasket 0111726 Teflon hoses 1000 Check teflon hoses Potential hose...

  • Page 609: Short-Circuiting Residual Voltage

    Short-circuiting residual voltage A grounding rod is supplied with every generator for the elimination Grounding rod of residual voltage by short-circuiting. The grounding rod is already connected to the generator cabinet. It must only be used for discharging the components of the generator cabinet.

  • Page 610: Tube Output Stage

    Discharge the following parts by short-circuiting with the grounding Short-circuiting rod to safely eliminate any residual voltage which is present. residual voltage Tube output stage • Isolate the generator and safeguard against unintentional restarting. • Wait for the generator’s discharge time to elapse before continuing work.
  • Page 611 Discharging the bushing-type capacitor Fig. 29828 Discharging grid resistance Fig. 29829 7-22 Maintenance of laser B337EN07.doc...
  • Page 612 Discharging the grid voltage resistance of capacitors at X2 Fig. 29830 Discharging the grid voltage resistance of capacitors at X4 Fig. 29831 7-23 Maintenance of laser B337EN07.doc...

  • Page 613: Hv Power Supply Unit

    HV power supply unit • Isolate generator safeguard against unintentional restarting. (Observe the discharge time for the generator). • Open the cover of the HV power supply unit. Discharging the HV capacitor Fig. 29832 Discharging the power-line filter Fig. 29833 7-24 Maintenance of laser B337EN07.doc...
  • Page 614 After you have short-circuited all residual voltage from the Hanging up the particular module, hang the grounding hook on the module you grounding rod on hook have just worked on. RF output stage RF output stage Fig. 30824 HV power supply unit HV power supply unit Fig 29834 7-25...

  • Page 615: Maintenance Work

    RF output stage fan RF generator Fig. 29835 • Open switch cabinet doors. • Listen for operation noises in the fans. • Close switch cabinet doors. Should operation noises eminate from the fans, please consult TRUMPF customer service. 7-26 Maintenance of laser B337EN07.doc...
  • Page 616 Maintenance point Interval / Maintenance information Operating hours Output stage 1000 h Check reactive anodes and (only for IS18/IS22) teflon hoses The sacrificial anodes on the water connections of the generator tube are recognisable by the Teflon hoses. The sacrificial anodes wear out in the course of time.
  • Page 617 Maintenance point Interval / Maintenance information Operating hours There is a difference between replacing reactive anodes of the Replacing sacrificial anodes IS22 and IS36/IS44 RF generators. Teflon hose Gasket Reactive anode (complete) Reactive anode Sacrificial anode and Teflon hose Fig. 29837 •...
  • Page 618 Maintenance point Interval / Maintenance information Operating hours Only for IS18/IS22: replacing teflon hoses RF – Potential hose Clamping ring Union nut Teflon screw joint with clamping ring Fig. 23456 Replace damaged Teflon hoses (RF potential hoses). • Loosen union nut (2) •...
  • Page 619 Maintenance point Interval / Maintenance information Operating hours Output stage 1000 h Check the group cathodes Danger Lethal voltage at seal caps when the earthing bracket plate is removed. Do not, under any circumstances, remove the earthing bracket plate. When operating the laser unit without bracket plates, there is a resulting DC potential of 500 V at the seal caps.
  • Page 620 Maintenance point Interval / Maintenance information Operating hours Generator tube 1000 h, Check operating values of the generator tube after 6 months The generator tube must be replaced if the generator power decreases or the operating values exceed the permitted deviations. The operating values are determined while generator is being operated.
  • Page 621 Laser number: Date Date Date Date Generator number: Generator type: Power output [kW] Reflected power of peak value Reflected power of mean value Anode voltage [kV] of generator tube Anode current of generator tube [mA] Grid voltage of generator tube Grid current of generator tube [mA] Nominal value of power output...
  • Page 622 Maintenance point Interval / Maintenance information Operating hours Generator tube 5000 – 8000 h As required: Replace generator tube Handle the generator tube carefully. Only touch it on the anode body and not on the ceramic part. Do not put the generator tube down with force or hit it with tools.
  • Page 623 Maintenance point Interval / Maintenance information Operating hours Union nuts Fixing screws Disassembly of generator tube Fig. 29839 • Unscrew Teflon screws joints at water-cooled resistor. • Loosen the union nuts on the sacrificial anode and remove the sacrificial anodes and Teflon hoses. •...
  • Page 624 Pay attention to the alignment of the generator tube: When looking at the front of the unit, the water connections are positioned one behind the other. The arrow indicates upwards while the TRUMPF logo indicates the front of the unit. 7-35 Maintenance of laser B337EN07.doc...
  • Page 625 Maintenance point Interval / Maintenance information Operating hours • Insert the generator tube carefully into the generator tube socket. • Press on the generator tube from above until it locks into its mount. Fig. 23460 Fig. 23462 • Fix the generator tube to the mounting plate using the fixing screws.

  • Page 626: Operating Steps During Maintenance Work

    Operating steps during maintenance work Opening the vacuum system • Select the Focus button. • Select 1 Activity field – 2 Set-up – 1 Switch elements in the menu bar. • Confirm with the Toggle key. • Select TLF laser intervene 2 in the pull-down menu. •...

  • Page 627: Checking Generator Values

    7.4 Checking generator values • Switch on laser unit. LASER Caution The operating values are measured while the unit is in service mode. Operational errors may result in beam emission at the machining head. To determine the operating values, perform the following steps only: •...
  • Page 629 Chapter 8 Aligning the MSL multi- beam safety light barrier Additional equipment for aligning........ 8-2 System example ............. 8-3 Aligning the light beam ..........8-4 Setting mirror ..............8-6 Cross-hairs to cut out............ 8-7 For machines with pallet changer. Additional equipment for aligning B337EN08.DOC...

  • Page 630: Additional Equipment For Aligning

    Additional equipment for aligning The transmitters, mirrors on the mirror posts and the receivers must be aligned with one another in order for the safety light barrier to function. TRUMPF supplies an alignment device for this purpose. Alignment device part no. 134023...

  • Page 631: System Example

    System example The illustration below offers an example for installing the transmitter, mirror posts and receiver. Transmitter (post) Mirror post 1 Receiver (post) Mirror post 2 Installing the multi-beam safety light barrier Fig. 23170 System example B337EN08.DOC...

  • Page 632: Aligning The Light Beam

    Aligning the light beam The fine-tuning described below relates to the system example in Fig. 23170. If the arrangement of transmitter, mirror post and receiver is different than in the example displayed, the steps 1-4 must be performed accordingly. Step 1: Before beginning the actual fine-tuning, the light exit on the Preparatory measures transmitter, the center of the mirrors on the posts and the light entry on the receiver must all be set to the same height.
  • Page 633 Step 3: Aligning the mirror ½ Adjust the mirror on post 2 until the beam hits the alignment of mirror post 2 device in the center (between the two black points) on the receiver. The mirror on mirror post 2 is aligned. Step 4: Aligning the receiver 1.

  • Page 634: Setting Mirror

    Setting mirror Mirror on mirror post Fig. 6309 1. Loosen screws at pos. 1 somewhat. 2. Align mirror. 3. Tighten the screws hand-tight again. Setting mirror B337EN08.DOC...

  • Page 635: Cross-Hairs To Cut Out

    Cross-hairs to cut out Cross-hairs to cut-out Fig. 6310 Cross-hairs to cut out B337EN08.DOC...
  • Page 636 Cross-hairs to cut out B337EN08.DOC...
  • Page 638 Chapter 9 Noise levels - Test certificate TLC 1005 Mess Test certificate............9-2 Measurement Results ............ 9-3 Diagram: Work piece ............. 9-4 Diagram: Location of measuring points ...... 9-5 Edition: 01/1998 Reference number: 93918-5-310.E Id. no.: 146123 Tab. 9-1 Mess Test certificate B337EN09.DOC...

  • Page 639: Mess Test Certificate

    Mess Test certificate Noise measurement in Place and date of measurement Ditzingen, the 21.01.98 accordance with DIN 45635 part 1 Measurement site Assembly bay D2/2 Accuracy class Machine Type TLC 1005 Laser TLF 3000t Cooling unit MLFB-KKW 2KAO 831 Measuring devices Sound level meter Brüel + Kjaer, Typ 2231 Module...

  • Page 640: Measurement Results

    Measurement Results Extraneous noise Extraneous noise level L" pAeq = 51.1 dB Measuring area sound Measuring-area sound pressure L pA,1m = 76.0 dB pressure level L pA,1m = L’ pA * - K 1 - K 2 Acoustic power Acoustic power level L WA = 98.8 dB = LpA,1m + L = 22.8 dB...

  • Page 641: Diagram: Work Piece

    Diagram: Work piece Einzelteil (component part) 2:1 alle Ecken mit R1 verrundet all edges made round with R1 Tafelbelegung sheet layout 1500 6 Reihen a 9 Teile Abstand 20 mm 6 lines with 9 parts distance 20 mm Arbeitsbereich TLC 1005 working range TLC 1005 : 2,3 m/min Vorschub...

  • Page 642: Diagram: Location Of Measuring Points

    Diagram: Location of measuring points &  & "  " " & %   • Measuring points Measuring point corresponds to operator’s position Diagram: Location of measuring points Fig. 17623 Diagram: Location of measuring points B337EN09.DOC...
  • Page 643 Diagram: Location of measuring points B337EN09.DOC...
  • Page 645 TRUMPF Werkzeugmaschinen TRUMPF Maskin AB GmbH + Co. KG Deutschland Johann-Maus-Straße 2 Schweden Aleforsvägen 5 Germany D-71254 Ditzingen Sweden Box 606 Allemagne 0 71 56/3 03-0 Suède S-441 17 Alingsås int. +49 (0) 71 56-3 03-0 03 22/63 91 00 int.

Table of Contents

Save PDF