Operator's manual
TruLaser Cell 8030
(L60)
Operator's manual
TruLaser Cell 8030
(L60)
Original operator's manual
Edition
2017-11-17
Order Information
Please specify when ordering this document:
Operator's manual
TruLaser Cell 8030 (L60)
Edition 2017-11-17
Document number B836en
Address for orders
TRUMPF GmbH + Co. KG
Technische Redaktion
Johann-Maus-Straße 2
D-71254 Ditzingen
Fon: +49 7156 303 - 0
Internet: http://www.trumpf.com
E-Mail: docu.tw@de.trumpf.com
For "partly completed machinery" in accordance with the EC
Machinery Directive, this document corresponds to the
assembly instructions.
© TRUMPF GmbH + Co. KG
Before you proceed ...
This operator's manual documents the laser processing machine
TruLaser Cell 8030 (L60), machine serial release S04. The beam
source is a laser device TruDisk.
The operator's manual is intended not only for the user (owner)
and the operator of the machine, but also for the maintenance
personnel. It should be made accessible to all of these people.
The machine documentation
includes the following
documents:
■
■
■
■
■
■
■
■
■
■
TruLaser Cell 8030 Operator's manual
Supplements to operator's manual: Configurable control interface KSS (option)
Supplements to operator's manual: Automation interface
(option)
"TruTops Cell Basic" manual (option)
Programming manual for the TruLaser Cell 8030
Data collection for the TruLaser Cell 8030
Electronic spare parts catalog for TruLaser Cell 8030
Schematics set for the TruLaser Cell 8030 with fluid plans
Documentation for Laser TruDisk from TRUMPF Laser
Schramberg:
− Operator's manual for the TruDisk
− Spare parts catalogue for the TruDisk
− Manual for TruControl 1000
− Circuitry documents and interface description
Supplier documents (electronic on DocOnCD_MA836):
− Compact dust extractor (Herding)
− Scrap conveyor (Kabelschlepp)
− Sick laser scanner
− Safety light curtain from Sick
Indication of hazards
The entire machine documentation contains important safety
information on the prevention of injuries and potential hazards to
life and health. Such information is marked by warning symbols.
Read the Safety chapter.
Online help
B836en
2017-11-17
The online help of the operator's manual on the machine's user
interface is an excerpt from the operator's manual.
Before you proceed ...
I
II
Before you proceed ...
2017-11-17
B836en
Table of contents
Chapter 1
Safety
Delivery variants
1‐4
1
For your safety
1‐5
2
Terms
1‐7
3
Operational safety
1‐8
3.1
Intended use
1‐8
3.2
Authorized personnel
1‐9
4
Hazards
1‐10
4.1
Overview of laser classes
1‐10
Laser classes of the machine
1‐11
Laser classes of laser device and components
1‐11
4.2
Hazards due to laser radiation
1‐11
4.3
Fire hazard
1‐13
4.4
Extinguishing the fire in the compact dust
extractor (Herding) without fire extinguisher
1‐14
Extinguishing the fire in the compact dust
extractor (Herding) with the CO2 fire extinguisher
1‐15
Extinguishing the fire in the compact dust
extractor (Herding) with the argon fire extinguisher
1‐16
Machining highly reactive materials
1‐17
Machining heavily oiled workpieces
1‐18
Dangers from magnetic fields
Magnetic coupling of the processing optics
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1‐19
1‐19
4.5
Dangers due to the open electrical cabinet
1‐20
4.6
Dangers due to live parts
1‐21
4.7
Danger from handling hot components
1‐22
4.8
Dangers due to configured movement sequences
1‐22
4.9
Dangers when handling clamping fixtures
1‐23
Table of contents
0‐1
0‐2
Table of contents
4.10
Dangers due to quickly-rotating rotational
changer
1‐24
4.11
Dangers due to quickly turning rotary indexing
table (option)
1‐25
4.12
Hazard risks due to the scrap conveyor
1‐26
4.13
Dangers due to a suspended axis
1‐26
4.14
Danger while teaching
1‐27
4.15
Dangers in the work area due to a bright
source of light.
1‐27
4.16
Dangers of slipping, tripping or falling
1‐27
4.17
Dangers handling workpieces
1‐28
Sharp-edged workpieces
1‐28
Hot workpieces
1‐28
Suspended loads when setting up workpieces
1‐28
4.18
Hazards due to collisions in the work area
1‐29
4.19
Dangers when working with the
Smart Optics Setup station
1‐29
4.20
Hazards due to escaping coolant or cooling
water
1‐30
4.21
The risks of no switch cabinet cooling
1‐30
4.22
Dangers due to Teleservice
1‐31
4.23
Dangers when using the MobilelControl app
1‐31
4.24
Hazardous materials
1‐32
Dusts, exhaust air
1‐32
Hazardous materials due to cutting oils
1‐33
Hazardous substances derived from polyethylene films
1‐33
5
Measures to be taken by the manufacturer
1‐34
5.1
Danger zones and safeguarding device
1‐34
5.2
Warning signs at the machine
1‐44
6
Organizational measures to be taken by the
user
1‐48
6.1
Observe warnings and warning signs
1‐48
6.2
Training and instructing operators
1‐48
Measures applicable worldwide
1‐48
Protection against radiation: information for
Germany
1‐49
Protection against radiation: additional
measures for the USA
1‐50
6.3
Duty of care when handling the machine
1‐50
6.4
Pay attention to water protection
1‐52
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Chapter 2
6.5
Observe the fire safety rules
1‐53
6.6
Using spare parts, accessories, software and
operating materials
1‐53
6.7
Safety data sheet on hazardous materials
1‐54
7
Overview of residual risks
1‐55
8
Machines without complete safety equipment
1‐59
8.1
Operating safety
1‐59
8.2
Suction system in the work area
1‐60
8.3
Laser safety
1‐61
8.4
Secondary radiation
1‐61
8.5
Overview of residual risks
1‐62
9
Disassembly and disposal
1‐67
Installation conditions TruLaser Cell
8030 (L60)
To what does this apply?
2‐4
1
Planning aid
2‐5
2
Installation site
2‐9
2.1
Space requirements
2‐9
2.2
Floor requirements
2‐9
2.3
Weight load
2‐11
2.4
Ambient conditions
2‐12
2.5
Installation of compact dust extractor
2‐15
2.6
Suction system in the work area
2‐17
2.7
Installation of the process cooler
2‐17
External cooling circuit
2‐18
2.8
Cable racks for laser light cables
2‐24
2.9
Customer screen options
2‐25
Installing the monitor
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2‐27
3
Gas supply
2‐28
3.1
Cutting gases
2‐29
Table of contents
0‐3
0‐4
Table of contents
Purity
2‐29
Cutting gas consumption
2‐29
Supply lines for cutting gas supply
2‐30
Requirements on the connection point of
the machine
2‐31
Cutting gas supply with cylinders or bundles
2‐31
Cutting gas supply with gas tank
2‐32
4
Electric power supply
2‐34
4.1
Electrical connection
2‐34
4.2
Power supply
2‐36
4.3
Connected load and fuse protection
2‐37
Central power supply
2‐37
Decentralized power supply
2‐38
4.4
Teleservice
2‐42
4.5
Network connection
2‐42
5
Compressed air supply
2‐43
6
Operating materials
2‐46
6.1
Gases
2‐46
6.2
Cooling water
2‐46
6.3
Dispensing material for MultiCoater
2‐49
7
Transport
2‐50
7.1
Dimensions and weights of the transport units
2‐52
7.2
Transporting machine and machine components
2‐56
Transporting basic machine with truck
2‐57
Loading and unloading container
2‐59
Transporting the basic machine to the
installation site
2‐60
Transport TruDisk laser device
2‐61
Transport rotational changer with a crane or
forklift
2‐62
Transporting rotary indexing table with
crane or forklift truck
2‐63
Transporting the safety cabin
2‐64
Transportation of scrap conveyor
2‐65
Transporting the compact dust extractor
(Herding)
2‐65
Transporting process cooler
2‐66
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Transporting the safety cabin
7.3
Installing the system
2‐66
Preparing the factory floor
Chapter 3
Chapter 4
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2‐66
2‐66
Description
1
Machine concept
3‐3
2
Coordinate system and working range
3‐4
2.1
Coordinate system
3‐4
2.2
Working range
3‐6
3
Machine components
3‐8
3.1
Sub-assemblies of the basic machine
3‐10
Machine body
3‐11
Motion unit
3‐11
Hydroforming package (option)
3‐11
Beam guidance
3‐12
Dynamic cutting optics
3‐13
3.2
Laser protection device
3‐19
3.3
Exhaust system and filtering installation
3‐21
3.4
Workpiece changer
3‐25
3.5
Clamping fixture
3‐29
Clamping fixture for hot-formed parts
3‐34
Clamping fixture for inner high-pressure
(IHU) formed workpieces
3‐37
3.6
Solid-state lasers
3‐43
4
Technical data
3‐45
Operation
1
Description of the controls and indicators
1.1
The machine's main switch
4‐11
1.2
Control panel
4‐14
Table of contents
4‐8
0‐5
1.3
Installing the MobileControl app
4‐22
Activate MobileControl at the machine.
4‐23
Switching between control and observation
mode
4‐27
Exiting MobileControl
4‐28
Access Control Key System user management
4‐29
1.5
Decentral control panel
4‐34
1.6
Status indicators
4‐37
1.7
Scrap conveyor
4‐38
1.8
Compact dust extractor
4‐40
1.9
Acknowledge the danger zone
4‐41
1.10
Mechanically lock the door
4‐42
2
Operating modes of the machine
4‐43
3
Operating the machine
4‐44
3.1
Entering the work area
4‐45
3.2
Switching the machine on and off
4‐46
3.4
3.5
3.6
Table of contents
4‐19
1.4
3.3
0‐6
MobileControl
Switching on the machine
4‐46
Switching off the machine
4‐48
Shutting down the machine in the event of a
malfunction/emergency
4‐50
Tripping the EMERGENCY STOP
4‐50
Cancelling the EMERGENCY STOP
4‐50
Trip the extinguisher with a manual alarm
4‐50
Check safety functionality
4‐52
Manually start the safety test
4‐53
Issue user consent
4‐54
Eliminate malfunction
4‐55
Triggering FEED HOLD
4‐55
Acknowledging FEED HOLD after opening
the door
4‐55
Acknowledging FEED HOLD after a collision involving the nozzle
4‐55
Restarting processing after knocking off the
processing optics
4‐56
Operating the workpiece changer
4‐57
Manual functions
4‐59
Rotating workpiece changer in setup mode
4‐59
RSTAcknowledge the loading operation in
automatic mode
4‐60
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3.7
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4‐60
Acknowledging malfunction
4‐61
Acknowledging clamping error
4‐61
Operate scrap conveyor
4‐62
Starting the conveyor belt
4‐63
Stopping the conveyor belt
4‐63
Starting the conveyor belt in reverse mode
4‐64
Eliminate malfunction
4‐64
4
Description of the user interface
4‐65
5
System settings
4‐71
5.1
Setting data and time
4‐71
5.2
Selecting language and measuring system
4‐71
5.3
Activate the on-screen keyboard
4‐72
5.4
Open TRUMPF Operating System (TOS)
4‐73
5.5
Close user interface
4‐73
5.6
Switching to the TruControl interface
4‐74
6
User administration
4‐75
6.1
Log on user group
4‐76
6.2
Change password
4‐77
6.3
Deleting the password
4‐77
7
Production plan
4‐78
7.1
Creating and editing a production plan
4‐81
Creating a new production plan
4‐82
Editing job data
4‐84
Disable job
4‐84
Delete the order in the production plan
4‐84
Delete programs and orders
4‐85
Deleting a production plan
4‐85
7.2
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RW: Acknowledge the loading operation in
automatic mode
Production with the production plan
4‐86
Starting a production plan (manual loading)
4‐87
Starting a production plan (automatic loading)
4‐89
Changing the program sequence
4‐90
Modifying the number of program runs
4‐91
Stopping the production plan with "Stop
after cycle end"
4‐92
Table of contents
0‐7
Starting to run empty, ending the production
plan
7.3
Exporting order
4‐93
7.4
Starting step-by-step cycle
4‐94
7.5
Loading and workpiece status
4‐94
7.6
Displaying the loading and workpiece status
4‐96
Changing the loading and workpiece status
4‐98
Acknowledging workpiece status with manual loading
4‐99
Acknowledging the workpiece status with
automatic loading
4‐99
Remaining time display
Configuring the remaining time display
4‐105
Production
4‐115
8.1
Current program
4‐115
Start program
4‐115
Pause program
4‐116
Aborting a program
4‐116
Switch screen view
4‐116
Display Switching over the axis positions
4‐117
Display NC simulation
4‐117
8.3
8.4
Preparing programs
4‐118
Import master file
4‐118
Prepare program
4‐119
Manual functions
4‐120
Call manual functions
4‐122
Activating marking test mode
4‐123
Activating STOP after single contour
4‐124
Display the workpiece counter
4‐124
Resetting the workpiece counter
4‐124
Utility tools
4‐125
Starting utility programs
4‐125
9
Setup
4‐126
9.1
Moving the axes manually
4‐126
9.2
Table of contents
4‐101
8
8.2
0‐8
4‐93
Moving the axis continuously
4‐126
Moving the axis incrementally
4‐126
Manual functions
4‐127
Call manual functions
4‐130
Requesting the laser in the laser network
4‐131
Enabling the laser in the laser network
4‐131
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9.3
9.4
Enabling the dynamic distance control system
4‐132
Deactivating the dynamic distance control
system
4‐132
Positioning the additional axis
4‐133
Activating distance regulation
4‐133
ControlLineRecord characteristic curve
4‐134
Switching the kinematic transformation on
or off
4‐134
Park axes
4‐135
Displaying and resetting workpiece counter
4‐135
Running a warm start
4‐136
Focal position without FocusLine setting
4‐136
MDA
4‐138
Execute the NC blocks in the following
block
4‐138
Execute the NC blocks in a single block
4‐138
Configuration
4‐139
Configure loading and unloading place
4‐141
Configure loading and unloading place
4‐141
10
Programming
4‐144
10.1
Program management
4‐144
10.2
10.3
Selecting program
4‐146
Creating a new program
4‐146
Copying a program
4‐147
Editing a program in the text editor
4‐147
Create subroutine
4‐148
Number program
4‐150
Exporting program
4‐150
Importing program
4‐151
Delete program
4‐151
Show setup plan
4‐152
Show PDF file
4‐152
Creating and managing subroutine macros
Creating a subroutine macro
4‐154
Processing a subroutine macro
4‐155
Deleting the subroutine macro
4‐156
Inserting the Subroutine macro
4‐156
Transformation
4‐159
Applying the actual position as the zero
point
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4‐153
Table of contents
4‐161
0‐9
10.4
10.5
Moving zero point incrementally
4‐162
Select Frame and fill transformation accumulator
4‐162
Deleting transformation accumulator
4‐163
Operate KSS
4‐163
Start KSS configuration
4‐163
Activate module and load module data
4‐164
Deactivating the module
4‐164
Programming system
4‐165
Starting TruTops Cell Basic
4‐165
Call up advanced shop floor programming
4‐165
11
Technology
4‐166
11.1
Laser cutting
4‐167
11.2
Selecting the setting for the "Table" selection field
4‐168
Creating a cutting table
4‐168
Edit the cutting table
4‐169
Ramp cycles
4‐170
Programming ramp cycles
11.3
Managing the tooling status
4‐172
Creating a new setup state
4‐173
Editing the tooling level
4‐174
Deleting a setup state
4‐175
12
Maintenance
4‐177
12.1
Manual functions
4‐177
12.2
Partial backup
4‐177
12.3
4‐177
File manager
4‐178
Edit and save file
Table of contents
4‐171
Activate setup state
Backing up data
0‐10
4‐170
4‐179
13
Diagnostics
4‐180
13.1
Displaying all messages
4‐180
13.2
Displaying all messages
4‐180
13.3
Displaying the software version
4‐181
13.4
Display I/O monitor
4‐181
13.5
Logging the process data for service purposes
4‐182
13.6
Starting Teleservice
4‐182
13.7
Visual Online Support (VOS)
4‐184
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Starting Visual Online Support
14
Help
4‐189
14.1
Starting online help
4‐190
14.2
Editing bookmarks
4‐190
14.3
Starting context-sensitive help
4‐191
15
Teachen
4‐192
15.1
Teach panel
4‐194
15.2
Description of the user interface
4‐201
15.3
Activating TEACHIN operating mode
4‐203
15.4
Starting online help
4‐204
15.5
Setting basic functions
4‐204
15.6
15.7
15.8
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4‐185
Automatically replacing the zero point
4‐204
Activate the imperial (inch) measuring system
4‐205
Activate and set the NC axes
4‐205
Setting threshold values for determination of
the geometry deviation
4‐206
Configure the function for F1 and F2 buttons
4‐208
Configure the cycle selection for the F1 key
4‐209
Delete the configuration for the F1 key
4‐210
Recording teach points
4‐211
Teaching a straight line
4‐211
Teaching the arc with CIP
4‐212
Teaching the macro center
4‐213
Teaching macro help point
4‐213
Teaching circular contour
4‐214
Teaching a rectangle contour (square)
4‐215
Teaching oblong hole
4‐217
Creating new program
4‐219
Creating a new program
4‐219
Setting the zero point
4‐220
Approach edge incrementally.
4‐220
Incorporating the contour
4‐223
Editing a program
4‐224
Searching and replacing NC text
4‐225
Insert and process cycles
4‐225
Select value for the name variable laser
technology table.
4‐226
Selecting the laser technology table
4‐227
Table of contents
0‐11
Inserting block numbering
15.9
Chapter 5
0‐12
Table of contents
Testing and correcting the program
4‐227
4‐227
Correcting the zero point
4‐228
Inserting H word
4‐228
Correct path
4‐229
Testing the program
4‐230
Setting work
Safety notes
5‐3
1
Overview of setting work
5‐4
1.1
Overview of cutting process setting work
5‐4
2
Tooling the processing optics
5‐6
2.1
Removing the processing optics
5‐6
2.2
Installing processing optics
5‐7
3
Checking the C and B axes and referencing
manually
5‐10
3.1
Checking the B and C axes
5‐10
3.2
Referencing the C and B axes manually
5‐13
4
Test sheet holder
5‐14
5
Smart Optics Setup
5‐17
5.1
Swiveling the test sheet holder into the setup
position and mounting a test sheet
5‐22
5.2
Swiveling the test sheet holder into the parking
position
5‐23
5.3
Approaching the start or reference position
5‐24
5.4
Resetting the reference position
5‐25
6
Wizard
5‐27
6.1
Test sheet holder: Starting the utility program
5‐29
6.2
Smart Optics Setup station: Starting the utility
program
5‐31
6.3
Defining new reference optics
5‐33
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7
Cutting process setting work
5‐34
7.1
Centering the beam
5‐34
7.2
Mounting the protective cover
5‐36
Installing the setting device
5‐37
Dismantling the setting device
5‐38
Centering nozzle to beam
5‐38
Determining and setting the focal position
Start focus search
Chapter 6
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5‐41
5‐42
7.3
Calibrate the B and C axes
5‐46
7.4
Determining the joint offset
5‐50
Determining the Z-axis joint offset
5‐51
Determining X axis and Y axis joint offset
5‐53
8
Calibrating the measuring equipment
5‐57
8.1
Mounting and activating the sensor
5‐59
8.2
Calibrating the sensor
5‐60
9
Setting up the clamping fixture
5‐63
9.1
Starting the utility program
5‐66
9.2
Checking the measuring sequence (option)
5‐68
9.3
Entering the required position
5‐69
9.4
Measuring the required position
5‐71
9.5
Measuring the actual position
5‐72
9.6
Determining the correction frame
5‐74
Machine maintenance
1
General guidelines
6‐5
2
Maintenance Overview
6‐6
3
Safety device
6‐10
3.1
Overview
6‐10
3.2
Maintenance Instructions
6‐12
Light grid
6‐12
Laser scanner
6‐13
Table of contents
0‐13
4
Laser protection device
6‐16
4.1
Overview
6‐16
4.2
Maintenance Instructions
6‐18
Safety cabin
6‐18
5
Lubrication
6‐24
5.1
Overview
6‐24
5.2
Maintenance Instructions
6‐25
X axis drive
6‐25
Y axis drive
6‐31
Z axis drive
6‐37
Device panel: Low-viscosity grease reservoir central lubrication
6‐44
6
Mechanical elements
6‐46
6.1
Overview
6‐46
6.2
Maintenance Instructions
6‐47
Machine and workspace
6‐47
Magnetic coupling
6‐56
Smart Optics Setup station
6‐58
Z barrel
6‐60
7
Pneumatic system
6‐61
7.1
Overview
6‐61
7.2
Maintenance Instructions
6‐62
Device panel: Maintenance unit basic
machine
6‐62
Device panel: Maintenance unit cutting gas
air (option)
6‐64
Device panel: service unit for expanded
compressed air supply or vacuum ejectors
(option)
6‐65
Device panel: Condensation collection tank
6‐66
Cutting optics: disposable filter, pneumatic
connection
6‐67
8
Gas
6‐68
8.1
Maintenance Instructions
6‐68
Cutting optics: disposable filter, gas connection
0‐14
Table of contents
2017-11-17
6‐68
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9
Water
6‐69
9.1
Overview
6‐69
9.2
Maintenance Instructions
6‐72
Cooling circuit of the machine
6‐72
Machine cooler (option), water/air chiller
6‐74
Machine cooler (option), water/water chiller
6‐81
10
Optics
6‐86
10.1
Overview
6‐86
10.2
Maintenance Instructions
6‐88
Cutting optics with a focal length of 150 mm
6‐88
Cutting optics with a focal length of 200 mm
6‐101
Angular gear: FocusLine mirror
6‐114
11
Electrics
6‐118
11.1
Overview
6‐118
11.2
Maintenance Instructions
6‐118
Switch cabinet: Battery/fan unit, NC CPU
6‐118
Switch cabinet: Industrial PC
6‐119
Switch cabinet: Air conditioning unit
6‐120
12
Compact dust extractor
6‐122
12.1
Overview
6‐122
12.2
Maintenance Instructions
6‐123
Compact dust extractor: dust container/fine
dust bag
6‐123
Compact dust extractor: spark arrester
6‐127
Compact dust extractor: clean gas space
6‐128
Compact dust extractor: MultiCoater
6‐130
13
Scrap conveyor
6‐133
13.1
Maintenance Instructions
6‐133
Scrap conveyor: Sensors
6‐133
Scrap conveyor: pedestal bearing
6‐134
Scrap conveyor: lubricant container
6‐135
Scrap conveyor: conveyor belt
6‐136
Scrap conveyor: housing bottom
6‐137
14
Clamping fixture
6‐140
14.1
Maintenance Instructions
6‐140
Table of contents
0‐15
Clamping fixture for hot-formed parts
6‐140
Clamping fixture for IHU workpieces
6‐141
15
TruDisk
6‐144
15.1
Overview
6‐144
15.2
Maintenance Instructions
6‐145
TruDisk cooling circuit
6‐145
16
Process cooler for TruDisk (chiller)
6‐146
16.1
Overview
6‐146
16.2
Maintenance Instructions
6‐147
Process cooler: chiller (water-air)
Chapter 7
Chapter 8
0‐16
Table of contents
6‐147
Noise level test certificate
1
Test report
7‐3
2
Measurement result
7‐4
3
Measuring point arrangement
7‐5
Index
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Chapter 1
Safety
Delivery variants
1‐4
1
For your safety
1‐5
2
Terms
1‐7
3
Operational safety
1‐8
3.1
Intended use
1‐8
3.2
Authorized personnel
1‐9
4
Hazards
1‐10
4.1
Overview of laser classes
1‐10
Laser classes of the machine
1‐11
Laser classes of laser device and components
1‐11
4.2
Hazards due to laser radiation
1‐11
4.3
Fire hazard
1‐13
Extinguishing the fire in the compact dust
extractor (Herding) without fire extinguisher
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Safety
1‐14
1‐1
4.4
Extinguishing the fire in the compact dust
extractor (Herding) with the CO2 fire extinguisher
1‐15
Extinguishing the fire in the compact dust
extractor (Herding) with the argon fire extinguisher
1‐16
Machining highly reactive materials
1‐17
Machining heavily oiled workpieces
1‐18
Dangers from magnetic fields
Magnetic coupling of the processing optics
1‐2
Safety
1‐19
1‐19
4.5
Dangers due to the open electrical cabinet
1‐20
4.6
Dangers due to live parts
1‐21
4.7
Danger from handling hot components
1‐22
4.8
Dangers due to configured movement sequences
1‐22
4.9
Dangers when handling clamping fixtures
1‐23
4.10
Dangers due to quickly-rotating rotational
changer
1‐24
4.11
Dangers due to quickly turning rotary indexing
table (option)
1‐25
4.12
Hazard risks due to the scrap conveyor
1‐26
4.13
Dangers due to a suspended axis
1‐26
4.14
Danger while teaching
1‐27
4.15
Dangers in the work area due to a bright
source of light.
1‐27
4.16
Dangers of slipping, tripping or falling
1‐27
4.17
Dangers handling workpieces
1‐28
Sharp-edged workpieces
1‐28
Hot workpieces
1‐28
Suspended loads when setting up workpieces
1‐28
4.18
Hazards due to collisions in the work area
1‐29
4.19
Dangers when working with the
Smart Optics Setup station
1‐29
4.20
Hazards due to escaping coolant or cooling
water
1‐30
4.21
The risks of no switch cabinet cooling
1‐30
4.22
Dangers due to Teleservice
1‐31
4.23
Dangers when using the MobilelControl app
1‐31
4.24
Hazardous materials
1‐32
Dusts, exhaust air
1‐32
Hazardous materials due to cutting oils
1‐33
Hazardous substances derived from polyethylene films
1‐33
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5
Measures to be taken by the manufacturer
1‐34
5.1
Danger zones and safeguarding device
1‐34
5.2
Warning signs at the machine
1‐44
6
Organizational measures to be taken by the
user
1‐48
6.1
Observe warnings and warning signs
1‐48
6.2
Training and instructing operators
1‐48
Measures applicable worldwide
1‐48
Protection against radiation: information for
Germany
1‐49
Protection against radiation: additional
measures for the USA
1‐50
6.3
Duty of care when handling the machine
1‐50
6.4
Pay attention to water protection
1‐52
6.5
Observe the fire safety rules
1‐53
6.6
Using spare parts, accessories, software and
operating materials
1‐53
6.7
Safety data sheet on hazardous materials
1‐54
7
Overview of residual risks
1‐55
8
Machines without complete safety equipment
1‐59
8.1
Operating safety
1‐59
8.2
Suction system in the work area
1‐60
8.3
Laser safety
1‐61
8.4
Secondary radiation
1‐61
8.5
Overview of residual risks
1‐62
9
Disassembly and disposal
1‐67
Safety
1‐3
Delivery variants
The TruLaser Cell 8030 is a laser processing machine for laser
cutting. It corresponds to the current state of technology and is –
when supplied as a complete machine – operationally safe.
The machine can be supplied with different kinds of safety equipment:
■
■
As fully secured complete machine in compliance with all
requirements contained in the EC Machinery Directive. These
machines are supplied with both CE marking and EU Declaration of Conformity. Sections 1 to 7 of this chapter apply to
such machines in their entirety.
or
As basic machine without complete safety equipment. These
machines do not comply with all requirements contained in
the EC Machinery Directive and are delivered with the EU
declaration of incorporation. Section 8 of this chapter also
applies to these machines. Sections 1 to 7 apply conditionally depending on the safety equipment which is absent in
each case.
If the machine is delivered without complete safety equipment,
the user must implement measures for the operational safety of
the system in accordance with the legal regulations of the country of operation. Without complete safety equipment means:
■
■
■
1‐4
Safety
Without safety cabin.
Without compact dust extractor (filtering installation).
Without safeguarding device for the danger zone inside or
outside of the machine.
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1.
Regulations and guidelines
For your safety
With the CE marking and the EU Declaration of Conformity,
TRUMPF confirms that the machine meets the basic health and
safety requirements of the EC Machinery Directive.
This TRUMPF machine was registered and certified for North
America by the US Food and Drug Administration (FDA), Center
for Devices and Radiological Health (CDRH), as per the Federal
Performance Standard Title 21 Chapter 1 Section 1040.
The CE marking is located on the nameplate of the machine.
The EU Declaration of Conformity is delivered along with the
machine.
Chapter Safety
This chapter describes the safety concept. The chapter describes
how potential dangers can be avoided. The overview of residual
risks contains measures to be taken by the operator in order to
reduce the residual risks.
Note
The operator must adhere to the valid safety and accident prevention regulations of the respective country and the safety laws
of the state and of the region!
Warnings and warning signs
Certain operations can be a source of danger during operation.
The documentation contains warnings before the instructions for
these activities. There are warning plates on the machine.
A warning contains signaling words that have been explained in
the following table:
Signaling word
Description
DANGER
... refers to great dangers. If not avoided, it can result
in death and serious injuries.
WARNING
... refers to a dangerous situation. It could lead to serious injuries, if it is not avoided.
CAUTION
... indicates a potentially dangerous situation. It could
lead to injuries, if it is not avoided.
NOTICE
If such a situation is not observed, it can lead to damage to property.
Tab. 1-1
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2017-11-17
For your safety
1‐5
Example of a warning:
DANGER
Suspended load!
Falling loads could lead to severe bodily injury or even
death.
Ø
Ø
Ø
Ø
Ø
1‐6
For your safety
Observe safety regulations for the handling of heavy loads.
Never walk under a suspended load.
Use tested and appropriately sized tackle and means of
transportation.
Employ qualified technicians to transport the machine.
Carry out transport in accordance with the transport regulations.
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2.
Terms
Term
Meaning
Laser
Device for generating laser radiation. Lasers consist of a resonator that comprises a
laser active medium and a partially reflective and translucent mirror.
Laser device
Laser plus components for operating the laser such as control technology, energy supply, cooling system, gas system etc.
Laser system
Machine, to which a laser device is connected or should be connected later. The
terms machine and laser system are used as synonyms in this document.
Laser network
A laser network is comprised of several processing systems which are connected to a
laser device via laser light cable. The processing systems can use the laser radiation
in alteration.
Processing optics
Processing optics is a generic term. It can mean either a laser cutting head, a laser
welding head or a combination head depending on the machine.
Terms
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Tab. 1-2
2017-11-17
Terms
1‐7
3.
Operational safety
The machine can become a source of danger if it is used inappropriately or for purposes other than those intended:
■
■
■
Dangers to the safety of the operator.
Damage to the machine and other material assets of the
operator.
Negative effect on the effective functioning of the machine.
Area of application in the USA:
■
Notice: Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.
3.1
Machine
Intended use
The user may use the machine only in the industrial sector.
The installation, operating and transport conditions prescribed by
TRUMPF must be adhered to and the maintenance work must
be performed. The installation and operation must comply with
the relevant national regulations that are valid in the country of
operation. The user must adhere to the national regulations.
The laser device may be operated, only if all protective and
safety devices are in place and working.
In case of malfunctions, the laser device must be switched off
immediately and prevented from being switched on again.
The user may laser cut three-dimensional workpieces with the
machine. Only metallic materials may be processed with the
machine.
The following is not allowed:
■
■
■
■
1‐8
Operational safety
Unauthorized alteration or conversion of the machine by the
user or personnel.
Operating the machine with a laser device that TRUMPF has
not supplied with this machine, without consulting TRUMPF.
Any working procedure that impairs the safety.
− For example, processing with laser beam on but no workpiece.
− For example, the safety cabin or other laser protection
devices being permanently exposed to laser energy.
Laser cutting
− of plastics.
− of wood.
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−
−
Laser protection device
of sheets layered with PVC foil.
of magnesium.
The machine's laser protection devices, for example the window
of the safety cabin, are designed for the wavelength and the
power of the laser device delivered with the machine.
If a laser device is connected with a different wavelength or
power, of if the machine was supplied without a laser, then the
user is obliged to check the effectiveness and suitability of the
existing laser protection devices. The user is responsible for safe
operation.
Laser network
If a product from a different manufacturer is connected to a
TRUMPF laser device or if a TRUMPF product is connected to
the laser device of a different manufacturer, then the user is
responsible for the safe operation of the laser network.
A machine without its own chiller (optional machine cooling unit)
may not be connected to a laser network. The integration in a
laser network is only allowed if the machine is retrofitted with a
machine cooling unit in consultation with TRUMPF.
When the machine and the laser device are powered by a
shared electrical connection (optional central power supply installation possibility), the machine must not be connected to a laser
network.
Exemption from liability
Any other form of use is considered unauthorized use. TRUMPF
is not liable for any damage, especially personnel injuries and
production failures resulting from this. The risk is borne solely by
the operator. The warranty will be voided.
3.2
■
■
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2017-11-17
Authorized personnel
Operation, setting and maintenance work may only be
carried out by authorized, trained and instructed personnel.
Qualified personnel may:
− Transporting the machine to the installation site.
− Carry out work at the laser-specific, pneumatic and electrical modules.
− Carry out setting work and work in teach mode.
− Disassembling the machine.
Operational safety
1‐9
4.
Hazards
4.1
Overview of laser classes
Laser systems are classified into laser classes as per the European Standard EN 60825-1 (USA: ANSI Z136.1, ANSI B11.21).
The laser class corresponds to the hazard level of the laser light
emitted.
class
Description
1
The accessible laser radiation is not dangerous under sensibly predictable
conditions.
2M
The accessible laser radiation lies in the visible spectral range of 400 nm
to 700 nm. It is not dangerous for eyes in the case of short exposure time
(up to 0.25 s) as long as the beam is not observed through optical instruments (magnifying glass, lens, telescope). Additional radiation parts
outside the wavelength spectrum of 400-700 nm fulfill the conditions of
class 1M.
2
The accessible laser radiation lies in the visible spectral range (400 nm to
700 nm). It is not dangerous for the eyes when the exposure time is limited (up to 0.25 s). Additional radiation parts outside the wavelength spectrum of 400-700 nm fulfill the conditions of class 1.
Eyes are normally protected from the laser light by turning away and closing the eyelids.
3R
The accessible laser radiation is in the wavelength spectrum of 302.5 nm
to 106 nm and is hazardous to the eye. The power or the energy is maximum 5x the limit value of the permissible radiation of class 2 in the wavelength range of 400 nm to 700 nm.
4
The accessible laser radiation is very dangerous to the eyes and dangerous to the skin. Diffused radiation can also be dangerous. The laser radiation can lead to a risk of fire and explosion.
Safety precautions must be implemented for laser devices of class 4; adequate eye protection is primarily important.
Laser systems of class 4 are usually sufficiently powerful to burn the skin,
ignite fires and ionize the atmosphere during focussing. Thus, a series of
additional safety measures is required.
Overview of laser classes
1‐10
Hazards
Tab. 1-3
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Laser classes of the machine
Operation
mode
Description
Normal mode
Normal mode is the mode of
the machine in the entire
scope of function including the
maintenance work that has
been described in the operator's manual.
Teach mode
class
Teach mode is the mode of
the machine when teaching/
generating NC programs.
Characteristics:
1
■
The machine is controlled by a program or
by hand.
■
The protective devices are activated.
■
The processing optics is in working position
above the workpiece when the laser beam
is switched on.
■
The personnel is located outside the danger
zone.
Characteristics:
■
1
The machine is operated via a separate
teach panel.
■
Teach mode is activated via a key switch.
■
The laser cannot be ignited in teach mode.
Laser classes of the machine
Tab. 1-4
Laser classes of laser device and
components
Laser device, component
class
■
Laser device with open hood.
4
■
Pilot laser at the emission opening of the laser
device.
3R
■
Pilot laser upon leaving the focusing lens.
2
■
Laser device with closed hood.
1
■
Laser light cable.
Laser classes of laser device and components
4.2
TruDisk
Tab. 1-5
Hazards due to laser radiation
The TruDisk is a class 4 solid-state laser.
Solid-state lasers generate intensive light in the invisible nearinfrared spectral range with a wavelength of 1030 nm.
Biological tissue absorbs light in different ways. It is usually converted into heat and causes thermal damage (e.g. burns,
destruction of protein) and permanent retina damage.
Eyes and skin are especially at risk due to direct and reflective
laser radiation.
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Hazards
1‐11
DANGER
Invisible, high-energy laser radiation!
Severe skin burns and eye injuries may occur. Effect on the
sight and blindness!
Ø
DANGER
Incorrect laser safety glasses!
Serious eye injuries. Impairment to sight and blindness!
Ø
Ø
WARNING
Operate machines only with active safety devices.
Do not mix up laser safety glasses for lasers with differing
wavelengths.
Before using laser safety glasses, check whether they are
approved for the wavelength of the laser radiation.
Invisible, high-energy laser radiation! Monitors and LED
indicators are integrated into the front side of the safety
cabin. If these devices and display elements are removed
from the safety cabin, laser radiation could escape from the
safety cabin.
Risk of severe skin burns and damage to the eyes. There is
a risk to your sight and a risk of blinding!
Ø
Pilot laser TruDisk
WARNING
The machine may only be operated if both monitors and all
LED indicators or alternatively their cover sheets are fitted to
the safety cabin.
The laser device can contain class 3R laser diodes. The red
light of the laser diodes is used for adjustment work on the
machine.
Eye injury due to laser radiation!
Laser radiation damages the eyes permanently.
Ø
Do not look directly into the beam.
Wavelength
630 nm to 680 nm
Max. power output
≤5 mW
class
3R
Pilot laser technical data
1‐12
Hazards
Tab. 1-6
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4.3
Fire hazard
The following fire extinguishers should be kept ready at the
machine for fire protection:
■
CO2 fire extinguisher (fire classification B) for fires in the
compact dust extractor if the compact dust extractor is equipped with a CO2 extinguisher.
■
Powder extinguisher (fire classification D) for fires in the
compact dust extractor if the compact dust extractor is equipped with an argon extinguisher.
Metal bucket (min. 20 l) with dry sand or fire extinguisher
(fire classification D) for metal fires.
■
Combustible objects in the manchine's work area increase
the risk of fire.
WARNING
Fire in the work area or in the compact dust extractor.
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Formation of foil lint when cutting film-coated aluminum.
WARNING
Health hazard and fire in the compact dust extractor.
Ø
Ø
Ø
Ø
B836en
Do not bring combustible objects, such as cigarettes, paper
or cardboard, into the work area of the machine.
Service the compact dust extractor (filtering installation),
especially the spark arrester, thoroughly and on a regular
basis.
Replace fine dust bag or dust container when the level is
25%.
Be sure that the clamped dust container at the dust discharge is air tight.
Only use genuine fine filter bags from TRUMPF.
In the event of a fire in the compact dust extractor, inform
the manufacturers (TRUMPF and Herding) without delay.
After a fire, only the manufacturer is permitted to repair the
compact dust extractor.
2017-11-17
During cutting of film-coated aluminum: observe the cutting
procedure. If film lint develops, abort the cutting process and
change the cutting parameters in consultation with TRUMPF.
Service the compact dust extractor (filtering installation) thoroughly and on a regular basis; in particular, the spark
arrester.
In the event of a fire in the compact dust extractor, inform
the manufacturers (TRUMPF and Herding) without delay.
After a fire, only the manufacturer is permitted to repair the
compact dust extractor.
Hazards
1‐13
Extinguishing the fire in the compact dust
extractor (Herding) without fire extinguisher
A fire can start in the filter elements or in the dust container. An
acoustic alarm is triggered in the event of a fire.
Means, Tools, Materials
■
■
CO2 fire extinguisher (fire classification B) for fires in the
compact dust extractor and smaller fires at the machine.
Fire extinguisher for metal fires (fire classification D) for
extinguishing again.
Notes
■
■
WARNING
The extinguishing openings at the compact dust extractor are
marked with a label and closed by a lid.
Caution when opening the extinguisher opening – flames can
emerge.
Risk of burns due to fires and hot components!
Ø
Ø
Only open the compact dust extractor door under cover.
Only touch hot components with protective gloves.
1. If a fire occurs in the compact dust extractor (fumes come
out of the clean gas outlet) immediately:
− Press the EMERGENCY STOP push-button.
− Switch off the MAIN SWITCH Machine.
2. Put on protective gloves.
3. Remove the sealing cap on the side and back.
4. Push the foam tube of the CO2 fire extinguisher all the way
into the extinguisher opening.
5. Insert the extinguishing agent intermittently into the compact
dust extractor.
6. Wait about 5 to 10 minutes for the extinguishing agent to
take effect.
7. Open the door to the clean gas space with someone else
standing by to cover you.
8. If the fire flares up again, extinguish it again by bursts with a
fire extinguisher for metal fires (fire classification D).
1‐14
Hazards
2017-11-17
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Extinguishing the fire in the compact dust
extractor (Herding) with the CO2 fire
extinguisher
A fire can start in the filter elements or in the dust container. An
acoustic alarm is triggered in the event of a fire. The CO2 extinguisher system is automatically triggered if a fire is detected.
Conditions
■
■
The extinguisher system is switched on.
Extinguishing gas cylinder is open.
Means, Tools, Materials
■
Fire extinguisher for metal fires (fire classification D) for
extinguishing again.
Note
Keep a fire extinguisher to hand at all times. A fire can re-ignite
if oxygen is added.
At compact dust extractors equipped with an extinguisher system, there may be a temporary increase in the concentration of
the extinguishing gas in the environment of the compact dust
extractor after triggering the extinguisher.
Lack of oxygen due to extinguishing gas after triggering of
the extinguisher system.
DANGER
Ø
Ø
Do not enter a pit in the area of the compact dust extractor.
Ensure good ventilation around the compact dust extractor.
Risk of burns due to fires and hot components!
WARNING
Ø
Ø
Only open the compact dust extractor door under cover.
Only touch hot components with protective gloves.
1. If a fire occurs in the compact dust extractor (fumes come
out of the clean gas outlet) immediately:
− Press the EMERGENCY STOP push-button.
− Switch off the MAIN SWITCH Machine.
2. Wait about 5 to 10 minutes for the extinguishing agent to
take effect.
3. Put on protective gloves.
4. Open the door to the clean gas space with someone else
standing by to cover you.
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2017-11-17
Hazards
1‐15
5. If the fire flares up again, extinguish it again by bursts with a
fire extinguisher for metal fires (fire classification D).
Extinguishing the fire in the compact dust
extractor (Herding) with the argon fire
extinguisher
A fire can start in the filter elements or in the dust container. An
acoustic alarm is triggered in the event of a fire. The argon
extinguishing system is automatically triggered.
Conditions
■
■
The extinguisher system is switched on.
Extinguishing gas cylinder is open.
Means, Tools, Materials
■
Powder hand-held fire extinguisher, fire classification D.
Note
Keep a fire extinguisher to hand at all times. A fire can re-ignite
if oxygen is added.
At compact dust extractors equipped with an extinguisher system, there may be a temporary increase in the concentration of
the extinguishing gas in the environment of the compact dust
extractor after triggering the extinguisher.
DANGER
Lack of oxygen due to extinguishing gas after triggering of
the extinguisher system.
Ø
Ø
WARNING
Do not enter a pit in the area of the compact dust extractor.
Ensure good ventilation around the compact dust extractor.
Risk of burns due to fires and hot components!
Ø
Ø
Only open the compact dust extractor door under cover.
Only touch hot components with protective gloves.
1. If a fire occurs in the compact dust extractor (fumes come
out of the clean gas outlet) immediately:
− Press the EMERGENCY STOP push-button.
− Switch off the MAIN SWITCH Machine.
1‐16
Hazards
2017-11-17
B836en
2. Wait about 5 to 10 minutes for the extinguishing agent to
take effect.
3. Put on protective gloves.
4. Open the door to the clean gas space with someone else
standing by to cover you.
5. If the fire flares up again, extinguish it again intermittently
with a powder hand-held fire extinguisher (fire classification
D).
Machining highly reactive materials
Titanium
Titanium is a highly reactive material. In the event of a fire, metallic titanium reacts with conventional extinguishing agents, such
as water, N2, CO2, which is why they are not permitted as extinguishing agents.
Titanium reacts violently with other substances!
WARNING
Risk of injury and damage to property due to fire.
Using the MultiCoater
Ø
Do not extinguish fires with water, N2 or CO2.
Ø
Only use extinguisher systems of fire class D to extinguish
fires.
The MultiCoater is an option for the compact dust extractor (filtering installation). The MultiCoaters works cyclically or in continuous operation to apply calcium carbonate or trass powder (dispensing material) to the filter elements of the compact dust
extractor.
If the MultiCoater is used for preventive fire protection ("inertization"), dispensing material is added continuously to the separated, highly reactive dust to minimize the risk of fires.
Notice! Even the use of a MultiCoater does not provide a
100% protection against fire.
The effectiveness of the preventive fire protection depends on
the metering of the dispensing material added. The dispensed
quantity and the metering interval are controlled by parameters
and depend on the material to be processed.
During start-up, the MultiCoater will be configured for a particular
operating mode: "Inertization" or "Precoating".
If the conditions for the "Inertization" mode change, the user may
only change the configuration of the MultiCoaters in consultation
with the manufacturer.
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2017-11-17
Hazards
1‐17
WARNING
Fire hazard in the compact dust extractor if the MultiCoater
is not operated correctly!
Ø
Ø
Ø
If highly reactive materials are processed, the MultiCoater
may be operated in "Inertization" operating mode only.
Only use the specified dispensing material.
Make sure there is sufficient dispensing material in the storage container.
Notes
■
■
If the MultiCoater is configured for "Precoating" operating
mode during start-up, there is no sufficient preventive fire
protection compared to the "Inertization" operating mode due
to the reduced addition of dispensing material to the separated dust.
If the user deviates from the parameters defined during
start-up without consulting the manufacturer, then the
user is solely responsible for the effectiveness of the
resulting preventive fire protection.
Machining heavily oiled workpieces
Oil residue on workpieces
Oil residue on workpieces, especially oil spills on, for example,
rolled or deep-drawn workpieces will vaporize during laser processing. The oil vapor becomes incrusted onto tube walls and filter elements.
If there is a high concentration of oil vapor and deposits, then
there is a risk of fires and explosions due to sparks.
WARNING
Risk of fires and explosions due to oil vapor and oil
deposits in pipelines, in the machine's work area as well as
in the compact dust extractor.
Ø
Ø
Ø
1‐18
Clean workpieces prior to set up.
Remove oil residues from fixtures, work tables and the factory floor at regular intervals.
Extinguish fires using a metal fire extinguisher (fire classification D).
Required safety device
If it is usually oiled workpieces that are machined in the laser
processing machine, then the compact dust extractor has be
equipped with a MultiCoater to protect the filter elements in the
compact dust extractor (filtering installation) and to minimize the
fire risk.
Using the MultiCoater
The MultiCoater is an option for the compact dust extractor (filtering installation). The MultiCoaters works cyclically or in contin-
Hazards
2017-11-17
B836en
uous operation to apply calcium carbonate or trass powder (dispensing material) to the filter elements of the compact dust
extractor.
If the MultiCoater is used for preventive fire protection ("inertization"), dispensing material is added continuously to the separated, highly reactive dust to minimize the risk of fires.
Notice! Even the use of a MultiCoater does not provide a
100% protection against fire.
The effectiveness of the preventive fire protection depends on
the metering of the dispensing material added. The dispensed
quantity and the metering interval are controlled by parameters
and depend on the material to be processed.
During start-up, the MultiCoater will be configured for a particular
operating mode: "Inertization" or "Precoating".
If the conditions for the "Inertization" mode change, the user may
only change the configuration of the MultiCoaters in consultation
with the manufacturer.
Fire hazard in the compact dust extractor if the MultiCoater
is not operated correctly!
WARNING
Ø
Ø
Ø
If highly reactive materials are processed, the MultiCoater
may be operated in "Inertization" operating mode only.
Only use the specified dispensing material.
Make sure there is sufficient dispensing material in the storage container.
Notes
■
■
If the MultiCoater is configured for "Precoating" operating
mode during start-up, there is no sufficient preventive fire
protection compared to the "Inertization" operating mode due
to the reduced addition of dispensing material to the separated dust.
If the user deviates from the parameters defined during
start-up without consulting the manufacturer, then the
user is solely responsible for the effectiveness of the
resulting preventive fire protection.
4.4
Dangers from magnetic fields
Magnetic coupling of the processing optics
The processing optics are held by a magnetic coupling. The
magnetic coupling consists of an overload flange, mounted on
the barrel, and an overload plate at the processing optics. The
holding force is generated by permanent magnets. The overload
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2017-11-17
Hazards
1‐19
flange is the primary part (permanent magnet). The overload
plate is the anchor part.
In case of a collision of the processing optics with workpieces or
objects in the work area, the electrical monitoring circuit between
the primary part and the anchor part is interrupted; the processing optics are released from the flange.
Magnetic flux density
The magnetic flux density is maximum on the surface of the permanent magnets in the primary part. If the distance is 30 cm, the
measured value is less than 100 μT (micro tesla).
According to modern medical standards, values up to 100 μT
with a permanent load and a frequency of 50 Hz, are medically
harmless for persons in good health (DIN VDE 0848, Part 4).
DANGER
Strong magnetic field of the magnetic coupling!
Risk of fatal injury for persons with pacemakers.
Ø
Ø
Ø
Ferromagnetic attractive
force
Persons with a pacemaker must, regardless of whether the
machine is switched on, keep a minimum distance of 30 cm
from the overload flange on the barrel.
Persons with a pacemaker may not perform any service,
maintenance or setting work on the Z axis or on the processing optics (if installed).
Advise personnel, visitors or visiting personnel of the dangers for persons with a pacemaker.
The permanent magnets create a magnetic field. The ferromagnetic attractive force is 1000 N.
The attractive force will act suddenly, and depends on the surface and on the mass of the object concerned.
CAUTION
The magnetic attractive force will act suddenly within the
immediate vicinity.
Ø
Do not bring heavy or large-surface objects made of steel or
iron near to the primary part.
4.5
Dangers due to the open electrical
cabinet
The electrical cabinet may be opened only by a specialist electrician.
1‐20
Hazards
2017-11-17
B836en
Electrical voltage!
DANGER
Electric shock!
Ø
Ø
Keep switch cabinet closed.
Before opening the switch cabinet: switch off the main
switch and secure against switching back on. Wait for the
discharging time (at least 5 minutes).
Hot components!
CAUTION
Burns!
Ø
Ø
Keep switch cabinet closed.
Before opening the switch cabinet: switch off the main
switch and secure against being switched back on. Wait for
the correct cooling phase (at least 5 minutes).
4.6
Dangers due to live parts
The power supply for the extinguisher cannot be switched
off via the main machine switch!
DANGER
Electric shock!
Ø
Ø
Ø
Only a qualified electrician may do work on electrical parts.
Before opening the compact dust extractor, switch off the
extinguisher.
Before touching, ensure that there is no live voltage present.
Live parts of TruDisk laser devices!
DANGER
Risk of electric shock!
Ø
Ø
Ø
Machine versions complying
with NEC
Only an electrician may work on electrical devices.
Before repair work: Switch off the laser device and secure it
against being switched on again.
Before touching: check whether the parts are de-energized.
For machine versions complying with NEC, the switch cabinet
doors as well as all other electrical switchboxes may not be
secured with safety switches.
These switch cabinet doors and switchboxes are labelled with
two warning signs (see "Warning signs at the machine",
pg. 1‐44).
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2017-11-17
Hazards
1‐21
Note
For warning signs, see the section "Warning signs on the
machine".
DANGER
Risk of fatal injury due to electric shock! If the main switch
is turned on, when opening the switch cabinet doors or a
switchbox, the mains disconnector will not switch the
power off.
Ø
Ø
Observe the warning signs.
Before opening the switch cabinet or a switchbox, set the
main switch to off and lock it to prevent its being switched
back on again. Wait for the discharging time (at least 5
minutes).
4.7
Danger from handling hot
components
There is a rink of burns from touching hot nozzles immediately
after machine operation.
WARNING
Risk of burns due to hot components!
Ø
Only touch hot components with protective gloves.
4.8
Configurable control
interface
Dangers due to configured movement
sequences
The configurable control interface (referred to as KSS in the following) is an option for the laser processing machine.
The user can configure automatic movement sequences themself
with this KSS, without having to add or replace hardware or software components in the machine control system.
With the KSS, both fixtures supplied and configured by TRUMPF
can be actuated on the machine, as well as those supplied and
configured by the user.
User responsibility
The configured sequences of motion and components must be
safe.
The user is required to produce a hazard assessment for fixtures
and configured sequences of motion.
1‐22
Hazards
2017-11-17
B836en
Danger due to configured movement sequences of the
components!
WARNING
Injury to personnel in the danger zone.
Ø
Ø
Ø
No danger may be posed by the configured movement
sequences or components.
The operator must be familiar with the configured sequences.
Manual operation via manual functions is only permitted
when there is no one in the danger zone and if there is no
hazard.
4.9
Dangers during transport
and assembly
Dangers when handling clamping
fixtures
Clamping fixtures can weigh up to 450 kg, depending on the
design.
Clamping fixtures for IHU workpieces usually have swivel axes,
which have to be secured during transport or assembly.
Dangers due to improper transport or assembly of the
clamping fixture on the workpiece changer!
WARNING
Ø
Ø
Ø
Ø
Ø
Ø
Danger while teaching
Do not step under suspended loads.
When transporting on a pallet: Secure the fixture against tilting and falling off the pallet.
In the case of fixtures for IHU workpieces: Lock in place
with the transport securing device before mounting to the
workpiece changer, as well as before transporting the swivel
unit.
Set up or dismount fixture from the workpiece changer outside of the enclosed protective housing.
Only remove the tackle once the fixture is securely mounted
on the workpiece changer.
If available, observe the project-specific transport regulation.
During the teaching process, the operator is in the machine's
work area.
A danger is posed to the operator by pneumatically moving fixture parts when a program is being run in test mode.
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Hazards
1‐23
WARNING
Swivel axes as well as actuators actuated via the KSS, such
as clamping devices or pneumatic cylinders, execute
immediate and unbraked movements in TEACHIN operating
mode!
Health hazard, particularly danger of sustaining a head
injury.
Ø
Ø
Ø
Ø
If an NC program is run in TEACHIN mode, step back from
the fixture and maintain a sufficient distance from the clamping device movement.
In the case of clamping fixtures with swivel axes in
TEACHIN mode, leave the work area before swiveling the
axis and close the safety door from the outside.
In the event of emergency triggering of the a clamping
device: Keep your head and upper body away from the danger zone of the clamping device movement.
It is not permissible to stand in the danger zone inside the
enclosed protective housing with the access door closed.
4.10 Dangers due to quickly-rotating
rotational changer
Danger zone inside the
safety cabin
DANGER
If the doors of the safety cabin are closed, the safety circuit will
be closed and the rotational changer can turn, provided the loading and unloading area is enabled by the safety circuit.
Risk of fatal injury from rapidly rotating rotational changer!
Ø
Ø
Ø
Ø
Ø
Danger zone outside the
safety cabin
1‐24
Hazards
Only press the ACKNOWLEDGE DANGER ZONE button
when leaving the danger zone.
Only press the ACKNOWLEDGE DANGER ZONE button
and close the door, if there is no one in the safety cabin.
Do not block the access doors from outside.
In an emergency, exit the safety cabin by the shortest possible route.
Before doing maintenance work in the work area or on the
rotational changer, press the EMERGENCY STOP push-button.
The loading area in front of the rotational changer is monitored
by a light grid and a scanner.
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Risk of fatal injury due to quickly rotating rotational
changer in the loading area!
DANGER
Ø
Ø
Ø
Do not step into the danger zone if the rotational changer is
not in its end position.
Before doing any maintenance work on the rotational
changer, press the EMERGENCY STOP push-button.
Do not step on the rotational changer and do not put anything down on it.
4.11 Dangers due to quickly turning rotary
indexing table (option)
Danger zone inside the
safety cabin
If the door of the safety cabin is closed, the safety circuit will be
closed and the rotary indexing table can turn, provided the loading and unloading area is enabled by the safety circuit.
In an emergency, the danger zone within the safety cabin can be
left on both sides of the working area. The access door on the
one side and the escape door on the other side can be opened
from inside. The laser unit has an EMERGENCY STOP button
next to the escape door.
Risk of fatal injury from rapidly turning rotary indexing
table.
DANGER
Ø
Ø
Ø
Ø
Ø
Danger zone outside the
safety cabin
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2017-11-17
Only press the ACKNOWLEDGE DANGER ZONE button
when leaving the danger zone.
Only press the ACKNOWLEDGE DANGER ZONE button
and close the door, if there is no one in the safety cabin.
Do not block the access and escape doors from outside.
In an emergency, exit the safety cabin by the shortest possible route.
Before doing maintenance work in the work area or on the
rotary indexing table, press the EMERGENCY STOP pushbutton.
The loading & unloading areas for the rotary indexing table are
each monitored with a light grid and a scanner.
Hazards
1‐25
DANGER
Risk of fatal injury from rapidly turning rotary indexing
table in the loading and unloading area.
Ø
Ø
Ø
Ø
Ø
Do not step into the danger zone if the rotary indexing table
is not in its end position.
Do not hold any objects through the protective screen.
Do not remove the protective cover between the protective
screen walls.
Before performing maintenance work on the rotary indexing
table, press the EMERGENCY STOP push-button.
Do not climb on to the rotary indexing table and do not
place any objects on it.
4.12 Hazard risks due to the scrap
conveyor
Waste parts or scrap skeleton parts can get jammed in the conveyor belt or between the conveyor belt and the housing, thus
causing malfunctions.
WARNING
Risk of injury due to jammed waste parts or scrap skeleton!
Ø
Ø
Disconnect the drive motor of the scrap conveyor from the
power supply: turn key switch to the neutral position.
Removed jammed waste parts using a suitable tool.
4.13 Dangers due to a suspended axis
The barrel on the motion unit with a Z axis drive is a suspended
axis.
A suspended axis can pose a fundamental risk of injury to personnel, for example during teaching, during installation or setup
work as well as maintenance work in the machine's work area.
WARNING
1‐26
Hazards
Risk of injury from a suspended axis.
Ø
Do not step under the barrel when in the machine's work
area.
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B836en
4.14 Danger while teaching
During the teaching process, the operator is in the machine's
work area.
A health hazard is posed by pneumatically moving fixture parts
when a program is being run in test mode.
Risk of injury during the teaching process!
WARNING
Ø
Ø
Ø
Ø
Ø
While an NC program is being run in test mode, maintain a
sufficient distance to the fixture.
In the case of clamping fixtures with swivel axes, leave the
work area before swiveling the axis and close the safety
door from the outside.
Do not step between the machine frame and the barrel.
Do not step under the barrel.
Do not reach with your fingers between the workpiece surface and the nozzle tip.
4.15 Dangers in the work area due to a
bright source of light.
The work area within the safety cabin is lit with 4 LED tube
lamps, which produce a very bright light.
There is a danger of being dazzled by looking directly into
the light source.
CAUTION
Looking directly into the light source can temporarily impair
your ability to see and can leave an image in your eyes.
This can lead to irritation, impairments or accidents.
Ø
Do not look straight into a light source.
4.16 Dangers of slipping, tripping or
falling
The scrap conveyor in the work area as well as the platform
inside the safety cabin are sources of danger.
Slipping, tripping or falling!
CAUTION
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Ø
2017-11-17
For machines with a rotary indexing table: when in the work
area, fold up the guide plate on the machine frame.
Hazards
1‐27
CAUTION
Cutting dust causes a risk of slipping. Very fine, oily cutting
dust can be deposited within the safety cabin.
Ø
Regularly clean the work area and the machine's components.
4.17 Dangers handling workpieces
Processing workpieces can be dangerous. These dangers and
measures are different for every workpiece.
Sharp-edged workpieces
WARNING
Workpieces have sharp edges!
Risk of injury!
Ø
Wear personal safety equipment.
Hot workpieces
WARNING
Hot workpieces after machining!
Burns!
Ø
Ø
Ø
Wear protective gloves.
Use auxiliary equipment for workpiece removal.
Avoid direct contact with hot surfaces.
Suspended loads when setting up
workpieces
Large and/or heavy workpieces can be set up on a fixture using
lifting tackle. Loads are suspended during loading and unloading.
DANGER
Risk of fatal injury due to suspended loads when loading
and unloading workpieces!
Ø
Ø
Ø
1‐28
Hazards
Observe the safety regulations for handling heavy loads.
Do not access areas under suspended loads.
Fasten workpieces securely with a suitable tackle.
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B836en
4.18 Hazards due to collisions in the work
area
Pay attention to the risk of
collision in the work area
There is always a risk of collisions between the Z barrel, processing optics and fixtures, table sets, or workpieces in the 3-D
working range of the machine.
There is a particular risk of collision:
■
■
■
When starting the axes.
When starting a machining program.
When resuming work with an interrupted machining program.
Risk of collision between Z barrel and fixture or workpieces
in the working range of the machine!
NOTICE
Considerable property damage to the barrel can result.
Ø
Each time before the axes or the NC program is started, the
operator must make sure that the barrel cannot collide with
objects in the workspace.
In the case of a collision of the processing optics with workpieces or components in the work area, the magnetic coupling triggers and the processing optics immediately separates from the
magnetic coupling. The machine stops with FEED HOLD. This
will greatly reduce the consequences of the collision.
4.19 Dangers when working with the
Smart Optics Setup station
The Smart Optics Setup station (option) is a swivelable setting
device, which can be used to perform setting work for the processing optics as well as for the machine.
The setting device is manually swiveled out of the parking position into the working range of the machine (setup position)
before beginning with setting work.
Test sheets, sacrificial plates and the test sheet holder get
hot during laser processing!
WARNING
Ø
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2017-11-17
Wear protective gloves.
Hazards
1‐29
CAUTION
Risk of crushing or hitting when swiveling the
Smart Optics Setup station!
Ø
Ø
Ø
When swiveling, make sure that no parts of the body get
caught.
Touch the swivel arm at the handle to swivel it.
Lock the swivel arm in the set-up position and in the parking
position.
4.20 Hazards due to escaping coolant or
cooling water
NOTICE
Escaping coolant or cooling water!
Ø
Ø
Switching off the process
cooler in case of emergency
Switch off the process cooler immediately.
Put the machine or system into service only once the malfunction has been eliminated.
In the case of a severe malfunction at the process cooler (e.g. a
leak in the cooling water circuit or coolant circuit), the process
cooler must be switched off immediately.
■
■
If the process cooler is switched on and off via the machine's
power supply: switch off the MAIN SWITCH of the machine
or
If the process cooler has its own power supply: switch off the
MAIN SWITCH on the process cooler.
4.21 The risks of no switch cabinet
cooling
The machine's cooling circuit can be arranged as follows:
■
■
The machine has a separate cooling unit (optional machine
cooler).
The machine's cooling circuit is cooled via the laser cooler
(the standard case).
The machine cooler variant: The switch cabinets in the body of
the machine will be cooled via its cooler unit. If the machine's
MAIN SWITCH is on, but the machine's drives are off (DRIVES
ON button is not lit), then the machine's cooling and thus the
switch cabinet's cooling will not be active.
1‐30
Hazards
2017-11-17
B836en
The switch cabinets in the body of the machine will not be
cooled if the machine's drives are switched off.
NOTICE
If the temperature rises, components in the switch cabinet
can prematurely age or fail.
Ø
Ø
If the machine is at a standstill for a longer period e.g. over
the week end, set the machine's MAIN SWITCH to off.
Only switch off the machine's drives when required and then
only for a short period.
The laser cooler variant: If the machine is not equipped with its
own cooler, then the switch cabinets in the body of the machine
will be cooled via the laser cooler.
The switch cabinets in the body of the machine will not be
cooled if the laser device is switched off.
NOTICE
If the temperature rises, components in the switch cabinet
can prematurely age or fail.
Ø
If the laser is switched off for a longer period, then you
should also set the machine's MAIN SWITCH to off.
4.22 Dangers due to Teleservice
Teleservice is used to establish a connection between the
machine and Technical Service.
The service engineer can access the user interface to analyze
problems and in some cases to eliminate them directly.
Teleservice activated!
WARNING
Injury and damage to property.
Ø
Ø
Only persons trained by TRUMPF may take part in a Teleservice session.
If doubts arise regarding the qualifications of the persons
involved or if comprehension issues arise, TRUMPF can
refuse Teleservice or terminate the Teleservice session.
4.23 Dangers when using the
MobilelControl app
The MobileControl app (option) allows the user to remotely control the machine via a mobile terminal.
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Hazards
1‐31
WARNING
Remote control of the machine with one mobile terminal!
Ø
Ø
Ø
While the remote control is in use, do not enter the
machine's danger zone.
The remote control may only be activated if the machine is
ready for operation.
The remote control is forbidden for maintenance work at the
machine.
4.24 Hazardous materials
In the case of hazardous materials, TRUMPF indicates the sources of danger only as an example. The user must estimate the
danger caused by a processed material. The user must check
and initiate the required measures.
WARNING
Insufficient exhaust system for the work area!
Hazardous gasses and particles enter the respiratory tract
during laser processing.
Ø
Do not operate without the required exhaust system for the
work area.
Dusts, exhaust air
Exhaust air compact dust
extractor, regulation outside
of Germany
The user must comply with the national regulations for handling
the exhaust air of the compact dust extractor and the dusts it
contains.
Exhaust air compact dust
extractor, regulation
Germany
For the laser processing of stainless steel and materials from
which harmful substances can arise as suspended dust, the
exhaust air of the compact dust extractor must be conducted to
the outdoors.
In Germany, the limits for the return of cleaned air into the room
air are defined in "Technical Rules for Hazardous Materials
TRGS 560".
Note
For the laser processing of mild steel or aluminum, for example,
the cleaned air of the compact dust extractor may be fed back
into the room air.
Cleaning the machine
1‐32
Hazards
The machine may only be cleaned with an industrial vacuum
cleaner which meets at least the standards for "dust-class M"
according to IEC/EN 60335-2-69.
2017-11-17
B836en
In Germany, when materials are processed that are listed in the
technical rules for hazardous materials TRGS 560, then an
industrial vacuum cleaner for "dust class H" must for used for
cleaning.
Further Information
The databases from GESTIS contain limit values for dust concentrations and notes about danger (hazardous substance information system of the German Social Accident Insurance). The
databases are available via the Internet in German and English.
Hazardous materials due to cutting oils
If metallic materials are processed with cutting oils, this might
lead to organic compounds (liquid or gaseous) during laser cutting or welding.
Note
If there is a danger of dangerous emissions, the user must carry
out measurements and implement safety measures.
Hazardous substances derived from
polyethylene films
Certain materials are covered with a polyethylene film in order to
protect the surface.
Polyethylene film is vaporized during laser cutting. The resulting
organic compounds (e.g. alcane) do not exceed the exhaust air
limit values.
However some of the resulting organic compounds lead to smell
load in very small concentrations (ppb area) in the exhaust air.
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Hazards
1‐33
5.
Measures to be taken by the
manufacturer
The danger zone of the machine is safeguarded by safety equipment. The machine may only be operated with these safety devices.
5.1
Danger zones and safeguarding
device
The service doors with electrical locking devices (option) have
their own control panel.
Depending on the configuration of the machine, the following
additional EMERGENCY STOP impact buttons are installed:
■
■
1‐34
Inside the safety cabin next to the escape door.
On the laser device, on the operating panel as well as on
the control panel of the laser device.
Measures to be taken by the manufacturer
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1
Escape door
4
Safety fencing
7
Control panel
2
Light grid
5
Laser scanner
8
Service door
3
Rotary indexing table control
panel
6
Safety strip
9
Main switch of the machine
Rotary indexing table: Danger zone safeguarding device
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2017-11-17
Measures to be taken by the manufacturer
Fig. 71419
1‐35
1
Protective wall
2
Rotational changer control panel 5
4
3
Light grid
Laser scanner
6
Service door
Main switch of the machine
7
Control panel
Rotational changer: Safeguarding the danger zone with Basic Loading
Fig. 73836
1
Rotational changer control panel 3
Laser scanner
5
Service door
2
Light grid
Control panel
6
Main switch of the machine
4
Rotational changer: Safeguarding the danger zone with Comfort Loading
1‐36
Measures to be taken by the manufacturer
Fig. 74464
2017-11-17
B836en
Light grid and laser scanner
for the rotational changer
There are two possible variants to safeguard the danger zone
around the rotational changer outside of the safety cabin:
■
■
The Basic Loading variant: The loading & unloading area is
safeguarded with side protective walls, a laser scanner and a
light grid (see fig. 73836).
The Comfort Loading variant: The loading & unloading area
is safeguarded with a laser scanner and a light grid around
three sides.
The danger zone is secured in all operating modes of the control.
■
■
■
Rotary indexing table, light
grid and laser scanner
The rotational movement of the rotational changer is only
enabled if the laser scanner does not register any objects
within the protected field.
The interruption of the light grid will trigger a feed hold while
the rotational changer is moving.
If the laser scanner detects an object in the danger zone, a
feed hold will be triggered.
By default, the loading & unloading area for the rotary indexing
table (option) is safeguarded by a vertical light grid, by a laser
scanner as well as with protective walls. The safeguarding of the
danger zone is effective in all of the control system's operating
modes.
■
■
■
The rotation of the rotary indexing table will only be enabled
if neither laser scanner registers any object within the protected field.
Interrupting a light grid will trigger a feed hold while the
rotary indexing table is moving.
If the laser scanner detects an object in the danger zone, a
feed hold will be triggered.
ACKNOWLEDGE DANGER
ZONE button
1
ACKNOWLEDGE THE DANGER ZONE button
Fig. 73839
As soon as an access door is opened, the movement of the
rotational changer or of the rotary indexing table (option) will be
disabled in all operation modes.
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2017-11-17
Measures to be taken by the manufacturer
1‐37
The movement of the rotational changer or of the rotary indexing
table and the starting of a machining program will only be enabled again if the acknowledgement button inside the safety
cabin, next to the access door, is pressed and the corresponding
access door is closed within the valid time window of 3 seconds.
Escape door for machines
with a rotary indexing table
In an emergency, the danger zone within the safety cabin can be
exited via the service door or via the escape door on the opposite side.
The working range inside the safety cabin is entered and exited
via the service door. The escape door is only to be opened in an
emergency, from inside. It is not an access door to the working
area.
Depending upon the version installed, the escape door may be
on the left or the right.
1
Service door
2
Escape door
Fig. 73832
1‐38
Measures to be taken by the manufacturer
2017-11-17
B836en
The escape door is labelled inside the safety cabin with an
"Emergency exit" sign and is secured by a safety switch. There
is also an EMERGENCY STOP push-button next to the escape
door.
1
EMERGENCY STOP push-button
2
Escape door
Fig. 73838
Safety cabin
For machines with a rotational changer: The machine is supplied with a completely enclosed safety cabin with a roof and
access doors on the left and right. One of the doors is fitted with
a laser protection window. The safety cabin is designed for a
maximum laser power of 4000 W.
For machines with a rotary indexing table: The machine is
supplied with a completely enclosed safety cabin with a roof as
well as one access door and an escape door. The access door
is fitted with a laser protection window. The safety cabin is
designed for a maximum laser power of 4000 W.
The doors are electrically secured and monitored by the control
system. The laser beam is only ignited if the doors are closed. If
a door is opened during machining, then a feed hold will be triggered.
Both opening a door as well as pressing the EMERGENCY
STOP push-button will immediately stop the movement of the
workpiece changer.
Do not access the roof of the safety cabin.
The access doors as well as the escape doors from the safety
cabin must be freely accessible from both sides and must not be
obstructed.
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2017-11-17
Measures to be taken by the manufacturer
1‐39
Main switch
The machine is switched on and off via the main switch. The
main switch can be secured against being switched on again
using a padlock.
The main switch has two positions:
Switch setting 0
The machine is switched off and the voltage
supply of the machine is interrupted.
Switch setting 1
The machine is switched on.
Tab. 1-7
EMERGENCY STOP pushbutton
Pressing an EMERGENCY STOP push-button results in the following:
■
■
■
■
■
■
TruDisk emergency stop
push-button
The shutter switch of the installed light path (LLK) is disabled
in the laser device.
The gas supply is interrupted.
All axis motions stop. All drives are shut down safely.
The central compressed air supply is switched off.
Stop workpiece changer and scrap conveyor.
Fixtures (option), which are actuated via the KSS:
− The power supply for the outputs of the I/O bus modules
is switched off.
− Valves remain in spring-loaded neutral position and retain
their respective status.
− Vacuum ejectors are not switched off; the vacuum is
maintained.
Note
If the laser device is located directly next to the machine or up
to a maximum of 10 m away from the machine, the EMERGENCY STOP push-button is enclosed and cannot be operated.
If the laser device is installed further away from the machine, the
EMERGENCY STOP push-button is not enclosed.
If the EMERGENCY STOP push-button is not encapsulated, the
following applies:
■
■
1‐40
The EMERGENCY STOP push-button on the laser device
causes an EMERGENCY STOP exclusively on the laser
device.
All potentially dangerous components of the laser device are
switched off.
Measures to be taken by the manufacturer
2017-11-17
B836en
■
■
The shutter switches of the installed laser light cable are disabled.
If the laser is assigned to the machine:
− Laser processing is discontinued.
− An error message is displayed in the PRODUCTION
main operation.
− All manual functions can continue to be used in the SET
UP main operation.
Note
The EMERGENCY STOP section on the laser device can only
be acknowledged on the laser device.
STOP push-button on teach
panel
Pressing the STOP push-button on the teach panel results in the
following:
■
■
■
■
■
■
■
FEED HOLD
A FEED HOLD leads to the following:
■
■
■
■
■
■
Key switch on the laser
device.
B836en
2017-11-17
The laser beam is switched off.
The shutter switch of the installed light path (LLK) is disabled
in the laser device.
The gas supply is interrupted.
All axis motions stop. The drives are shut down safely.
The central compressed air supply is switched off.
Stop workpiece changer and scrap conveyor.
Fixtures (option), which are actuated via the KSS:
− The power supply for the outputs of the I/O bus modules
is switched off.
− Valves remain in spring-loaded neutral position and retain
their respective status.
− Vacuum ejectors are not switched off; the vacuum is
maintained.
All axis motions are stopped.
No beam enable for the installed light path.
The rotational movement of the rotational changer stops.
The rotational movement of the rotary indexing table stops.
The waste conveyor belt stops.
Fixtures (option), which are actuated via the KSS:
− The power supply for the outputs of the I/O bus modules
is maintained.
− The voltage supply for the fixture in the loading position
is interrupted.
− Vacuum ejectors are not switched off; the vacuum is
maintained.
The key switch on the laser device can be turned into the positions 0 and 1.
Measures to be taken by the manufacturer
1‐41
Switch setting 0
The key can be removed in this setting. The
unauthorized activation of the laser is prevented.
Switch setting 1
The laser is in the operating state.
Tab. 1-8
Key-operated switch
TEACHIN
In TEACHIN operating mode, the separate teach panel can be
used to manually program 3D workpieces and move NC axes.
The TEACHIN operating mode is activated or deactivated on the
control panel with the TEACHIN key switch.
In TEACHIN operating mode, the machine axes move at
reduced speed and only if the operator keeps at least one enable key constantly pressed. If no enable key is pressed then a
FEED HOLD will be applied.
TEACHIN mode is deactivated.
Switch setting 0
■
Switch setting 1
TEACHIN operating mode is activated. The following functions are activated automatically in
teach mode:
■
LASER TEST is activated: the shutter switch
of the installed light path (LLK) is disabled.
■
Axes can only be moved with the teach
panel.
■
The axes move at a safely reduced speed.
■
−
X axis: 10000 mm/min.
−
Y axis: 10000 mm/min.
−
Z axis: 5000 mm/min.
−
B axis: 12 rpm (3600°/min).
−
C axis: 4 rpm (1800°/min).
The drive of the rotational changer or of the
rotary indexing table is shut down safely.
Tab. 1-9
Safety Integrated
The machine is equipped with the control software Safety Integrated by Siemens. The functions of this safety concept are
effective with open or closed safety devices (safety cabin, light
barrier, light grid, laser scanner, etc.) and during teaching. Safety
Integrated is effective in all control operating modes.
The safety functions of Safety Integrated include:
■
■
1‐42
Safe operating stop (SBH) when a safety device is open.
The drives are regulated and monitored for safe standstill.
The software issues a FEED HOLD.
Safely reduced speed (SG):
− Monitoring of the limit values for the speed of all axes
when the safety device is open and during teaching.
− Monitoring of the limit values for the speed of all axes
when the safety device is closed.
Measures to be taken by the manufacturer
2017-11-17
B836en
The following must be ensured for the Safety Integrated safety
function to be able to function correctly and reliably:
■
■
MobileControl App
If the remote control of the machine is activated by the MobileControl app (option), the following safety measures become
effective:
■
■
■
■
■
Magnetic coupling barrel
All NC axes must be referenced safely.
A safety test has to be performed every 8 operating hours.
The safety test is used to check if the drives of the NC axes
are switched off electrically in the event of an error.
Operation by the control panel is disabled. A red/yellow
warning frame is shown on the control panel.
The Internet connection is limited to the local WLAN of the
machine.
The remote control is activated by a WPA key created
dynamically at the machine.
The mobile terminal cannot access the Internet while the
remote control is active.
The WLAN connection is terminated as soon as the remote
is disabled via the MobileControl app.
To reduce the consequences of a collision of the processing
optics e.g. with the workpiece, there is a magnetic coupling
(overload coupling) between the processing optics and the flange
on the barrel.
If there is a collision, the processing optics is separated from the
flange. The processing optics is held by a catch strap. FEED
HOLD is triggered.
The magnetic coupling's holding power is 1000 N.
Suction system in the work
area
The work area of the machine is vacuum-cleaned through the
open surface of the scrap conveyor. The air which is suctioned
off is guided to the compact dust extractor through the 2 connection sockets and a piping system.
The extraction and filtration system (compact dust extractors)
provided by TRUMPF in combination with the machine is
designed in such a way that the aerosols and dust emitted are
efficiently separated if the machine is used as intended (refer to
the "Hazardous substances" section.
Laser status lamp
The laser status lamp (orange) indicates that the laser device is
assigned to the machine or that laser radiation is escaping at the
processing optics.
Laser status lamps are part of the machine's safety equipment
and are monitored by the control. A faulty laser status lamp will
block the beam path to the machine, resulting in a FEED HOLD.
It will have to be replaced.
B836en
2017-11-17
Measures to be taken by the manufacturer
1‐43
Laser warning lamp, laser
device
Laser warning lamps on the laser device indicate that the laser
light is being emitted at the processing point and that the laser is
ready to emit laser light even when laser light is no longer being
emitted (in the "Laser is on" status).
5.2
Warning signs at the machine
Location of signs, machine with rotational changer
1‐44
Measures to be taken by the manufacturer
Fig. 71414
2017-11-17
B836en
Location of signes for a machine with rotary indexing table
Fig. 71415
Warning signs draw attention to dangers when operating the
machine.
Sign no.
Warning signs on the basic machine
Meaning
1
Laser Product Class 1
2, 3
Caution, there will be invisible
laser radiation when the cover
is opened and the safety lock is
bypassed.
Avoid eye or skin exposure to
direct or scattered radiation.
B836en
2017-11-17
Measures to be taken by the manufacturer
1‐45
Sign no.
Warning signs on the basic machine
2, 4
Meaning
Caution, there will be invisible
laser radiation when the cover
is opened.
Avoid eye or skin exposure to
direct or scattered radiation.
2, 5
Laser radiation – do not look
into the beam.
P ≤ 1mW: λ=630-660 nm
Laser class 2
-
Machine versions complying
with NEC:
CAUTION: To be opened only
by qualified personnel.
-
Machine versions complying
with NEC:
DANGER: Hazadous Voltage
Contact will cause electric
shock.
Disconnect and lock out power
before servicing.
-
For machines with a rotary
indexing table: "Emergency exit"
escape door.
-
Warning of laser beam.
-
Warning of electrical voltage.
-
Warning of hot surface.
-
Warning of suspended axis.
1‐46
Measures to be taken by the manufacturer
2017-11-17
B836en
Sign no.
Warning signs on the basic machine
Meaning
-
Warning of the risk of crushing.
-
No access for persons with a
pacemaker or with an implanted
defibrillator.
-
Entering the area prohibited.
-
Climbing on prohibited.
Warning signs at the machine
B836en
2017-11-17
Tab. 1-10
Measures to be taken by the manufacturer
1‐47
6.
Organizational measures to be taken
by the user
6.1
Observe warnings and warning signs
Certain operations can be a source of danger during operation.
The documentation contains warnings before the instructions for
these activities and warning signs are provided on the machine.
6.2
Training and instructing operators
Measures applicable worldwide
The user must take the following measures before the personnel
start working on the machine:
■
■
■
■
■
■
■
■
Protection against radiation
in service mode
1‐48
Train personnel appropriately.
Inform the personnel about the possible dangers and the
safety measures.
Keep personal protective gear ready.
As far as possible, ensure personnel wear protective gear
(e.g. gloves, safety shoes, hearing protection, safety
glasses...).
Define responsibilities for safety, operation, maintenance, setting work and service.
Require that personnel read the technical documentation of
the machine. Recommendation: obtain written confirmation
from the personnel.
Inform the personnel about the measures for protection
against radiation:
− Instruct the personnel in operating processes of the laser.
− Use protection against radiation correctly, e.g. wear laser
safety glasses.
− Instruct the personnel about the accident prevention procedures.
− Explain the biological effects of laser radiation on eyes
and skin.
For fault diagnosis and error correction, a connection will be
made via Teleservice by TRUMPF between the machine and
Technical Service. When the machine is commissioned the
user will be informed about the sequence and possible risks
of the Teleservice. The user must provide safety instruction
to operators who are involved in the Teleservice.
Only personnel trained and instructed in laser radiation and
appropriately equipped may carry out adjustment and setup work
Organizational measures to be taken by the user
2017-11-17
B836en
in service mode. In service mode, the machine's laser corresponds to class 4.
■
■
Appointing a laser safety
officer
The personnel must wear laser safety glasses that conform
to the requirements of the following standards IEC/
EN 60825-1 or EN 207, for the USA: ANSI Z87.1.
If necessary, the danger zone must also be secured by the
customer (e.g. with portable barriers made of sheet steel
and/or laser safety glass).
When the user operates the machine during service mode, or
carries out adjustment and setup work in service mode, he or
she must designate a laser safety officer in writing.
The user has to observe national laws and regulations.
The standard IEC/EN 60825 as well as ANSI-Norm Z136.1,
which is for the USA, describe the area of responsibility of the
laser safety officer.
Protection against radiation: information
for Germany
Observe the accident
prevention regulations
In Germany, the employer's liability insurance association regulation on laser radiation (DGUV regulation 11, formerly numbered
BGV B2).
Training a laser safety
officer
The following organizations in Germany train laser safety
officers, for example:
■
■
■
■
B836en
2017-11-17
Berufsgenossenschaft für Feinmechanik und Elektrotechnik
(German Employer's Liability Insurance Association for Precision Mechanics and Electrical Engineering), Postfach
510580, Gustav Heinemann Ufer, D-50968 Cologne, Germany.
Physikalisch-Technische Bundesanstalt (Physical-technical
Federal Agency), Bundesallee 100, D-38116 Braunschweig.
TÜV Akademie Bayern/Hessen GmbH (Technical Inspection
Academy of Bavaria/Hesse Ltd), Postfach 210420, Westendstraße 199, D-80686 München, Germany.
Technische Akademie Esslingen, Postfach 1265, In den Anlagen 5, 73760 Esslingen, Germany.
Organizational measures to be taken by the user
1‐49
Protection against radiation: additional
measures for the USA
Appointing a laser safety
officer
The following instances, the user must appoint a laser safety officer:
■
■
■
For class 3B or 4 laser systems.
The user operates the machine in service mode.
The user carries out adjustment and setup work in service
mode.
The area of responsibility of the laser safety officer is defined in
the ANSI standard Z136.1. The standard can be obtained from
the American Laser Institute.
Laser Institute of America (LIA)
13501 Ingenuity Drive, Suite 128
Orlando, FL 32826
www.laserinstitute.org
LIA also offers training courses for laser safety officers.
6.3
Checking the danger zone
and safety devices
Duty of care when handling the
machine
The operator must always make sure that nobody is within the
danger zone before starting up the machine.
The operator may only operate the machine using safety devices. Safety devices may not be removed or put out of operation,
except when performing maintenance and repair work. The operator must replace and put the safety devices into operation after
completing work.
Once per shift, preferably before starting the production:
■
■
Check the light grids and laser scanner for proper function.
Check the safety cabin, viewing window, partition wall and
sealing strips on the rotational changer or rotary indexing
table and on the scrap conveyor to make sure there is no
damage: do not put the machine into operation if the safety
equipment is damaged (deep scorching, holes, cracks, deformations, etc.).
After all work on safety light barriers and light grids, particularly
when the layout has changed:
■
1‐50
Check the safety light barriers and the light grids for proper
function.
Organizational measures to be taken by the user
2017-11-17
B836en
Ensuring the perfect
working order
User:
■
■
■
■
■
■
The user must ensure that the machine is installed as per
the installation plan and installation conditions.
The user must ensure that only authorized personnel works
at the machine.
The user must ensure that damaged or missing warning
signs on the machine are replaced.
The user or the persons appointed by him/her must operate
the machine when it is in perfect working order.
The user must ensure that the work station is kept clean and
tidy by issuing appropriate instructions and conducting
inspections.
The user must ensure that the working areas are supplied
with sufficient fresh air.
Operator:
■
■
Teach panel: Ensuring its
perfect working order
The operator must immediately report changes (including the
operating performance) occurring in the machine to the user.
The machine must be checked for externally visible defects
and damage at least once per shift.
The operator must immediately press the EMERGENCY
STOP push-button if a viewing window is damaged during
laser operation. Processing may only continue once the window has been properly replaced.
The gray STOP push-button on the teach panel is a safety-relevant component. It has the same functionality as an EMERGENCY STOP push-button.
The teach panel can be disconnected. The electrical interface
can then by bypassed using a plug in the scope of delivery.
The following should be observed when using the teach panel:
■
■
■
■
■
Observing the shutdown
procedure
B836en
2017-11-17
The STOP push-button is only active if the teach panel is
connected.
A disconnected teach panel must be stored in such a way as
to prevent any operating error. It must be stored e.g. in a
drawer.
When the teach panel is not used, store it in the mounting
device provided on the enclosed protective housing.
The STOP push-button must be tested in cycles. Recommendation: every 6 months.
After any severe impact to the teach panel, e.g. due to it falling down, the function of the STOP push-button must be
checked.
The prescribed shutdown procedures must be adhered to during
all operations (e.g. setting and maintenance work).
Organizational measures to be taken by the user
1‐51
Switching off the process
cooler in case of emergency
In the case of a severe malfunction at the process cooler (e.g.
leakage in the cooling water circuit), the process cooler must be
switched off immediately.
■
■
Pay attention to the user
responsibilities for the
process cooler
If the process
power supply:
or
If the process
Switch off the
cooler is switched on and off via the machine's
switch off the MAIN SWITCH of the machine
cooler has its own power supply:
MAIN SWITCH at the process cooler.
The process cooler is subject to the EU directive 2014/68/EU
about the provision of pressure devices on the market.
The user has to observe regulations and laws.
According to the European standard EN 378 for cooling systems,
the following is to be observed:
■
■
■
The operator must maintain a system log for the process
cooler.
The user must have the process cooler inspected regularly
by a qualified person and the result must be document the
test in the system log.
The user must install a quick guide in clear view and in durable form on the process cooler or the machine.
Note
The operator's manual for the cooling unit always includes one
sample for the quick guide and the information required by
EN 378 for the system log.
6.4
Pay attention to water protection
Water-pollutant substances (e.g. oil) should not enter the ground
or into water bodies.
Cooling water may be disposed off together with waste water
only in agreement with the local waste disposal authority.
The Federal Republic of
Germany
The principle of precaution is applicable for machines in the Federal Republic of Germany: water should not become contaminated when using water-pollutant substances (Federal Water Act
WHG).
The plant decree and the administrative regulations of the Federal states explain how this principle of precaution should be
adhered to.
1‐52
Water-pollutant materials
Lubricants
Water Hazard Class
1 or 2
Organizational measures to be taken by the user
2017-11-17
B836en
Volume of water-pollutant materials
≤1000 l (≤264 gal)
Hazard level of the machine
A
Water protection specifications
Outside the Federal
Republic of Germany
Outside the Federal Republic of Germany, the respective
national regulations as regards water protection must be adhered
to.
6.5
Extinguisher system
Tab. 1-11
Observe the fire safety rules
If the compact dust extractor is equipped with an extinguisher
system, the user must have the extinguisher system serviced
and checked once a year. The test must be recorded.
Maintenance work on the extinguisher system may only be carried out by service engineers from the manufacturer or other
authorized and accordingly trained personnel.
6.6
Using spare parts,
accessories and software
Using spare parts, accessories,
software and operating materials
Spare parts and accessories that have not been released by
TRUMPF (in the following: "External parts and accessories") are
not checked. Installing and using external parts and accessories
can change design-related properties of the machine and
weaken the safety.
Only software that has been approved for installation by
TRUMPF may be installed.
Liability disclaimer
■
■
Using permissible operating
materials as per the
regulations
The permissible operating materials (especially lubricating and
cleaning agents) must be used as per the regulations. If a safety
data sheet has been prescribed for the manufacturer of the operating material (European Directive 1907/2006 REACH), the
instructions in it must be followed, such as:
■
■
■
■
B836en
2017-11-17
TRUMPF is not liable for damage if external parts and
accessories are used or if spare parts and accessories
approved by TRUMPF are not installed or replaced properly.
TRUMPF cannot be held liable for damages resulting from
the installation or operation of software which is not
approved by TRUMPF.
Chemical properties.
Physical and safety-related specifications.
transport.
Regulations
Organizational measures to be taken by the user
1‐53
■
■
■
■
Safety measures, storage, and handling.
Procedures in the event of accidents or fires.
Specifications for toxicology and ecology.
Waste code with prescribed disposal method for the operating materials.
Note
Safety data sheets can be obtained from the manufacturers of
the respective operating materials.
6.7
Safety data sheet on hazardous
materials
The safety data sheets e.g. for lubricants, cleaners or gases can
be downloaded from the TRUMPF web page: http://
www.trumpf.com/s/msds.
1‐54
Organizational measures to be taken by the user
2017-11-17
B836en
7.
Overview of residual risks
The machine has residual risks in spite of its safety devices and
construction type.
The following overview of residual risks is a summary of the
main potential threats to life and limb posed by the machine.
Any additional precautions that can be taken by the machine
owner to reduce residual risks are specified in the overview of
residual risks.
For detailed descriptions of the measures: (see "Hazards",
pg. 1‐10).
Residual risk
Dangerous point
Type of danger
Measure to be taken by
the operator
While teaching
Risk of injury
■
If there is a danger
risk, immediately press
the STOP push-button
on the teach panel.
■
Do not step between
the machine body and
the barrel.
■
Do not reach between
the workpiece surface
and nozzle tip.
■
Do not go under the Z
barrel.
■
Lower the barrel before
doing maintenance
work.
■
Create a risk assessment for integration of
the fixture.
■
Observe the notes in
the operating manual.
■
For clamping fixtures
for hot-formed workpieces: Maintain a sufficiently large distance
from the fixture while
the NC program is run
in test mode.
■
For clamping fixtures
for IHU workpieces:
Before the NC program
is run in test mode,
leave the work area
and close the door
from the outside.
■
Observe the notes in
the operating manual.
Mechanical elements
Crushing
Shearing
Impacts
Z barrel: Suspended axis
within the safety cabin
Integration of fixtures by
the user
Fixtures with swivel axes
and/or pneumatically actuated clamping elements:
fast clamp movement or
swivel movement of axes
during teaching
B836en
2017-11-17
Risk of injury
Risk of injury
Risk of injury
Overview of residual risks
1‐55
Residual risk
Dangerous point
Type of danger
Measure to be taken by
the operator
Crushing
Danger zone inside the
safety cabin
Risk of fatal injury
■
Exit the safety cabin
immediately by the
nearest door in the
event of danger.
■
For all maintenance
and cleaning work,
press the EMERGENCY STOP pushbutton and leave the
service door open.
■
Only acknowledge the
danger zone when
leaving the safety
cabin.
■
Observe the notes in
the operating manual.
■
The doors to the safety
cabin must be freely
accessible from both
sides and must not be
obstructed.
■
Observe safety regulations for the handling
of heavy loads.
■
Never walk under a
suspended load.
■
Fasten workpieces or
fixtures firmly using
suitable tackle.
Shearing
Impacts
When setting up large
and/or heavy workpieces
or fixtures
Risk of fatal injury
Jammed scrap and scrap
skeleton parts in the
scrap conveyor or waste
conveyor belt.
Risk of injury
■
Before every fault elimination, de-energize the
drive motor of the
scrap conveyor: Turn
the scrap conveyor key
switch into the neutral
position.
Swivel arm
(Smart Optics Setup
option)
Risk of injury
■
Observe the notes in
the operating manual.
Remote control with MobileControl (option)
Risk of injury
■
Observe the notes in
the operating manual.
Hot workpieces
Risk of injury
■
Wear protective clothing and gloves.
■
Use gloves and tools
to remove workpieces.
Heat
Touching
Hot slag
Hot nozzle
Risk of injury
■
Wear protective gloves.
Hot sacrificial plates and
hot test sheet holder
(option,
Smart Optics Setup station)
Risk of injury
■
Wear protective gloves.
■
Observe the notes in
the operating manual.
Radiation
1‐56
Overview of residual risks
2017-11-17
B836en
Residual risk
Dangerous point
Type of danger
Measure to be taken by
the operator
Laser
Alignment laser (Pilot
laser TruDisk)
Risk of injury
■
Observe the notes in
the operating manual.
■
Do not gaze into the
laser beam.
Optical radiation
Impermissible openings in
the safety cabin with no
monitor or no LED display
Risk of injury
■
Observe the notes in
the operating manual.
Lighting within the safety
cabin
Risk of injury
■
Do not look direct into
the light source.
Cutting gas, dust, aerosols, cutting oils, PEcoated profiles
Health hazard.
■
Ventilate the workplace
sufficiently.
■
Observe the notes in
the operating manual.
Thermally decomposed
lenses or mirrors
Health hazard.
■
Observe prescribed
measures in the event
of an accident.
■
Dispose of corrupted
lenses properly.
Materials
Through contact with or
by inhaling toxic fluids,
gases, mist, vapors, and
dust.
Extinguishing gasses CO2
or argon
Health hazard.
■
After triggering the
extinguisher, ensure
proper ventilation of
the area.
Reflection of laser radiation
Risk of injury
■
Keep a powder handheld fire extinguisher
ready (fire classification
D).
■
Smoking is prohibited
■
Keep a CO2 hand-held
fire extinguisher ready
(fire classification B).
■
Keep a powder handheld fire extinguisher
ready (fire classification
D).
■
Smoking is prohibited
■
Do not turn off extinguishing gas cylinder.
■
Do not switch off the
extinguisher.
■
Reactivate the extinguisher following maintenance work on the
compact dust extractor.
Risk of injury
■
Replace the dust container on a daily basis.
Risk of injury
■
Do not enter the danger zone.
Fire and explosion
Fire hazard
Compact dust extractor
If available: extinguisher
deactivated
Machining oily sheets or
highly reactive materials
Risk of injury
Risk of injury
Malfunction or incorrect function
Malfunction / error rotational changer
The workpiece changer
stops at an undefined
position and does not
reach an end position
Magnetic fields
B836en
2017-11-17
Overview of residual risks
1‐57
Residual risk
Dangerous point
Type of danger
Measure to be taken by
the operator
Magnetic field of the permanent magnet, regardless of whether the
machine is switched on or
off
On the surface of the
magnetic coupling on the
B/C gearbox of the Z barrel
Danger to life of persons
with pacemakers
■
Persons with pacemakers must keep a minimum distance of 30
cm to the magnetic
coupling on the Z barrel.
Ferromagnetic attractive
force when no voltage is
present
On the surface of the
magnetic coupling (without
processing optics)
Attractive force of the permanent magnet (300 N)
takes effect suddenly
■
Do not hold metallic
objects, watches, etc.,
up against the magnetic coupling.
On the surface of the
magnetic coupling (without
processing optics)
Attractive force of the primary part (1000 N) takes
effect suddenly
■
Do not hold metallic
objects, watches, etc.,
up against the magnetic coupling.
Components with residual
voltage
Risk of fatal injury
■
The residual voltage is
>60 V. Note a discharge time of more
than 5 s (see warning
sign).
The mains disconnector
does not switch off when
opening the electrical cabinet doors
Risk of fatal injury
■
Observe warning stickers.
■
Work on electrical
facilities may only be
carried out by a trained
electrician or a person
with electrical engineering training.
Movements of the
machine
Risk of injury
■
Have Teleservice performed only by persons
who have been trained
by TRUMPF.
■
If the danger zone has
to be accessed: assign
a second person with
safeguarding.
■
Reduce the speed of
dangerous movements
as far as possible.
Electrics
Electric shock
Teleservice
Crushing, cutting, separating, impacting
Residual risks
1‐58
Tab. 1-12
Overview of residual risks
2017-11-17
B836en
8.
Machines without complete safety
equipment
8.1
Operating safety
If the machine is supplied and operated without the complete
array of safety equipment, then there will be certain hazards connected with the operation of the machine, e.g.:
■
■
■
■
Unsecured danger zone.
Danger due to laser radiation.
Danger due to secondary radiation.
Danger from dusts and gases.
The operator is obligated to implement suitable measures for the
operational safety of the machine:
■
■
■
■
■
■
The operator needs to be informed of the dangers originating
in the machine.
The danger zone around the machine, including projectrelated handling components need to be secured with appropriate measures.
The user must mark the danger zone and place suitable
warning signs in view.
For machines without compact dust extractors (filter system),
the working area needs to be vacuum-cleaned effectively.
Dust which accumulates needs to be disposed of properly.
Machines without safety cabins must provide the operator
and other personnel in the danger zone of the machine with
protection against laser radiation and secondary radiation.
In the case of machines with a depression in the work area,
adequate measures must be applied to secure the danger
zone.
When partly completed machinery is operated in the EC region,
the owner must take suitable measures for operational safety to
meet the requirements of the EC Machinery Directive
2006/42/EC.
B836en
2017-11-17
Machines without complete safety equipment
1‐59
8.2
Suction system in the work area
For machines supplied without compact dust extractor and/or
without scrap conveyor, the user must extract dust from the
machine's work area effectively. If the exhaust system is insufficient then neither the continued operation of the machine nor
compliance with the permissible emission values can be guaranteed.
WARNING
Health hazard due to insufficient or no dust extraction at
the work area!
Ø
NOTICE
The machine must not be put into operation if dust extraction is insufficient in the work area.
Insufficient or no dust extraction at the work area.
Damage to the guide rails and drive by laser dust accumulating in the work area.
Ø
Ø
The following specification for a filtering installation to be
provided by the customer must be ensured.
The following specification for waste disposal by the customer must be ensured.
If a customer's filter system/filtering device is integrated, the user
is obliged to comply with the following specification:
■
■
■
The required suction power (volume rate of flow) at the
extraction inlets is in all at least 4500 m3/h (per extraction
inlet 2250 m3/h).
The flow speed in the suction channel of the customer's piping has to be at least 15 m/s at all points along the entire
length of the piping.
The underpressure inside the safety cabin must be at least
11.5 Pa (test pressure).
If a scrap conveyor to be provided by the customer is integrated,
the user is obliged to comply with the following specification for
the design of the exhaust piping in the work area:
■
■
■
■
1‐60
There are at least 2 exhaust inlets in the safety cabin.
The total suction power at the exhaust inlets is a minimum of
4500 m3/h (2250 m3/h per extraction point).
The distance of the exhaust inlets from the machining position is no more than 500 mm.
The underpressure inside the safety cabin must be at least
11.5 Pa (test pressure).
Machines without complete safety equipment
2017-11-17
B836en
8.3
Laser class
Laser safety
Laser machines without safety cabins are categorized as Class 4
laser systems in accordance with EN 60825-1.
Invisible, high-energy laser radiation
DANGER
Serious burns of the skin and injury to the eyes may occur.
Impairment of vision or even complete blindness can be the
consequence.
Ø
Ø
Ø
Ø
No personnel are permitted to be present in the machine's
danger zone during machining.
The areas where the operator is to be found during machining operations need to be marked and properly secured.
The operator must be protected against hazardous laser
radiation during processing operations: personal protective
gear is necessary, and laser safety glasses are to be worn.
The machining may not be started until all other personnel
have been cleared from the danger zone of the machine.
Identification of the laser
system
Class 4 laser product
Tab. 1-13
8.4
Secondary radiation
For machines without a safety cabin, the operator will be
exposed to hazardous secondary radiation during the laser processing. The secondary radiation It is composed of ultraviolet (<
400 nm), harsh, visible and infrared radiation (> 780 nm).
Danger due to secondary radiation during laser processing
DANGER
Intense visible and invisible radiation can irreversibly
damage the retina in your eyes as well as your skin.
Ø
B836en
2017-11-17
The operator must be protected from secondary radiation.
Machines without complete safety equipment
1‐61
8.5
Overview of residual risks
The following overview of residual risks is a summary of the
main potential threats to life and limb posed by the machine.
Any additional precautions that can be taken by the machine
owner to reduce residual risks are specified in the overview of
residual risks.
The residual risks differ depending on the delivery version of the
machine.
Residual risk
Dangerous point
Type of danger
Measure to be taken by
the operator
Motion of the X, Y, Z, B
and C axis
Risk of injury
■
Secure danger zone.
Movement of project-specific workstations or
clamping stations
Risk of injury
■
Secure danger zone.
Movement of project-specific material supply and
removal equipment
Risk of injury
■
Secure danger zone.
While teaching
Risk of injury
■
If there is a danger
risk, immediately press
the STOP push-button
on the teach panel.
■
Do not step between
the machine body and
the barrel.
■
Do not reach between
the workpiece surface
and nozzle tip.
Mechanical elements
Crushing
Shearing
Impacts
1‐62
Z barrel: Suspended axis
within the safety cabin
Risk of injury
■
Do not go under the Z
barrel.
Fixtures with swivel axes
and/or pneumatically actuated clamping elements:
fast clamp movement or
swivel movement of axes
during teaching
Risk of injury
■
For clamping fixtures
for hot-formed workpieces: Maintain a sufficiently large distance
from the fixture while
the NC program is run
in test mode.
■
For clamping fixtures
for IHU workpieces:
Before the NC program
is run in test mode,
leave the work area
and close the door
from the outside.
■
Observe the notes in
the operating manual.
Machines without complete safety equipment
2017-11-17
B836en
Residual risk
Dangerous point
Type of danger
Measure to be taken by
the operator
Crushing
Danger zone inside the
safety cabin
Risk of fatal injury
■
Check the danger zone
in the safety cabin
before each restart or
following an interruption.
■
In case of danger,
leave the danger zone
immediately.
■
For all maintenance
and cleaning work,
press the EMERGENCY STOP pushbutton and leave the
service door open.
■
Observe the notes in
the operating manual.
Shearing
Impacts
For machines with a pit in
the work area, e. g. for
disposing of scrap material.
Risk of injury
■
Secure danger zone.
Jammed scrap and scrap
skeleton parts in the
scrap conveyor or waste
conveyor belt.
Risk of injury
■
Before every fault elimination, de-energize the
drive motor of the
scrap conveyor: Turn
the scrap conveyor key
switch into the neutral
position.
Swivel arm
(Smart Optics Setup
option)
Risk of injury
■
Observe the notes in
the operating manual.
Remote control with MobileControl (option)
Risk of injury
■
Observe the notes in
the operating manual.
Movement of rotating
work or clamping stations
(project-specific)
Risk of injury
■
Secure danger zone.
Cutting gas
Risk of injury
■
Secure danger zone.
Compressed air reservoir
Risk of injury
■
Secure danger zone.
Thermal radiation or spurting melted parts
Ejected slag spatters
Risk of injury
■
Secure danger zone.
Touching
Hot workpieces
Risk of injury
■
Wear protective clothing.
■
Use gloves and tools
to remove workpieces.
Getting caught or due to
winding
Due to fluids and gases
being expelled under high
pressure
Heat
Hot nozzle
Risk of injury
■
Wear protective gloves.
Hot sacrificial plates and
hot test sheet holder
(option,
Smart Optics Setup station)
Risk of injury
■
Wear protective gloves.
■
Observe the notes in
the operating manual.
Radiation
B836en
2017-11-17
Machines without complete safety equipment
1‐63
Residual risk
Dangerous point
Type of danger
Laser
In machines without a
safety cabin: radiation during machining
Health hazard, blindness
Pilot laser TruDisk
Light source
Measure to be taken by
the operator
Risk of injury
■
Secure danger zone.
■
Determine and mark
the position of the
operator during
machining
■
Wear protective clothing and laser safety
glasses.
■
Do not gaze into the
laser beam.
■
Observe the notes in
the operating manual.
Impermissible openings in
the safety cabin with no
monitor or no LED display
Risk of injury
■
Observe the notes in
the operating manual.
For machines without a
safety cabin: Secondary
radiation during processing
Permanent damage to the
retina in your eyes and to
your skin
■
Observe the notes in
the operating manual.
Lighting within the safety
cabin
Risk of injury
■
Do not look direct into
the light source.
Cutting gas, dust, aerosols, cutting oils, PEcoated profiles
Health hazard.
■
Vacuum clean the
working range.
■
Ventilate the workplace
sufficiently.
■
Dispose of dust properly.
■
Observe prescribed
measures in the event
of an accident.
■
Dispose of corrupted
lenses properly.
■
After triggering the
extinguisher, ensure
proper ventilation of
the area.
Materials
Through contact with or
by inhaling toxic fluids,
gases, mist, vapors, and
dust.
Thermally decomposed
lenses or mirrors
Extinguishing gasses CO2
or argon
Health hazard.
Health hazard.
Fire and explosion
1‐64
Machines without complete safety equipment
2017-11-17
B836en
Residual risk
Dangerous point
Type of danger
Measure to be taken by
the operator
Fire hazard
Reflection of laser radiation
Risk of injury
■
Keep a powder handheld fire extinguisher
ready (fire classification
D).
■
Smoking is prohibited
■
Keep a CO2 hand-held
fire extinguisher ready
(fire classification B).
■
Keep a powder handheld fire extinguisher
ready (fire classification
D).
■
Smoking is prohibited
■
Vacuum clean the
working range.
■
Ventilate the workplace
sufficiently.
■
Smoking is prohibited
■
Do not turn off extinguishing gas cylinder.
■
Do not switch off the
extinguisher.
■
Reactivate the extinguisher following maintenance work on the
compact dust extractor.
Risk of injury
■
Replace the dust container on a daily basis.
The workpiece changer
stops at an undefined
position and does not
reach an end position
Risk of fatal injury
■
Do not enter the danger zone.
Magnetic field of the permanent magnet, regardless of whether the
machine is switched on or
off
On the surface of the
magnetic coupling on the
B/C gearbox of the Z barrel
Danger to life of persons
with pacemakers
■
Persons with pacemakers must keep a minimum distance of 30
cm to the magnetic
coupling on the Z barrel.
Ferromagnetic attractive
force when no voltage is
present
On the surface of the
magnetic coupling (without
processing optics)
Attractive force of the permanent magnet (300 N)
takes effect suddenly
■
Do not hold metallic
objects, watches, etc.,
up against the magnetic coupling.
On the surface of the
magnetic coupling (without
processing optics)
Ferromagnetic attractive
force when live
■
Do not hold metallic
objects, watches, etc.,
up against the magnetic coupling.
Compact dust extractor
Concentration of dust in
the working area
If available: extinguisher
deactivated
Machining oily sheets or
highly reactive materials
Risk of injury
Risk of injury
Risk of injury
Malfunction or incorrect function
Malfunction/error case in
the workpiece changer
Magnetic fields
Electrics
B836en
2017-11-17
Machines without complete safety equipment
1‐65
Residual risk
Dangerous point
Type of danger
Measure to be taken by
the operator
Electric shock
Components with residual
voltage
Risk of fatal injury
■
The residual voltage is
>60 V. Note a discharge time of more
than 5 s (see warning
sign).
The mains disconnector
does not switch off when
opening the switch
cabinet doors
Risk of fatal injury
■
Observe warning stickers.
■
Work on electrical
facilities may only be
carried out by a trained
electrician or a person
with electrical engineering training.
Movements of the
machine
Risk of injury
■
Have Teleservice performed only by persons
who have been trained
by TRUMPF.
■
If the danger zone has
to be accessed: assign
a second person with
safeguarding.
■
Reduce the speed of
dangerous movements
as far as possible.
Teleservice
Crushing, cutting, separating, impacting
Residual hazards connected with machines lacking complete safety equipment
1‐66
Machines without complete safety equipment
2017-11-17
Tab. 1-14
B836en
9.
Disassembly and disposal
TRUMPF recommends that TRUMPF machine tools be disassembled and disposed of by Technical Customer Support or a
specialist disposal company. The following notes are to be
passed on to the specialist disposal company performing the disposal work, to guarantee fast, environmentally sound and safe
disposal.
The following points should be observed when disposing of a
TRUMPF machine tool.
Preparing disassembly
■
■
■
■
■
■
Overview of hazardous
materials
Contamination, in particular types of dust which can be stirred up or which be hazardous during disassembly are to be
removed.
Close off the disassembly and storage area over a wide
area.
Move down movable parts and suspended loads as far as
possible. Secure or support suspended loads in the event of
a defective machine.
Have the machine disconnected from the power supply by a
trained electrician.
If available: close off the compressed air and gas supply and
disconnect from the machine.
Wait at least an hour to allow any residual voltage in the
machine to dissipate and hot components to cool down. All
assemblies/components can then be touched.
The following hazardous substances are to be disposed of
according to applicable legislation prior to disassembly:
Hazardous substance
Installed in assembly
Arsenic
Diodes (Solid-state laser)
Refrigerant
Lubricant container (e.g. central
lubrication)
Basic machine
Cooling water with biocides
Process cooler
Filter plates
Compact dust extractor
Metal dust
Compact dust extractor
Batteries
Electrical cabinet, APC, control system, ...
Possible hazardous substances
Declaration of substances in
acc. with GB/T 26572‑2011
(China RoHS 2)
B836en
2017-11-17
Tab. 1-15
The declaration of substances is only necessary for the area of
application in China.
Disassembly and disposal
1‐67
Conformity label at the nameplate
Part designation
Fig. 82463
Hazardous substances
Lead
Mercury
Cadmium
Hexavalent
chromium
Polybrominated
biphenyls
Polybrominated
diphenyl
ethers
(Pb)
(Hg)
(Cd)
(Cr+6)
(PBB)
(PBDE)
Basic
machine
X
O
O
O
O
O
Laser
X
O
O
O
O
O
Dust extractor
X
O
O
O
O
O
Process
cooler
X
O
O
O
O
O
Automation
components
(option)
X
O
O
O
O
O
O:
Indicates that this hazardous substance is present in all homogeneous materials for the parts listed. In terms of
EIP-A, EIP-B and EIP‑C, the value is below the limit stipulated in GB/T 26572‑2011.
X:
Indicates that this hazardous substance in all homogeneous materials in terms of EIP-A, EIP-B and EIP-C is
above the limit value stipulated in GB/T 26572‑2011.
Comments: Tab. 1-16
Dismantling
■
■
■
■
1‐68
Poisonous vapors can result when thermally cutting painted
components or components made out of composite materials!
− Select a suitable cutting process.
or
− Wear a suitable protective mask and ensure there is a
sufficient supply of fresh air.
Secure top-heavy assemblies to prevent them from tipping
over and carefully put them in a good transport position (center of gravity down).
Moving assemblies may be unbraked after being disconnected from the power supply!
− Fix movable assemblies prior to disassembly/transport, so
that the center of gravity cannot move in an uncontrolled
manner.
Mechanical stresses can be released when undoing chains,
ropes and steel constructions!
− Wear suitable protective gear and close off the area over
a wide area.
Disassembly and disposal
2017-11-17
B836en
Transporting assemblies
■
■
■
B836en
2017-11-17
Close off transport routes and storage positions over a wide
area.
Use suitable lifting gear. See installation conditions.
Fasten assemblies above the center of gravity as far as possible.
Disassembly and disposal
1‐69
1‐70
Disassembly and disposal
2017-11-17
B836en
Chapter 2
Installation conditions
TruLaser Cell 8030 (L60)
To what does this apply?
2‐4
1
Planning aid
2‐5
2
Installation site
2‐9
2.1
Space requirements
2‐9
2.2
Floor requirements
2‐9
2.3
Weight load
2‐11
2.4
Ambient conditions
2‐12
2.5
Installation of compact dust extractor
2‐15
2.6
Suction system in the work area
2‐17
2.7
Installation of the process cooler
2‐17
External cooling circuit
2.8
Cable racks for laser light cables
2‐24
2.9
Customer screen options
2‐25
Installing the monitor
B836en
2‐18
Installation conditions TruLaser Cell 8030 (L60) Version 4
2‐27
2‐1
2‐2
3
Gas supply
2‐28
3.1
Cutting gases
2‐29
Purity
2‐29
Cutting gas consumption
2‐29
Supply lines for cutting gas supply
2‐30
Requirements on the connection point of
the machine
2‐31
Cutting gas supply with cylinders or bundles
2‐31
Cutting gas supply with gas tank
2‐32
4
Electric power supply
2‐34
4.1
Electrical connection
2‐34
4.2
Power supply
2‐36
4.3
Connected load and fuse protection
2‐37
Central power supply
2‐37
Decentralized power supply
2‐38
4.4
Teleservice
2‐42
4.5
Network connection
2‐42
5
Compressed air supply
2‐43
6
Operating materials
2‐46
6.1
Gases
2‐46
6.2
Cooling water
2‐46
6.3
Dispensing material for MultiCoater
2‐49
7
Transport
2‐50
7.1
Dimensions and weights of the transport units
2‐52
7.2
Transporting machine and machine components
2‐56
Transporting basic machine with truck
2‐57
Loading and unloading container
2‐59
Transporting the basic machine to the
installation site
2‐60
Transport TruDisk laser device
2‐61
Transport rotational changer with a crane or
forklift
2‐62
Transporting rotary indexing table with
crane or forklift truck
2‐63
Transporting the safety cabin
2‐64
Transportation of scrap conveyor
2‐65
Installation conditions TruLaser Cell 8030 (L60) Version 4
B836en
7.3
Transporting the compact dust extractor
(Herding)
2‐65
Transporting process cooler
2‐66
Transporting the safety cabin
2‐66
Installing the system
Preparing the factory floor
B836en
Installation conditions TruLaser Cell 8030 (L60) Version 4
2‐66
2‐66
2‐3
To what does this apply?
The installation conditions contain all information for the installation of the machine including the following lasers:
TruDisk 2000, TruDisk 3001 and TruDisk 4001.
The TruLaser Cell 8030 is a system for laser cutting metallic
materials.
Machining of plastic materials is not permitted!
Who does what?
Customer: All the conditions described in this chapter must be
fulfilled before the machine is delivered. If this is not the case,
the TRUMPF service engineers will not be able to start up the
machine.
Pass along the respective subsections in accordance with the
following planning aid to the specialist companies/plants (e.g.
electrical installer, specialist plant for industrial gases...) in a
timely manner.
Note
During start-up, the main switch on the machine may only
be switched on by TRUMPF service engineers.
Technical Service: Start-up of the machine is performed by the
service engineer. It includes the following activities.
■
■
■
■
■
■
2‐4
Installing, aligning, leveling and securing the machine.
Laying laser light cable.
Filling up the process cooler.
Connecting the machine to the supplies (with the exception
of the electrical power supply).
Performing a functional test.
Instructing personnel.
Installation conditions TruLaser Cell 8030 (L60) Version 4
B836en
1.
Planning aid
The planning aid checklist below provides an overview of the
measures and preparations to be undertaken by the customer.
Detailed information can be found in the respective sections of
the installation conditions.
Time before
the delivery of
the machine
Planning criterion
14 weeks
Personnel and
training
Measures
-
Measure
implemented
Appoint a member of staff to be
responsible for the handover of the
machine.
Appoint operating and service
personnel and programmers.
Arrange training schedules for specialist
personnel.
Check whether a laser safety officer is
needed. Observe national laws and regulations (Germany: DGUV regulation 11). Further information in the
standards: IEC/EN 60825 and
ANSI Z136.1 (for the USA)
14 weeks
Installation site
See Section 2,
Installation site
(see "Installation
site", pg. 2‐9)
Check space requirements as specified
in the installation plan.
Check the floor requirements (floor
quality, how level it is, oil-proof floor
without expansion joints). Keep the
weight and dimensions of the machine
in mind.
Check that the requirements for the
ambient conditions are met (ambient
temperature, insolation, purity of ambient air.)
Contact the responsible government
agency to determine whether the purified exhaust air of the compact dust
extractor must be channeled outdoors.
Check the transport route (gateway
dimensions, header heights, cable rack
heights, space to maneuver around corners etc.).
12 weeks
B836en
Gas supply
See Section 3,
Gas supply (see
"Gas supply",
pg. 2‐28)
Arrange for the installation of supply
lines for welding gas and cutting gas
supply to the installation site.
Decide about the gas supply method
(gas cylinders, cylinder bundles or gas
tank).
Planning aid - Version 4
2‐5
Time before
the delivery of
the machine
Planning criterion
12 weeks
Electrical supply
Measures
See Section 4,
Electrical power
supply (see
"Electric power
supply",
pg. 2‐34)
Measure
implemented
Install electrical connections on the
installation site. The conductor crosssection and fuse protection should be
installed in accordance with legal
requirements.
Note: There can be a different number
of connections depending on the configuration.
4 weeks
Operating materials
see Section 6,
Operating materials (see "Operating materials",
pg. 2‐46)
■
In default: The basic machine, the
laser device and the process cooler
for the laser device each require a
separate electrical connection.
■
Central power supply option: A
shared electrical connection is installed for the basic machine, the laser
device and the process cooler
(chiller). If a user's process cooler is
to be connected, a connection cable
for the process cooler is required.
Stock up on operating material: cutting
gases and cooling water.
Dispensing material if a MultiCoater is
used (option).
Please note:
■
Cooling water in the required quantity and quality is to be provided for
the commissioning.
■
"High purity ethylene glycol" must be
provided for the commissioning of
the process cooler if it is to be
installed in areas vulnerable to frost.
4 weeks
Teleservice
See Section 4,
Electrical power
supply (see
"Electric power
supply",
pg. 2‐34)
Provide access to the internet.
4 weeks
Network connection
See Section 4,
Electrical power
supply (see
"Electric power
supply",
pg. 2‐34)
The network connection requires a separate power supply.
2‐6
Planning aid - Version 4
B836en
Time before
the delivery of
the machine
Planning criterion
4 weeks
Fire protection
Measures
-
Measure
implemented
Keep the following fire extinguisher
ready at the machine for reasons of fire
protection:
■
If the compact dust extractor is
equipped with a CO2-extinguisher:
CO2 fire extinguisher (fire classification B)
■
If the compact dust extractor is
equipped with an argon extinguisher:
powder extinguisher (fire classification D).
■
Hand-held fire extinguisher for metal
fires (fire classification D).
4 weeks
Transport
See Section 7,
Transport (see
"Transport",
pg. 2‐50)
If you are transporting the machine to
the installation site yourself, ensure the
required means of transportation and
transport aids are available.
4 weeks
Laser safety
-
Observe the regulations applicable in
the country of operation.
Valid for Germany:
Register the laser machining system
with the employer's liability insurance
association and with the trade board.
Make laser safety glasses available for
service work, safety glasses for laser
light with a wavelength of 1030 nm.
4 weeks
Planning aid
preparation
installation and
start-up
-
Check whether all necessary measures
for preparing installation and commissioning of the machine have been
taken.
Send the "Installation and start-up planning aid" to Technical Service in the
respective country or to the respective
representative.
4 weeks
Foundation
See Section 7.2,
Installing the
system (see
"Installing the
system",
pg. 2‐66)
Prepare the foundation of the basic
machine according to the foundation
plan. Apply bore holes and cut-outs.
4 weeks
Cable rack for
laser light cable
See Section 7.2,
Installing the
system (see
"Installing the
system",
pg. 2‐66)
Please note: If no "standard cable
rack" is installed, the user must install
the cable racks himself in which the
laser light cable is routed from the laser
installation site to the machine.
4 weeks
Accessories
option
Access Control Key
-
B836en
Planning aid - Version 4
2‐7
Time before
the delivery of
the machine
Planning criterion
During the delivery of the
machine
Transport
Measures
See Section 7,
Transport (see
"Transport",
pg. 2‐50)
Measure
implemented
If the customer transports the machine
to the installation site himself:
■
Make the required means of transportation available.
■
Have qualified transport personnel
available.
Note: TRUMPF Technical Service provides the required means of transportation and auxiliary transport equipment
when assigned with conveying the
machine to the customer's site.
During installation and start-up
of the machine
Qualified electricians
-
Have qualified electricians available to
connect the system.
Check list for planning aid
Tab. 2-1
2‐8
B836en
Planning aid - Version 4
2.
What does the customer
need to do?
Platform installation
Installation site
Please consult a structural analyst for professional support, particularly in connection with the topic of floor requirements, and
give him a copy of the pertinent section.
If supply units of the machine, such as process coolers, compact
dust extractors or electrical cabinets, are put up on a platform,
note the following:
■
■
■
The platform does not belong to the machine's scope of
delivery.
The platform must meet applicable standards and national
regulations concerning safety of being stepped on.
Leaking water, oil or other operating materials have to be
captured.
2.1
Space requirements
An installation plan is created for each machine. The required
space for opening the doors of the control cabinet, suction system and the laser device is illustrated there.
Any subsequent supplementations to the machine by the customer, for example automation components, are not included in
the installation plan and must be taken into account by the operator.
2.2
Flatness
■
■
Installation surface
■
■
B836en
Floor requirements
The floor on which the machine is installed should be as
even as possible. Minor unevenness can be compensated for
using adjustable legs or wedge mounts.
In the range of the machine's installation surface, the height
variation may not exceed 12 mm per 10 m. In the range of
the safety doors at the front and the side, for laser safety
reasons the floor's height variation must not exceed 5 mm .
The installation surface for the basic machine must consist of
a continuous base plate in the area of the load-bearing
points.
There may not be any expansion joints between the loadbearing points.
Installation site - Version 4
2‐9
■
■
In the area around the wedge mounts plastic or asphalt
coatings are not permissible
In the case of newly laid floor/ceiling plates, it is imperative
e.g. during the drying process, to avoid settling effects which
would exceed the maximum values indicated above.
External influences due to changing loads in the immediate vicinity of the machine can affect the quality of the workpieces.
These are e.g.:
■
■
■
Fork lifts, industrial trucks, etc.
The installation or removal of other machines in the immediate vicinity of the machine.
Machines which excite vibrations during operation, such as
punch presses etc.
Note
Exact inspections must be conducted in individual cases.
Flexible base plate
■
■
■
Load capacity 20 kN/m2.
Minimum thickness 250 mm.
Concrete quality (corresponding to a strength class of
C 25/30):
− Cylinder compressive strength fck, cyl ≥ 25 N/mm2.
−
■
Cube compressive strength fck,
cube
≥ 30 N/mm2.
Concrete steel reinforcement with:
− characteristic rated value fy ≥ 435 N/mm2.
−
an elasticity module for which Es ≥ 200000 N/mm2.
−
■
■
Ceiling plate/free span base
plate
a reinforcement at the top, crosswise for each 3.7 cm2/m.
− a reinforcement at the bottom, crosswise for each
3.7 cm2/m.
Elastic cushioning of the base plate on foundation with a
minimum ballast number of C ≥ 5000 kN/m3 (loess loam).
No joint of any kind, nor any dummy joint (separated shielding panel) may be located in the area of the machine or
within at least 1.0 m of it.
■
Load capacity 20 kN/m2.
■
Minimum thickness 250 mm (for load capacity 20 kN/m2).
As a fundamental principle, the statics of the ceiling or floor plate
on hand must be checked by a structural analyst.
Maximum stress due to
vibration for TruDisk laser
Acceleration of vibration
0.01 g (100 mm/s2)
Maximum stress due to vibration in vertical direction
Tab. 2-2
If the vibration at the installation site is higher, then shockabsorbing pads must be used. To correctly dimension the shock-
2‐10
Installation site - Version 4
B836en
absorbing pads, the vibration at the installation site must be
measured.
2.3
Structural stress analysis
Foundation load
Weight load
The load capacity of the floor surface must be subjected to a
structural stress analysis prior to installation. The weights of the
relevant components and the loads on the support points can be
taken from the following overview.
Component
Weight
in kg
Distribution of
weight
Basic machine TruLaser Cell
8030, including switch cabinet
9100
Weight is distributed
over 10 wedge
mounts (surface 120
mm x 175 mm). The
wedge mounts on the
extension arm side
carry approx. 2/3 of
the total load.
Compact dust extractor
DELTA Comp 1500-14/9 SB
-
The edges support the
main load.
- without soundproofing cover
1250
- with soundproofing cover
1350
MultiCoater type 55/1 (option)
170
-
Workpiece changer:
-
-
- Rotational changer
2500
- Rotary indexing table (option)
4500
Weight is evenly distributed over 8 surfaces.
Scrap conveyor:
-
-
- For rotational changer
1270
- For rotary indexing table
(option)
1500
Weight is evenly distributed over 12 surfaces.
Basic machine system components
Tab. 2-3
Laser device filled with cooling
water
Weight
in kg
Distribution of
weight
TruDisk 2000
470
TruDisk 3001
470
TruDisk 4001
470
Weight is evenly distributed over 4 adjustable legs.
Laser device TruDisk
B836en
Tab. 2-4
Installation site - Version 4
2‐11
The following table is valid for water/air process coolers manufactured by Riedel, product group type RLxx/0 SR (TR):
Machine without machine cooler
Machine with machine cooler
Laser device
Process cooler
filled
Weight in kg
Process cooler
filled
Weight in kg
TruDisk 2000
RL13/0
300
RL10/0
300
TruDisk 3001
RL17/0
410
RL17/0
410
TruDisk 4001
RL20/0
440
RL17/0
410
Process cooler, chiller for TruDisk
Distribution of
weight
Weight is evenly
distributed over
4 adjustable
legs.
Tab. 2-5
The following table is valid for water/water process coolers
manufactured by Riedel, product group type RWxx/0 SR (TR):
Machine without machine cooler
Machine with machine cooler
Laser device
Process cooler
filled
Weight in kg
Process cooler
filled
Weight in kg
TruDisk 2000
RW13/0
300
RW13/0
300
TruDisk 3001
RW17/0
400
RW13/0
300
TruDisk 4001
RW20/0
400
RW17/0
400
Process cooler, chiller for TruDisk
Weight is evenly
distributed over
4 adjustable
legs.
Tab. 2-6
2.4
Ambient temperature
Distribution of
weight
Ambient conditions
Notes
■
■
Avoid one-sided, direct exposure to sunlight or drafts coming
from one side.
Keep the ambient temperature constant while operating the
machine. Ensure sufficient circulation of air in the factory hall.
Temperature
Operation
between +10 °C and +43 °C
Storage
between +5 °C and +43 °C
Permissible machine ambient temperature
Tab. 2-7
Temperature
Operation
between +10 °C and +50 °C
Storage
Relative air humidity
(see dew point diagram)
2‐12
Installation site - Version 4
maximum 100% at 28°C
Tropical version: maximum of 100 % at 32 °C
B836en
Temperature
Protection class
IP 54 with closed doors and covers
Note: If the environment is exposed to large
quantities of dust or aerosol, TRUMPF recommends a housing for the laser device.
Permissible ambient temperature TruDisk
Dew point
Tab. 2-8
Dew point diagram TruDisk 2000:
U
Ambient temperature
RL Relative humidity
Dew point diagram
Fig. 88327
Dew point diagram TruDisk 3001, TruDisk 4001:
t
Ambient temperature
RL Relative humidity
Dew point diagram
Fig. 87523
When operating the laser device, the values must be within the
gray area of the dew point diagram.
B836en
Installation site - Version 4
2‐13
The closer the ambient conditions are to the limit values shown
in the diagram, the longer the advance time of the air cleaner
can become. In some cases, it is advisable to leave the laser
control system, and thus the air treatment, switched on.
If the required ambient conditions cannot be maintained, appropriate conditions must be created artificially for the laser device
(e.g. cabin, air-conditioning).
Tropical version
When the ambient temperature is between +35°C and +43°C the
machine is delivered in tropical version.
Switch cabinet cooling
The air conditioning unit sucks the warm air from the switch cabinet and blows cold air back into the switch cabinet. Cooling is
switched off while the switch cabinet doors are open.
Note
Damp rooms are not suitable for the operation of the control systems, mainly because contact corrosion can develop on contactors and relay contacts, resulting in control system errors.
2‐14
Installation site - Version 4
B836en
2.5
Installation of compact dust extractor
The machine is standard equipped with a Herding compact dust
extractor. The air in the machine's work area is extracted and is
conducted via a pipeline system to the compact dust extractor,
where it is cleaned.
Note
The compact dust extractor may only be installed in the interior
space.
International/national
regulation
Regulation outside of Germany:
■
The user must comply with the national regulations for handling the exhaust air of the compact dust extractor and the
dusts it contains.
Regulation in Germany:
■
■
Exhaust air system
The exhaust air system beginning at the clear gas duct port of
the compact dust extractor must be installed by the customer.
The pipeline must be installed as follows:
■
■
■
B836en
For the laser processing of stainless steel and materials from
which harmful substances can arise as suspended dust, the
exhaust air of the compact dust extractor must be conducted
to the outdoors.
− In Germany, the limits for the return of cleaned air into
the room air are defined in "Technical Rules for Hazardous Materials TRGS 560".
For the laser processing of mild steel or aluminum, for example, the cleaned air of the compact dust extractor may be fed
back into the room air.
Max. of two 90° tube bends (radius = diameter x 1.5).
Max. length: 10 m.
Tube diameter: at least 300 mm.
Installation site - Version 4
2‐15
A
without soundproofing
B
with soundproofing
Clear gas duct connection according to DIN 24154-R2
MultiCoater (option)
Fig. 73826
The compact dust extractor may be optionally equipped with a
MultiCoater.
The MultiCoater may only be installed in the interior space.
2‐16
Installation site - Version 4
B836en
2.6
Suction system in the work area
If a waste conveyor provided by the customer and/or a filtering
installation provided by the customer are/is to be integrated, a
sufficient and effective exhaust system must be provided in the
work area. Continued operation of the machine cannot be guaranteed if the exhaust system is insufficient.
Exhaust system
requirements if a customer's
waste conveyor is integrated
If a scrap conveyor to be provided by the customer is integrated,
the user is required to comply with the specification recommended by TRUMPF for the design of the exhaust piping in the
work area.
All on-site measures should be implemented in accordance with
the specification "Interface for Integration of the Scrap Conveyor
to be Provided by the Customer", drawing no. 93964-425-A50.
In this case, this interface description belongs to the project layout.
Exhaust system
requirements if a customer's
filtering installation is
integrated
If a customer's filtering installation is integrated, the user is obligated to comply with the following specification:
■
■
■
The total suction power at the exhaust inlets is a minimum of
4500 m3/h (2250 m3/h per extraction point).
The flow speed in the suction channel of the customer's piping has to be at least 15 m/s at all points along the entire
length of the piping.
It must be ensured that no dust is deposited in the pipeline.
The underpressure inside the safety cabin must be at least
11.5 Pa (test pressure).
Note
The filtering installation belongs to the safety equipment of the
laser machine. The filtering installation is a significant feature for
the issue of the EU declaration of conformity. In order to issue
an EU declaration of conformity for the laser machine, the filtering installation provided by the customer must meet the safety
requirements defined by TRUMPF.
2.7
Installation of the process cooler
Note
The standard-process cooler is not suitable for outdoor installation.
B836en
Installation site - Version 4
2‐17
Outdoor installation
If the process cooler is installed outdoors, the following must be
observed:
■
■
■
■
■
■
Process coolers for outdoor installation have their own main
switch and require a separate power supply.
Process coolers for outdoor installation have tank heating.
At an ambient temperature under 0 °, the MAIN SWITCH of
the process cooler may not be switched off.
At an ambient temperature of < 6 ° ethylene glycol must be
added to the cooling water.
The installation surface for the process cooler must be
designed in such a way that no escaping water or oil passes
into the ground.
A weather protection cover, or weather protection hood is
required for the process cooler. In order to allow access for
maintenance and repair work, comply with the minimum distances as shown in the drawing.
Example: Minimum distances for the weather protection
cover
Process cooler laser device
Fig. 39478
The laser device is delivered with an external process cooler
(chiller). The chiller is connected to the internal cooling circuit of
the laser device.
External cooling circuit
Note
This section is only relevant if the user connects the laser device
TruDisk to an on-site in-house water system or to a process
cooler provided by the user.
2‐18
Installation site - Version 4
B836en
What does the customer
need to do?
B836en
The user sets out the external cooling circuit according to the
performance data which follows and connects the in-house water
connections or the process cooler to the laser device.
Installation site - Version 4
2‐19
Requirements on an external
cooling circuit
The laser device may be connected to an on-site in-house water
system or to a process cooler provided by the user.
Supply and return connections on the laser device
Hose fitting with 1" outside diameter or union nut with 1 1/4" internal thread
Permitted connection materials
V2A, V4A, brass/red brass, PVC-U, EPDM, red brass, nitrile rubber (NBR), copper
Line pressure on the connection point
≤ 6 bar
Permitted differential pressure between supply and
return lines at the connection point
TruDisk 2000
1 bar ≤ Δp ≤ 6 bar
TruDisk 3001
TruDisk 4001
0.2 bar ≤ Δp ≤ 6 bar
Permitted supply temperature
TruDisk 2000
+5 °C up to +25 °C
TruDisk 3001
TruDisk 4001
+5 °C up to +28 °C
Water quality
Cooling water tower according to VDI 3803, appendix B, table B3.
A prefilter ≤ 135 μm must be installed for heavily contaminated water.
Overflow valve
An overflow valve is required for process coolers (chillers).
External laser device cooling circuit
Tab. 2-9
Notes
■
■
Cooling water requirement
characteristic curve
If the machine does not have a machine cooler, the optical
components of the machine are cooled by means of the
process cooler for the laser device (chiller). This means that
the process cooler provided by the user or the in-house
water system must have a 4 KW higher cooling capacity than
a machine with a machine cooler.
For the required cooling capacity for process coolers with a
water-air cooling circuit, see: Required cooling capacity for
water-air cooling circuit.
The cooling water requirement for an external process cooler or
an in-house water system is dependent on the laser power and
the maximum supply temperature of the external cooling unit.
The characteristic curves indicate the minimum cooling water
requirement at maximum power input (service case), dependent
on the maximum supply temperature.
Note
The following characteristic curves are only valid for the laser
device TruDisk. This does not takes account of the 4 KW higher
cooling capacity for cooling the optical components of the
machine.
2‐20
Installation site - Version 4
B836en
A
Minimum water requirement [l/h] t
Supply temperature [°C]
Cooling water requirement characteristic curve
B836en
Installation site - Version 4
Fig. 88325
2‐21
Differential pressure
characteristic curve
The minimum differential pressure (with internal valves open) at
the connection point on the laser device is obtained from the
flow rate calculated.
B
Flow rate [l/h]
ΔP Differential pressure [bar]
Differential pressure characteristic curve
Calculating the minimum
differential pressure
2‐22
Fig. 88326
The required minimum differential pressure between the supply
and return at the connection point is obtained from the supply
temperature and the flow rate calculated.
Installation site - Version 4
B836en
In this example, the required minimum differential pressure is
1 bar between the supply and return.
A
Minimum water requirement [l/h]
B
t
Supply temperature [°C]
ΔP Differential pressure [bar]
Flow rate [l/h]
Calculating the minimum differential pressure
Fig. 79721
Notes
■
■
Required cooling capacity
for water-air cooling circuit
If the cooling capacity of the external cooling circuit is set too
low, the cooling unit's regulation reserve reduces. This could
result in frequent operational malfunctions of the laser device
due to excess temperature.
TRUMPF recommends incorporating a safety margin of
0.5 bar in the calculated minimum differential pressure for the
design of the hose cross sections and hose lengths.
The following cooling capacities are required for process coolers
with a water-air cooling circuit1:
Laser
Machine with
machine cooler
Machine without
machine cooler
TruDisk 2000
≥ 9.4 KW
≥ 13.4 KW
TruDisk 3001
≥ 14.5 KW
≥ 18.5 KW
TruDisk 4001
≥ 17 KW
≥ 21 KW
Required cooling capacity
Tab. 2-10
Note
The required pump pressure at the connection point is calculated
from the total pressure loss: pressure loss at the connection
point as per the characteristic curve "Pressure difference" + pressure loss from supply line = total pressure loss.
1
B836en
Rated power following degradation.
Installation site - Version 4
2‐23
2.8
Cable racks for laser light cables
Note
The laser light cable is installed by Technical Service.
The laser light cable (LLK) is guided in a cable rack from the
installation site of the laser to the machine. If a standard cable
rack is installed, this belongs to the machine's scope of delivery.
If no standard cable rack is installed, the following applies:
■
■
■
■
■
■
■
2‐24
The user must install the cable racks before the machine is
delivered.
The cable racks are to be constructed as follows:
− Width of the cable racks 250 mm (10 in).
− Use cable racks open on one side made of slats; thus
the cable will be able to be inserted and fastened in
place easily from the side during installation.
− Design the corner elements and transitions in such a way
that a minimum bending radius of 200 mm (8 in) is
always ensured.
The distance between the LLK and the low voltage cables
must be at least 50 mm (2 in).
The LLK is not permitted to be laid together with a high voltage cable in the same cable rack.
If cable racks are used without slats, then the LLK must be
fastened in place with cable binders.
The LLK must not be pulled, pushed or turned.
Wall openings must have a minimum diameter for 100 mm
(4 in) and be designed with smooth surfaces (e.g. with a
core drill).
Installation site - Version 4
B836en
2.9
Customer screen options
Screens are integrated in the front side of the safety cabin for
the functions "Residual run time display" and "Work area monitoring". The monitors can be delivered as an option.
Alternatively, the user has the option to insert their own screens
in the recesses provided for this purpose. The screen for observing the work area is mounted and connected on the left and the
screen for displaying the residual run time on the right.
What does the customer
need to do?
Screen specification
If a customer's screen is to be installed, the user must mount
the screen in the safety cabin wall and connect it electrically
themselves.
TRUMPF recommends installing screens with the following specification:
Monitor
32" TFT screen
Resolution:
1920 x 1080
Voltage supply
24 V DC.
Power
typically 80 Watt, maximum
90 Watt
Plug socket
3 individual connections for plug
type Cinch
Tab. 2-11
Mechanical interface
The following mechanical interface is available for the screen in
the front side of the safety cabin:
Mechanical interface for the screen
Screen holder
B836en
Fig. 78929
To fasten the screens in place, a screen holder, type VESA MISF (600 mm x 200 mm) can, for example, be installed.
Installation site - Version 4
2‐25
Electrical interface
To connect the screen (transfer the video signal) an Cinch connection cable with 3 individual plugs is mounted in the recess for
the screen.
Cover for screen recess
For the customer screen option, the recess for the screen in the
safety cabin is provided with a cover on delivery of the machine.
Cover for screen recess (rear view)
2‐26
Installation site - Version 4
Fig. 78931
B836en
Installing the monitor
1. Unscrew the four marked fastening screws on the inner wall
of the safety cabin to be able to remove the cover in the
front side.
1
Fixing screws
Cover attachment from inside
Fig. 79719
2. Remove the cover for the screen recess at the front side of
the safety cabin.
1
Screen recess cover
Cover
Fig. 78928
3. To install the screen:
− Insert the screen into the recess in the safety cabin.
− Screw the screen from the inside onto the safety cabin
wall either directly or by means of the screen holder.
− Connect the screen electrically.
B836en
Installation site - Version 4
2‐27
3.
What does the customer
need to do?
Gas supply
Professional gas installation is a basic prerequisite for smooth
commissioning and trouble-free operation of the installation. The
following chapter must therefore be passed along to the specialist company for industrial gases you have contracted with in a
timely manner in accordance with the planning aid.
Notes
■
■
■
■
■
WARNING
Short circuit or fire hazard when gas lines and electrical
cables are laid together.
Ø
Ø
2‐28
Recommendation from TRUMPF: Contact your gas supplier
regarding the gas supply.
Installation must be performed by a qualified industrial gas
company. A specialized company certified by the DVGW
(German Technical and Scientific Association for Gas and
Water) or a gas and water fitter is not suitable.
The gas installation at the customer site must be laid up to
the connection points on the machine.
Observe applicable standards
Separate gas connections are required for the gas supply of
fixtures. It is not permitted to used the gas supply from the
machine.
Gas supply - Version 4
Do not lay gas lines together with electrical cables in a single cable duct.
Keep gas lines separate up to the connection point on the
machine.
B836en
3.1
Cutting gases
Note
Compressed air cutting gas: see "Compressed air supply" section.
Purity
Cutting gas
Purity
Oxygen (O2)
3.5
99.95 % by vol.
Nitrogen (N2)
5.0
99,999% by vol.2
Argon (Ar)
4.6
99.996 % by vol.
compressed air
See Section “compressed air supply“
Cutting gas purity
Tab. 2-12
In exceptional cases, nitrogen of purity 4.6 (99.996) or other purities can be used as long as the following limit values are not
exceeded:
■
O2 ≤ 100 ppm
■
H2O ≤ 5 ppm
■
CnHm ≤ 1 ppm
■
≤100 particles (for particles ≤0.3 µm; based on 2.83 l ≙ 0.1
ft3)
Cutting gas consumption
Typical consumption during
high-pressure cutting
The cutting gas consumption depends on the nozzle diameter
and on the cutting gas pressure:
N2 high pressure
2
B836en
Minimum input pressure (required flow
pressure at the connection point of the
machine)
27 bar
Cutting gas pressure
20 bar
Nozzle diameter
2.3 mm
When using nitrogen with low purity, oxygen impurities of 100 ppm and
above can cause discoloration of the cutting edges during high-pressure cutting. This can only be avoided by using nitrogen with a purity
of 5.0 or by a cutting gas supply from a gas tank (the nitrogen purity
in the gas tank is usually 5.0).
Gas supply - Version 4
2‐29
N2 high pressure
Cutting gas consumption (under standard conditions)
55 m3/h
High-pressure cutting with nitrogen
Tab. 2-13
Supply lines for cutting gas supply
This symbol indicates the connection point for the cutting gas in
the installation plan.
The customer must provide the cutting gas supply lines up to the
connection point on the machine:
■
■
■
■
■
The supply lines must be installed up to the connection point
on the installation plan indicated by the symbol on the left.
Pipes should be used for the entire gas installation from the
gas cylinder or central gas tank to the connection point of
the machine.
The vaporizer must be designed to accommodate the maximum consumption of all connected machines. The line from
the vaporizer to the connection point must be kept as short
as possible.
Set up the external gas installation in such a way that the
supply lines to the connection point of the machine and the
connection point itself are unable to ice up.
As a general principle, a stopcock must be mounted before
each branch in a ring pipeline in order to make it possible to
shut down the each ring pipeline segment separately.
Note
The gas temperature must not exceed 50 °C. This is of
particular importance if the required gas pressure is generated
by means of pressure booster systems!
Pipes
■
■
■
Oil and grease-free lines made of special quality copper piping ("refrigerator quality", inert-soldered with simple forming
gas) are sufficient for the cutting gases.
Use Swagelok clamping ring screw fittings.
Secure sealing points with flat gaskets.
Notes
■
■
■
2‐30
Gas supply - Version 4
Teflon tape, liquid Teflon, sealing sprays, lubricants and lubricating pastes must not be used.
Stainless steel pipes are not necessary.
Protect pipes against contamination during transport and storage.
B836en
Pipeline section
Pipe dimensions
Nominal
width [mm]
For tank installation: from the vaporizer to
the ring pipeline
¾" or 22 x
1.5
19
Ring pipeline for supplying more than two
laser systems
1" or 28 x
1.5
25
From the ring pipeline/main supply strand
to the tapping point (N2)
5/8" or 18 x
1.5
16
From the tapping point to the connection
point on the machine (O2)
½" or 15 x 1
13
Supply line for the cutting gas supply
Tab. 2-14
Requirements on the connection point of
the machine
O2 Standard pressure
N2 High
pressure
8
27
21
33
Max. cutting gas pressure in bar
6
20
Volume rate of flow4 in m3/h (under
standard conditions)
10
55
Tube connection, outside diameter
in mm
∅ 8
∅ 10
Min. input pressure flow pressure in bar
Max. static input pressure
3
in bar
Cutting gas supply: Machine connection point
Tab. 2-15
Cutting gas supply with cylinders or
bundles
Note
Cylinders or bundles are not suitable for high-pressure cutting
with N2.
Cylinders or bundles
B836en
■
The supply of cutting gas with pressure reducers for cylinders or bundles require increased handling, however, due to
3
The machine is equipped with blow-off valves that respond at high
input pressure, making a whistling sound in the process.
4
The volume rate of flow depends on the maximum cutting gas pressure selected and the nozzle diameter specified
Gas supply - Version 4
2‐31
the high level of consumption. One bundle consists of twelve
cylinders = approx. 120 m3 gas.
The gas flow is interrupted when changing the cylinder or
bundle.
■
Cylinder banks or cylinder
bundle banks
■
Switchover devices are required for uninterrupted operation
with bottle or cylinder banks.
■
The switchover is performed manually or automatically.5
Cylinder banks or cylinder bundles are frequently installed at
some distance from the laser machine. For this reason, the
use of a tapping point pressure reducer close to the laser
system is recommended.
■
Pressure control
specifications
O2 Standard
pressure
N2 High pressure
Admission pressure in bar
0 - 200
0 - 200
Maximum permissible back pressure in bar
25
40
Minimum flow rate in m3/h
(under standard conditions)
30
90
Other requirements
Suitable for oxygen; free of oil
and grease
Oil and greasefree
Cutting gas supply: pressure control specifications
Tab. 2-16
Note
The pressure must be monitored by installing the specified pressure regulators on the supply unit. The pressure regulators must
be secured against the maximum input pressure (intrinsically
safe).
Cutting gas supply with gas tank
Gas tank
■
■
■
5
2‐32
Gas supply - Version 4
A tank system is appropriate for safe gas supply at a gas
consumption of at least about 200-400 m3/week.
The optimum tank size depends on the tapping quantity and
on the local conditions.
The customer should consult the gas supplier.
We recommend using a signaling unit for automatic switchover, since
otherwise both sides of the cylinder or bundle bank could be drained
without being noticed.
B836en
The following are requirements for high-pressure cutting with
nitrogen:
■
■
Do not use a tapping point pressure regulator between the
gas tank and the machine behind the pressure regulating
station.
Between the gas tank and the machine, a stop valve must
be installed at the end of the pipeline, i.e. at the machine
entrance.
O2 Standard
pressure
N2 high pressure
Required pressure in bar
18
36
Maximum tapping pressure
in bar
14
30
Cutting gas supply – tank system
Tab. 2-17
Pressure control
specifications
O2 Standard
pressure
N2 High pressure
Optional
Recommended
Tapping point pressure regulator
Recommended
Not recommended
Back pressure in bar
0-16
-
Other requirements
Suitable for oxygen,
oil and greasefree
Oil and greasefree
First pressure stage (tank)
Safety pressure regulation system6
Second pressure stage (tapping
point)
Cutting gas supply: pressure control specifications
6
B836en
Tab. 2-18
The safety pressure regulation system is installed close to the tank. It
ensures uniform pressure in the circuit. The built-in pressure relief
valve ensures that gases are blown away into the open air in the
event of malfunctions. In this way, risks are avoided in the area of the
laser system due to a concentration of oxygen (O2) or depletion of
oxygen (N2).
Gas supply - Version 4
2‐33
4.
What does the customer
needs to do?
Area of application IEC-/NEC
Professional electrical installation is a basic prerequisite for
smooth commissioning and trouble-free operation of the installation. The following chapter must therefore be passed along to
the specialist company for electrical installation you have contracted with in a timely manner in accordance with the planning
aid.
■
■
Decentralized power supply
IEC is valid worldwide.
NEC applies only to Canada and the USA.
In a standard case, the user has to install 3 individual electrical
connections for the laser processing machine:
■
■
■
Central power supply
Electric power supply
For the basic machine.
For the laser device.
For the external laser process cooler.
Optionally, the laser processing machine can be equipped with
a central power supply. All machine components, including the
the laser device and the external process cooler are then powered via a common electrical connection.
A central power supply is also possible in the following conditions:
■
■
If the customer connects the laser device to a process cooler
provided by the user. In this case, the process cooler can
also be powered from the central feed.
If the user integrates an on-site scrap conveyor. In this
case, the user must install a separate electrical connection for the scrap conveyor. The scrap conveyor is not
powered from the central feed.
A central power supply is not possible in the following cases:
■
■
If the laser device or the process cooler are set up in a different room, e.g. in the basement.
If the laser device or the process cooler are set up on a platform.
4.1
2‐34
Electrical connection
Area of application
Rated voltage
Frequency
IEC
400 V ±10 %
50 Hz ±1 %
460 V +10%/ -5%
60 Hz ±1 %
Electric power supply - Version 4
B836en
Area of application
Rated voltage
Frequency
NEC
460 V +10%/ -5%
60 Hz ±1 %
Rated voltage and frequency
Tab. 2-19
Notes
■
■
■
■
■
The tolerance range applies to the short-term supply fluctuations. Impermissible voltage fluctuations endanger the faultless operation of the machine and reduce performance.
In the event of continuous impermissible fluctuations, e.g. a
network stabilizer or an undervoltage supply is recommended.
The line tolerance must be determined if the nominal voltage
is 380 V or 415 V at 50 Hz.
No isolating transformer is required if the tolerance is
between 360 V and 440 V.
NEC: the specification complies with the standards of the
American National Standard (ANSI) C84.1-1989 Table 1,
"Voltage range A".
The symbol indicates the connection points in the installation
plan.
The following table applies to the connection of the basic
machine and to the connection of the external process cooler
for the laser device.
IEC
NEC
Electrical supply
Version according to
DIN EN 60204-1/4.3.1
-
Leadership
Four-core copper cable
(L1, L2, L3, PE)
Four-core copper cable (L1, L2, L3,
PE):
Conductor cross-section
Version according to
IEC 60364-4-43
(VDE 0100, part 430)
■
THHN copper or equivalent is
recommended (2000 V test voltage) designed for a maximum
temperature of 90 °C/194 °F.
■
No aluminum cables may be
used for the connection.
■
The conductor cross-section
must comply with NEC 670-4
(a). The conductor cross-section
must be designed for at least
125 % of the nominal current.
The nominal current is specified
on the nameplate.
■
To ensure voltage stability and
rating, the line dimension should
be larger than specified in the
NEC table 310-16.
Ground wire
Version according to
IEC 60364-5-54
(VDE 0100, part 540)
-
Fuse type
gL/gH
RK1/Class J
Electrical connection cable
B836en
Tab. 2-20
Electric power supply - Version 4
2‐35
4.2
Uninterruptable power
supply (USV)
Power supply
The following applies if it is necessary to connect the machine to
an uninterruptible power supply (UPS):
■
■
When working out the dimensions of the UPS, the short-circuit and overload responses of the UPS system are to be
taken into account, along with the continuous power and the
electrical connected loads (see Section "Connected loads,
fuse protection").
As a rule: overload capacity of the UPS ≥200 % for 0.5 s.
Note
The dimensioning of the uninterruptible power supply must be
established by the manufacturer of the UPS plant.
Fault current circuit breaker
(RCD)
A fault current circuit breaker provides protection from fault currents due to directly or indirectly touching live parts.
■
■
If a fault current circuit breaker is used to provide protection
from direct contact, an isolating transformer must be used.
This is because the leackage current resulting from the
design is >30 mA.
If a fault current circuit breaker is to be used to provide protection from indirect contact, this must be selected depending on the machine's leakage current.
Notes
■
■
■
Power supply configurations
Whether a fault current circuit breaker has to be used
depends upon the local electricity company.
The machine must be separated from the power supply by
an isolating transformer if the leakage current of the machine
is higher than the fault current set when using a fault current
circuit breaker (EN 50178, Point 5.2.11.1, VDE 0160).
On the line side, only fault current circuit breakers of type B
(sensitive to all types of fault current, EN 50178,
Point 5.2.11.2; VDE 0160) are approved to provide protection
against direct or indirect contact.
The power supply for the connection is configured as a TN system with grounded star point. The connecting cable has four
cores (L1, L2, L3 with clockwise phase rotation and PE).
With IT and TT line structures as well as asymmetrical lines (one
phase grounded - corner-grounded delta network), the machine
must be connected via an isolating transformer.
Note
A surge diverter is required if the machine is connected to an IT
system.
2‐36
Electric power supply - Version 4
B836en
NEC conditions
The following conditions apply in the area of application of the
standards UL489 and UL248 (for USA and Canada):
■
■
■
Isolating transformer
Grounding: The machine and power distributor system must
be equipped with a grounding line in accordance with
NEC article 250, "Grounding".
Three phase power supply: For a three phase power supply without a ground, an unregulated isolating transformer
must be installed (NEC item 450-5). Less faults will occur,
excessive voltages will be reduced and the power network
will be protected from voltage shifts.
Back-up fuse: the user must equip the machine with a backup fuse for its connection which limits the SCCR value to
35 kA, insofar as the power supply has a higher SCCR
value.
The following requirements apply for the isolating transformer:
■
■
■
■
■
■
■
■
Construction service: at least 125 % of the maximum connected load.
Power-on time: 100 %.
Short-circuit voltage: ≤2.4 %.
Winding structure (circuit): DYN5.
Secondary voltage:
− At 50 Hz: 400 V.
− At 60 Hz: 460 V.
Additional connections on the primary side for adjusting the
line voltage: +10 V, +20 V, –20 V, –10 V.
Recommendation: insert transformer with copper coil. Aluminum wound transformers are not recommended because of
their inherently higher impedance.
Registration for the corresponding country, e.g. CE marking
for Europe or UL for USA.
Note
The isolating transformer does not belong to the machine's
scope of delivery. It must be provided by the user.
4.3
Connected load and fuse protection
Central power supply
Central power supply is an option. All machine components,
including the laser device and the external laser process cooler
are powered via a shared electrical connection.
B836en
Electric power supply - Version 4
2‐37
Machine including TruDisk and
laser cooler, machine with:7
TruDisk
2000
TruDisk
3001
TruDisk
4001
TruDisk
2000
TruDisk
3001
TruDiks
4001
Valid for water-air process cooler
Valid for water-water process cooler
Typical rated power [kVA]
35.5
40
45.7
36
38.5
44.2
Connected load [kVA]
at 400 V and 460 V
38
46
51
38.5
44.5
49.5
Nominal current [A] at 400 V
51
57
67
52
55
65
Nominal current [A] 460 V
45
53
61
45
51
59
Maximum fuse protection [A]
at 400 V and 460 V
100
100
100
100
100
100
Connection cable cross-section
[mm2] [Cu]
35
35
35
35
35
35
Maximum acceptable interruption
of nominal voltage [ms]
See EN 60204, Part 1, Sect. 4.3.2, Alternating current supply
Standard values, connected load and fuse protection, central power supply
Variant if process cooler
provided
Tab. 2-21
The process cooler provided by the user is connected in the
machine switch cabinet. The interface is a motor circuit-breaker
with the following fuse protection:
Laser device
Motor circuitbreaker interface
For a machine
with a machine
cooler
For a machine
without a
machine cooler
TruDisk 2000
=EP.EL+CB1A1.F2
16 - 25 A
16 - 25 A
16 - 25 A
25 - 32 A
25 - 32 A
32 - 40 A
TruDisk 3001
TruDisk 4001
Motor circuit-breaker fuse protection
Tab. 2-22
Note
The process cooler is connected by the user. The required connection cable for the process cooler is provided by the user.
Decentralized power supply
The electrical power supply of the laser processing machine
each requires 3 separate electrical connections as standard:
■
■
■
7
2‐38
A connection for the electrical supply of the basic machine,
including rotational changer or rotary indexing table, scrap
conveyor and compact dust extractor.
A connection for the electrical power supply of the laser
device.
A connection for the electrical power supply of the external
process cooler (chiller) for the laser device.
The values are valid for the central power supply option regardless of
whether the machine has a machine cooler or whether a process
cooler provided by the user is connected.
Electric power supply - Version 4
B836en
Single connection, basic
machine
Typical rated power [kVA]
18.5
Connected load for basic machine [kVA]
24
Maximum fuse protection of the basic machine
and 400 V and 460 V [A]
100
Cross-section of the connection cable for the
basic machine [mm2] [Cu]
35
Maximum acceptable interruption of nominal voltage [ms]
See EN 60204,
Part 1,
Sect. 4.3.2,
Alternating current supply
Recommended values, connected load and fuse protection,
basic machine
Single connection, laser
device
Tab. 2-23
Electrical supply
Version according to
DIN EN 60204-1 TN network
according to 60364-1, clockwise
phase rotation
cos φ (DPF) with rated output
0.96
λ with rated power (total power
factor)
0.96
Insulation resistance
TruDisk 2000
210 kΩ
TruDisk 3001
TruDisk 4001
260 kΩ
TruDisk 2000
≤700 mΩ
TruDisk 3001
TruDisk 4001
≤180 mΩ
TruDisk 2000
25 A
TruDisk 3001
TruDisk 4001
32 A
Maximum permitted external
impedance Zv at the mains connection point8
Back-up fuse, line configuration
operating class gl/gG line protection
Electrical connection cable and fuse protectionTruDisk
Tab. 2-24
Laser device
Typical rated
power [kW]
Maximum
power input
[kW]
Typical connected load
[kVA]
Maximum
connected
load [kVA]
Current [A] typical
at 400 V
Current [A] maximum
at 400 V
TruDisk 2000
9.4
11.8
10
12.4
14.2
18
TruDisk 3001
11.2
17.4
12
18.4
17
26
TruDisk 4001
14.2
21
15.2
22.2
22
32
Connected loadTruDisk
Tab. 2-25
8
B836en
If the external impedance is exceeded, the safety measures for protection against electrical shocks must be re-assessed.
Electric power supply - Version 4
2‐39
Single connection, external
process cooler
The following table is valid for water/air process coolers manufactured by Riedel, product group type RLxx/0 SR (TR) for the
variant Machine without machine cooler:
Process
cooler for
laser device
Maximum
power input
[kW]
at 50 Hz
Connected
load [kVA]
at 50 Hz
Typical rated
power [kW]
at 60 Hz
Maximum
power input
[kW]
at 60 Hz
Connected
load [kVA]
at 60 Hz
Maximum
fuse protection [A]
Process
cooler
RL13/0 for
TruDisk 2000
7.5
9.0
14.1
10.3
11.2
20
Process
cooler
RL17/0 for
TruDisk 3001
9.5
11.5
20.6
11.7
14
25
Process
cooler
RL20/0 for
TruDisk 4001
12
14.2
21.3
16
18.3
35
Connected load for process cooler, chiller for TruDisk
Tab. 2-26
The following table is valid for water/air process coolers manufactured by Riedel, product group type RLxx/0 SR (TR) for the
variant Machine with machine cooler:
Process
cooler for
laser device
Maximum
power input
[kW]
at 50 Hz
Connected
load [kVA]
at 50 Hz
Typical rated
power [kW]
at 60 Hz
Maximum
power input
[kW]
at 60 Hz
Connected
load [kVA]
at 60 Hz
Maximum
fuse protection [A]
Process
cooler
RL10/0 for
TruDisk 2000
6.4
8
11.2
8
9.8
16
Process
cooler
RL17/0 TruDisk 3001
TruDisk 4001
9.5
11.5
20.6
11.7
14
25
Connected load for process cooler, chiller for TruDisk
2‐40
Electric power supply - Version 4
Tab. 2-27
B836en
The following table is valid for water/water process coolers
manufactured by Riedel, product group type RWxx/0 SR (TR) for
the variant Machine without machine cooler:
Process
cooler for
laser device
Maximum
power input
[kW]
at 50 Hz
Connected
load [kVA]
at 50 Hz
Typical rated
power [kW]
at 60 Hz
Maximum
power input
[kW]
at 60 Hz
Connected
load [kVA]
at 60 Hz
Maximum
fuse protection [A]
Process
cooler
RW13/0 for
TruDisk 2000
6
7.3
17.4
7.5
8.8
16
Process
cooler
RW17/0 for
TruDisk 3001
9
10.5
24.7
11
13
25
Process
cooler
RW20/0 for
TruDisk 4001
9.8
11.2
23.3
12.4
14.3
25
Connected load for process cooler, chiller for TruDisk
Tab. 2-28
The following table is valid for water/water process coolers
manufactured by Riedel, product group type RWxx/0 SR (TR) for
the variant Machine with machine cooler:
Process
cooler for
laser device
Maximum
power input
[kW]
at 50 Hz
Connected
load [kVA]
at 50 Hz
Typical rated
power [kW]
at 60 Hz
Maximum
power input
[kW]
at 60 Hz
Connected
load [kVA]
at 60 Hz
Maximum
fuse protection [A]
Process
cooler
RW13/0 for
TruDisk 2000
TruDisk 3001
6
7.3
17.4
7.5
8.8
16
Process
cooler
RW17/0 for
TruDisk 4001
9
10.5
24.7
11
13
25
Connected load for process cooler, chiller for TruDisk
B836en
Tab. 2-29
Electric power supply - Version 4
2‐41
4.4
Teleservice
The following interface for the network connection is available in
the machine electrical cabinet: RJ45 plug.
Net work requirements for
Teleservice via Internet
For Teleservice via Internet the following configuration is required
in the user's LAN:
UDP Port 500 and UDP Port 4500, enabled for Internet access
via the LAN.
Note
Access to the user's LAN from the Internet is not required: communication takes place via the two enabled UDP ports.
4.5
Network connection
An RJ45 plug is installed in the machine's switch cabinet to
allow the machine control system to be integrated in a network
(e. g. connection to a programming system).
A personal hub (netwrk distributor) is required if several
machines are to be connected to the network. It is located in the
switch cabinet of the machine and must be supplied with AC current by the customer, as the distributor must als work if the
machine is switched off. The power supply must be provided in
the same way as for the following production control technology
projects.
For production control projects connected to a CELL SERVER,
the power supply must be provided by the customer next to the
PC cabinet.
■
■
Network tolerance
Power supply (except in the USA and Canada): 230 V with
grounded outlet socket. The machine is provided with a
grounded coupling.
115 V power supply in the USA and Canada with standard
USA socket.
Area of application
Rated voltage
Frequency
IEC
400 V ±10 %
50 Hz ±1 %
460 V +10%/ -5%
60 Hz ±1 %
460 V +10%/ -5%
60 Hz ±1 %
NEC
Rated voltage and frequency
2‐42
Electric power supply - Version 4
Tab. 2-30
B836en
5.
What does the customer
needs to do?
Compressed air supply
For professional use with respect to the subject of compressed
air supply, please consult a suitable specialist company and pass
along the following subchapter to the appropriate officials there.
The symbol indicates the connection points in the installation
plan.
The following should be observed during installation at the site:
■
■
■
■
The supply line for the compressed air supply must be installed by the user up to the connection points marked in the
installation plan.
The compressed air connection may be flexible or may consist of a fixed pipeline to the machine.
Each compressed air connection must be equipped with a
manual shut-off valve.
Recommendation: In case of an unstable compressed air
network or low system pressure, connect compact dust
extractor independently of the machine.
Note
The requirements for the purity of the compressed air and for
the installation of the supply lines are identical for all compressed air supply ports required at the machine.
Additional compressed air
connection
A separate compressed air supply is required in addition to the
basic machine compressed air supply:
■
■
■
Basic machine consumption
B836en
For laser cutting with compressed air.
For the vacuum ejectors (option) or for the additional compressed air supply (option) on the rotational changer or the
rotary indexing table.
Note: The additional compressed air supply is only possible
as an alternative to the vacuum ejectors.
For project-specific components requiring compressed air.
A (shared) compressed air connection is required for the compressed air supply of the basic machine, including the supply to
existing valve arrays on the rotational changer or rotary indexing
table.
Compressed air supply - Version 4
2‐43
Average consumption (required volume flow rate according to
ISO 1217 or DIN 1945):
Required flow pressure in bar
min. 6 - max.12
Typical consumption of basic machine in m3/h
(under standard conditions)
approx. 30
Temporary maximum consumption over a period
of two to five minutes, no more than once an hour
in m3/h/ (under standard conditions)
approx. 40
Maximum permissible consumption for valve terminals in m3/h (under standard conditions)
approx. 30
maximum: 78
Compressed air consumption
Compressed-air cutting
Tab. 2-31
A separate compressed air supply is necessary for compressedair cutting. The compressed air consumption depends on the
nozzle diameter and on the cutting gas pressure.
Typical application
Mild steel 1 mm
Mild steel 2 mm
Maximum permissible line pressure in bar
18
18
Minimum input pressure in bar
(flow pressure required at the
connection point)
12
14
Cutting gas pressure in bar
9
12
1.7
2.3
15
35
Nozzle diameter in mm
Cutting gas consumption in
(under standard conditions)
m3/h
Compressed-air cutting
Supply lines
The following specification applies to all compressed air supply
ports:
Min. nominal diameter of the
supply line
½" (DN13)
Ring circuit length in m
max. 50 (due to formation of water
condensation)
Ring circuit diameter
at least 1" (26 mm)
Length of the connection line
from the ring circuit to the connection point on the machine
in m
max. 5
Hose range for the sleeve at the
connection point
Nominal width DN 13
Connection point (without grommet)
Thread ½"
Specification for supply lines
2‐44
Tab. 2-32
Compressed air supply - Version 4
Tab. 2-33
B836en
Purity
The compressed air must have the following properties at its tapping point:
Property
Requirement
Quality class
ISO°8573-1
Edition 2001
Measure (recommendation)
Dust-free
Maximum particle size: 40 μm
Maximum particle density:
10 mg/m3
7
Air filter on the
compressor
Condensate-free
cooled to +3°C /
37°F (pressure
dew point)
4
Cold dryer
Oil-free
Maximum oil
content:
5 mg/m3
4
Oil-free compressing screwtype compressor
Requirements
B836en
Tab. 2-34
Compressed air supply - Version 4
2‐45
6.
What does the customer
need to do?
Operating materials
Operating materials must be provided by the user for starting up
the machine.
Notes
■
■
Provide cooling water (deionized water) in sufficient quantity
and in suitable containers.
If the laser device is to be connected a local water system or
to a process cooler provided by the user, the cooling circuit
provided at the site must be ready for use and available at
the time of starting up.
6.1
Gases
Gas types, their purity and connections, hoses, etc. are specified
in section 2, "Gas supply."
6.2
Cooling water
Cooling water is required to cool the laser unit and for cooling
the optical components on the machine. There are the following
cooling circuits:
■
■
■
Internal cooling circuit, laser device.
External cooling circuit, laser device chiller (external process
cooler or in-house water system).
Machine cooling circuit for cooling the optical components on
the machine. This cooling circuit only occurs when the
chiller is integrated into the machine body.
For cooling the optical components of the machine, there are the
following variants:
■
■
■
2‐46
Standard: The optical components of the machine are cooled
via the external cooling circuit of the laser device (chiller).
Option: The optical components of the machine are cooled
via the internal chiller in the machine body.
The internal chiller in the machine body is absolutely necessary in the following variants:
− Connection of the laser device to a facility water installation at the customer site
− Connection of the laser device to a process cooler provided by the user
− Pedestal or cellar installation of the laser device or the
external process cooler (chiller).
Operating materials - Version 4
B836en
Damage is caused to the machine and to the laser device if
tap water or contaminated water is used!
NOTICE
Ø
Ø
Ø
Ø
Required cooling water
Cooling water should be stored only for short periods.
Transport and store water in clean plastic containers (without
deposits).
Avoid contact with the water. Foreign substances (excluding
algae inhibitors and anticorrosive agents) impair the quality
of the water.
Use additional equipment for filling water, such as pumps,
hoses or stop valves, exclusively for handling the cooling
water.
All of cooling circuits will be flushed repeatedly and then filled
with cooling water at the time the machine is commissioned.
This table is valid in connection with a chiller, water/air
type RLxx/0 SR/TR:
Cooling water
quantity in l
Internal cooling circuit
of the laser device
External cooling circuit, laser device9
Machine cooling circuit
Requirement
Requirement
Requirement
Volumetric
capacity of
cooling circuit
Volumetric
capacity of
cooling circuit
Total
requirements10
Volumetric
capacity of
cooling circuit
Variant: Machine with machine cooler
Process cooler
RL10/0 for TruDisk 2000
approx.
120
approx. 30
approx.
320
approx. 80
approx.
160
48
approx.
600
Process cooler
RL17/0 for TruDisk 3001
TruDisk 4001
approx.
220
approx. 55
approx.
600
approx.
150
approx.
160
48
approx.
980
Process cooler
RL13/0 for TruDisk 2000
approx.
120
approx. 30
approx.
320
approx. 80
-
-
approx.
440
Process cooler
RL17/0 for TruDisk 3001
approx.
220
approx. 55
approx.
600
approx.
150
-
-
approx.
820
Process cooler
RL20/0 for TruDisk 4001
approx.
220
approx. 55
approx.
600
approx.
150
-
-
approx.
820
Variant: Machine with machine cooler
Required cooling water at time of commissioning
9
Tab. 2-35
They are valid for Riedel process coolers: type RLxx/0 SR(TR).
10 Total requirement for starting up the laser processing machine
B836en
Operating materials - Version 4
2‐47
This table is valid in connection with a chiller, water/water
type RWxx/0 SR/TR:
Internal cooling circuit
of the laser device
External cooling circuit, laser device11
Machine cooling circuit
Cooling water
quantity in l
Requirement
Volumetric
capacity of
cooling circuit
Requirement
Requirement
Process cooler
RW13/0 for TruDisk 2000
approx.
120
approx. 30
approx.
320
approx. 80
approx.
160
48
approx.
600
Process cooler
RW13/0 for TruDisk 3001
approx.
220
approx. 55
approx.
320
approx. 80
approx.
160
48
approx.
700
Process cooler
RW17/0 for TruDisk 4001
approx.
220
approx. 55
approx.
600
approx.
150
approx.
160
48
approx.
980
Volumetric
capacity of
cooling circuit
Total
requirements10
Volumetric
capacity of
cooling circuit
Variant: Machine with machine cooler
Variant: Machine with machine cooler
Process cooler
RW13/0 for TruDisk 2000
approx.
120
approx. 30
approx.
320
approx. 80
-
-
approx.
440
Process cooler
RW17/0 for TruDisk 3001
approx.
220
approx. 55
approx.
600
approx.
150
-
-
approx.
820
Process cooler
RW20/0 for TruDisk 4001
approx.
220
approx. 55
approx.
600
approx.
150
-
-
approx.
820
Required cooling water at time of commissioning
Requirements
Tab. 2-36
The cooling water must be de-ionized.
Cooling water.
Properties
Conductivity of freshly filled water
max. 10 μS/cm
Conductivity for newly replaced water
after 10 minutes of circulation
Max. 20 μS/cm
Conductivity limit of the cooling water
after addition of the anti-corrosive agent
Cu cooling circuit:
max. 200 μS/cm
Max. permissible carbonate content
less than 100 mg/l
Color
Colorless
Cloudiness
None
Odor
odorless
Requirements
Tab. 2-37
Notes
■
The specified chemical/physical characteristics must be
observed.
11 Valid for standard Riedel process coolers: type RLxx/0 SR(TR).
2‐48
Operating materials - Version 4
B836en
■
■
■
■
Installing process cooler in
an area with a risk of frost
Do not use distilled water! The quality of distilled water can
fluctuate considerably.
For a local water system provided at the site as the external
cooling system for the TruDisk laser device, tap water
according to VDI Norm 3803 can be used.
Odor is an indication for a biological contamination of the
water.
Any type of cloudiness (e.g. from suspended matter, threads,
flakes, particles) marks an impurity in the water.
If the process cooler is installed in an area with a risk of frost,
then the "high purity ethylene glycol" antifreeze agent must be
added to the cooling water.
The antifreeze agent is to be provided by the customer at
machine start-up.
The mixing ratio is dependent on the temperature at the installation site.
Temperature
up to -15 C (5°F)
up to -24 C (11.2°F)
Percent by weight in
%
30
40
Percent by volume in
%
27
35
Mixing ratio
6.3
Tab. 2-38
Dispensing material for MultiCoater
Note
Calcium carbonate or trass powder are required exclusively as
the dispensing material for the MultiCoater (optional compact
dust extractor).
Name
Calcium carbonate
(CaCo3)
Trass powder
Grain size range
≥0 µm and ≤90 µm
≥0 µm and ≤150 µm
Average grain size
≥5 µm and ≤15 µm
≥20 µm and ≤40 µm
Purity level
99.1 %
-
Filling volume of storage container
55 liters
55 liters
Specification of dispensing material for MultiCoater
B836en
Operating materials - Version 4
Tab. 2-39
2‐49
7.
What does the customer
need to do?
Transport
All components are to be examined upon receipt for any damage
caused during transit. Any visible damage caused during transit
must be recorded on the consignment note and countersigned
by the truck driver. Hidden damage caused during transport must
be reported to the insurance company and to TRUMPF within six
days at the latest.
The customer must (unless other agreements have been
made) make the necessary arrangements and convey the
machine and components from the truck to its final installation
site.
The transport route to the machine's installation site must be
clarified in due time prior to the machine's delivery. In particular,
gates, header heights, cable rack heights, ground conditions for
armored rollers etc. must be checked by the customer. The
transport route must take the dimensions of the machine into
account according to the installation plan!
Transport regulation
Transport of the machine and machine components: see transport regulation drawing no. 93964-5-800, material no. 1848703
(drawing in folder for TRUMPF service engineer).
The transport regulation documents the loading process, transport and the unloading process of the machine and its components in different ways:
■
■
2‐50
Transport - Version 4
Transport via trucks: see Sheet A.
Transport via container: see Sheet A and Sheet B.
B836en
Transport equipment and
additional equipment
The following means of transport and additional equipment must
be provided by the user at the time of delivery and for positioning the machine.
■
■
■
■
■
B836en
With container transport: Double ladder or telescopic boom
lift for opening the container lid.
For the transport and construction of the safety cabin:
− Two double ladders, each 4 m high or telescopic boom
lift.
− Forklift truck with min. stroke height of 4.5 m and minimum fork length of 3.5 m.
For transport by crane:
− Indoor crane or mobile crane with a carrying capacity of
at least 10 MP.
− VIP sling chain ND16, two-stranded, 2500 mm long with
locking hooks VIP Copra. Minimum carrying capacity
10 MP at an angle of twist of 45° to 60°. The sling chain
(TRUMPF mat. no. 1850719) is not part of the machine's
scope of delivery. It can be purchased from the Carl
Stahl Co. under order number 6201.VO.16.
− Alternative to the sling chain: Spreader bar (carrying
capacity of at least 15 MP) with two chain strands and
load hooks for swivel bearer WBG8 M36.
− Chains and transport straps.
− 4 eyebolts M12.
− Transport beam and steel rods for transporting the laser
device.
For corridor transport of the basic machine:
− Armored rollers (1 x steerable, 2 x rigid).
− 4 hydraulic hoisting jacks with a min. carrying capacity of
8 MP (adjustable height ≤ 50 mm).
− Hoisting iron (1 m) and extension.
For transport with a forklift truck or pallet jack:
− Pallet jack or forklift truck with minimum carrying capacity
of 4 MP or 8 MP.
− For the rotational changer on the pallet: Pallet jack or
forklift truck with carrying capacity of at least 4 MP. If the
rotational changer is to be grabbed longitudinally, a minimum fork length of 2.8 m is required.
− For the rotary indexing table (optional) on pallet: Pallet
jack or forklift truck with carrying capacity of at least
8 MP and minimum fork length of 2.8 m.
− For the compact dust extractor on the pallet: Forklift truck
with carrying capacity of at least 4 MP. If the pallet is to
be grabbed longitudinally, a minimum fork length of 2.8 m
is required.
Transport - Version 4
2‐51
Container transport
If the machine and the components are delivered in the container, an indoor crane or mobile crane must be available.
If an indoor crane is not available or if the clearance height
below the indoor crane is less than 5 m, the container will
have to be unloaded outside.
The container can be unloaded either on the face side through
the open door or through the open roof. The required crane
hook clearance above the factory floor for unloading the basic
machine is:
■
■
Greater than 6 m when unloading the basic machine from
the container from the face side.
Greater than 9 m when unloading the basic machine through
the open roof of the container.
The basic machine and the workpiece changer are transported
High Cubein one container. All other system components are
transported in 3 or 4 standard containers.
Basic machine with
workpiece changer and
point of the jib.
Length
in mm
Width
in mm
Height
in mm
12190
2440
2800
High Cube container
7.1
Dimensions and weights of
the basic machine
Tab. 2-40
Dimensions and weights of the
transport units
The machine body and motion unit, the switch cabinets installed
in the machine body and the chiller (optionally on the console)
for the basic machine all belong to the transport unit of the basic
machine.
Basic machine
Length
in mm
Width
in mm
Height
in mm
Weight
in kg
TruLaser Cell 8030
with console12
approx.
5900
approx.
3017
approx.
3030
approx.
9100
TruLaser Cell 8030
without console
approx.
5320
approx.
3017
approx.
3030
approx.
9100
Basic machine including transport equipment
Tab. 2-41
12 Console for machine chiller (optional).
2‐52
Transport - Version 4
B836en
Dimensions and weights of
system components
Component
Length
in mm
Width
in mm
Height
in mm
Weight
in kg
- Rotational changer
4100
1500
1500
approx.
2700
- Rotary indexing
table
2700
2300
1500
approx.
4500
Workpiece changer
without fixtures on
pallet:
Compact dust extractor horizontal on pallet:
DELTA Comp 1500-14/9 SB
- without soundproofing
approx.
3500
1780
1050
approx.
1250
- with soundproofing
approx.
3500
1780
1050
approx.
1350
Scrap conveyor on
pallet:
Scrap conveyor
- for rotational
changer
6500
1200
2130
1270
- for rotary indexing
table
7200
1200
2130
1500
Transport units
Dimensions and weights safety cabin
Tab. 2-42
The modules of the safety cabin are supplied on three wooden
pallets and transported.
Pallet
Length
in mm
Width
in mm
Height
in mm
Weight
in kg
Pallet 1
5700
1600
1800
approx.
3000
Pallet 2
3300
2300
1700
approx.
2000
Pallet 3
3000
2300
2000
approx.
1500
Safety cabin modules
Dimensions and weights TruDisk
Tab. 2-43
Laser device
(without packaging)
Length
in mm
Width
in mm
Height
in mm
Weight
in kg
TruDisk 2000
1120
730
1375
approx.
470
TruDisk 3001
TruDisk 4001
1175
725
1430
approx.
470
TruDisk laser device
B836en
Tab. 2-44
Transport - Version 4
2‐53
Dimensions and weights,
chiller for TruDisk
The following table is valid for water/air process coolers manufactured by Riedel, product group type RLxx/0 SR (TR) and for
the variant Basic machine without chiller:
Process cooler
(empty)
Length
in mm
Width
in mm
Height
in mm
Weight
in kg
Process cooler
RL13/0 for TruDisk
2000
1144
720
1550
220
Process cooler
RL17/0 for TruDisk
3001
1244
800
1550
260
Process cooler
RL20/0 forTruDisk
4001
1244
800
1550
290
Process cooler, chiller for TruDisk
Tab. 2-45
The following table is valid for water/air process coolers manufactured by Riedel, product group type RLxx/0 SR (TR) and for
the variant Basic machine with chiller:
Process cooler
(empty)
Length
in mm
Width
in mm
Height
in mm
Weight
in kg
Process cooler
RL10/0 for TruDisk
2000
1144
720
1440
215
Process cooler
RL17/0 for TruDisk
3001TruDisk 4001
1244
800
1550
260
Process cooler, chiller for TruDisk
Tab. 2-46
The following table is valid for water/water process coolers
manufactured by Riedel, product group type RWxx/0 SR (TR)
and for the variant Basic machine without chiller:
Process cooler
(empty)
Length
in mm
Width
in mm
Height
in mm
Weight
in kg
Process cooler
RW13/0 for TruDisk
2000
1280
800
1244
200
Process cooler
RW17/0 for TruDisk
3001
1280
800
1244
245
Process cooler
RW20/0 for TruDisk
4001
1280
800
1244
255
Process cooler, chiller for TruDisk
2‐54
Transport - Version 4
Tab. 2-47
B836en
The following table is valid for water/water process coolers
manufactured by Riedel, product group type RWxx/0 SR (TR)
and for the variant Basic machine with chiller:
Process cooler
(empty)
Length
in mm
Width
in mm
Height
in mm
Weight
in kg
Process cooler
RW13/0 for TruDisk
2000
TruDisk 3001
1280
800
1244
200
Process cooler
RW17/0 for TruDisk
4001
1280
800
1244
245
Process cooler, chiller for TruDisk
B836en
Tab. 2-48
Transport - Version 4
2‐55
7.2
DANGER
Suspended load!
Falling loads could lead to severe bodily injury or even
death.
Ø
Ø
Ø
Ø
Ø
DANGER
Transporting machine and machine
components
Observe relevant safety regulations regarding the handling
of heavy loads.
Never walk under a suspended load.
Use tested and appropriately sized tackle and means of
transportation.
Employ qualified technicians to transport the machine.
Carry out transport work in accordance with the transport
regulations.
Improper handling can cause the basic machine to tip over
during transport or during installation.
This could lead to severe bodily injury or even death
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Ø
Ø
2‐56
Transport - Version 4
The basic machine may only be transported with a crane or
with armored rollers.
During transport, no-one may be in the danger zone.
The basic machine may only be transported with transport
devices (support) fitted.
The transport devices must not be removed until the
machine body is anchored in the foundation.
When transporting the basic machine with armored rollers,
the armored rollers may only be attached at the marked
points pos. C (rotational moving device) and pos. D (fixed
armored rollers) according to fig. 71416.
The machine may not swing.
Observe center of gravity position.
Machine must hang horizontally on the cross beam or from
the sling chains.
If a cross beam is being used, the chains must hang vertically and symmetrically from the cross beam.
B836en
1
Sling chains
B
Sling chain securing point
D
Position of the armored rollers
2
Transport device support
C
E
A
Transport locking points
Rotational moving device position
Position of hydraulic hoisting
jack
Transport of the basic machine TruLaser Cell 8030 (L60)
Fig. 71416
Transporting basic machine with truck
The machine body with extension arm, including the switch cabinets in the machine body, the process cooler for the machine on
a console (optional) and the rear wall of the safety cabin are all
part of the transport unit of the basic machine.
B836en
Transport - Version 4
2‐57
Conditions
■
■
■
■
Cantilever is located centrally at position X1500.
Y slide is at position Y0.
Barrel is lowered to Z0.
Transport securing devices for switch cabinet doors are
mounted.
Means, Tools, Materials
■
■
Sling chain two-stranded (or spreader bar).
Indoor crane or mobile crane.
Note
The basic machine and the machine components may only be
transported on a truck withpneumatic suspension.
Preparing the basic machine
for transport
1. Screw the transport securing device support tightly in the
middle of the machine body. Tighten the fastening screws to
a max. torque of 100 Nm. Set the screw jack in such a way
that there is some 15 mm of space between the lower edge
and the factory floor.
2. For crane transport: tightly screw in the left swivel bearer into
the lower thread and the right swivel bearer into the upper
thread on the machine body up to the limit stop.
Attach sling chain to the swivel bearers at pos. B in accordance with fig. 71416.
Transporting the basic
machine
Unloading the basic
machine from truck
3. Lift the basic machine onto the loading area of the truck
using the indoor crane or crane truck.
4. Lock the support onto the loading area.
5. Remove sling chains.
6. Securely clamp the machine bodies to all of the locking
points (fig. 71416, pos. A, front and rear side) with transport
belts on the loading area of the truck.
7. Loosen transport belts.
8. Attach sling chains to the swivel bearers.
Note
For further transport using armored rollers: The machine
body should not be lowered to the floor without a support
frame as it would otherwise no longer be possible to install
hydraulic hoisting jacks under the machine body. The distance between the lower edge of the machine body and the
floor must be at least 100 mm.
9. Unload the basic machine from the truck using a crane or
crane truck.
2‐58
Transport - Version 4
B836en
Loading and unloading container
The basic machine and the workpiece changer are transported
together in one container.
Conditions
■
■
■
■
■
■
■
Cantilever is located centrally at position X1500.
Y slide is at position Y0.
Barrel is lowered to Z0.
Transport securing devices for switch cabinet doors are
mounted.
The point of the jib is disassembled and the transport protection is attached.
Energy chains of the X and Z axes are lowered and secured
with transport securing devices.
Partition walls and supporting sheets of the rotary indexing
table (optional) are disassembled.
Means, Tools, Materials
■
■
■
■
Sling chain two-stranded (or spreader bar).
Indoor crane or mobile crane.
Double ladder or telescopic boom lift.
Pallet jack or forklift truck.
Notes
■
■
B836en
The point of the jib is transported on a pallet.
Rotational changer or rotary indexing table (optional) are
transported on a pallet.
Loading container
1. First load the basic machine into the container either from
the top or from the front wall.
2. Securely clamp the machine bodies to all of the locking
points (fig. 71416, pos. A, front and rear side) with transport
belts in the container.
3. Then load and secure the other transport units into the container.
Unloading container
4. Open container at the top: Remove cover tarpaulin and
strengthening ribs or cover sheets.
5. Open container door.
6. Either fully remove the door bar or open and swivel to the
side on which the rear wall of the machine body is standing.
7. Loosen transport belts.
8. Attach sling chain or spreader bar to the swivel bearers
(fig. 71416, pos. B).
Transport - Version 4
2‐59
Note
For further transport using armored rollers: The machine
body should not be lowered to the floor without a support
frame as it would otherwise no longer be possible to install
hydraulic hoisting jacks under the machine body. The distance between the lower edge of the machine body and the
floor must be at least 100 mm.
9. Unload components one after the other: either by lifting them
out through the container wall or on the face side, horizontally through the open door.
Transporting the basic machine to the
installation site
Means, Tools, Materials
■
■
Sling chain two-stranded (or spreader bar).
Indoor crane or mobile crane.
or
■
Armored rollers and hydraulic jack.
Note
The basic machine and components are first positioned
beside the actual installation site.
1. With crane transport: Attach sling chains or spreader bars to
the swivel bearers securing points pos. B in accordance with
fig. 71416 and transport.
2. If the basic machine is to be transported with armored rollers
and rotational moving device to the installation site:
− Apply a hydraulic hoisting jack in accordance with
fig. 71416, pos. E to the machine body at the front and
rear sides.
− Lift all four hydraulic hoisting jacks slowly and evenly.
− Position armored rollers (pos. D) and rotational moving
device (pos. C) in accordance with fig 71416 underneath
the machine body.
− Lower the hydraulic hoisting jacks slowly and evenly.
− Drive the basic machine slowly to the installation site.
− Leave the basic machine standing on armored rollers
and rotational moving device.
2‐60
Transport - Version 4
B836en
Transport TruDisk laser device
The laser device can be transported by crane truck or forklift
truck. Please note:
■
■
When transporting with a forklift: The laser device may
not be tilted by more than a maximum of 10°. Use a padded
mat to protect the laser device from damage. Secure the
laser device from falling down using a transport belt on the
mast of the forklift truck.
When transporting using a lift truck: insert the lift truck so
that front rollers do not touch the bottom plate of the laser
device.
Conditions
■
■
■
■
Laser device is switched off.
Laser light cable (LLK) is disconnected.
Supply connections have been removed.
At temperatures below 0 °C or for long-distance transport:
The cooling circuit has been drained completely and blasted
using compressed air.
Means, Tools, Materials
■
■
NOTICE
Damage to the laser device!
Ø
Ø
Ø
Ø
B836en
Padded mat.
Pallet jack or forklift truck.
Carefully raise, transport and set down the laser device.
Transport the laser device standing and horizontally leveled.
Transport the laser device with an air-cushioned truck.
Use plywood crates for long-distance transport.
Transport - Version 4
2‐61
1
Padded mat
Transporting TruDisk
Fig. 81494
1. Cover laser device with a padded mat.
2. Insert the lift truck or forklift in the bottom plate of the laser
device according to Fig. 81494.
3. When transporting using a forklift truck: Secure the laser
device with a transport belt.
4. Lift and transport the device.
Transport rotational changer with a crane
or forklift
The rotational changer is transported completely mounted on a
wooden pallet. It can be transported either by crane or forklift
truck.
The wooden pallet can be grabbed either longitudinally or crosswise when transporting using the forklift truck.
If the wooden pallet is to be grabbed longitudinally by the forklift
truck, a fork length of at least 2.8 m is required.
Condition
■
Fixtures and horizontal fixture port are disassembled.
Means, Tools, Materials
■
■
■
2‐62
Transport - Version 4
Indoor crane or mobile crane.
Chains or transport belts.
Pallet jack or forklift truck.
B836en
Note
When transported with a forklift truck, the rotational changer is
transported on the wooden pallet.
1
4 securing points, load stand threading M16
Transporting the rotational changer
Fig. 73824
1. When the rotational changer is transported with a crane:
− Attach transport belts or chain slings to the four securing
points on the rotary table.
− Raise the rotational changer.
− Remove the wooden pallet.
− Transport the rotational changer to the installation site.
2. When the rotational changer is transported with a forklift
truck:
− Grab wooden pallet crosswise or longitudinally.
− Remove the wooden pallet at the installation site.
Transporting rotary indexing table with
crane or forklift truck
The rotary indexing table is supplied on a wooden pallet. It can
be transported either by crane or forklift truck.
Conditions
■
■
Fixtures and horizontal fixture port are disassembled.
Partition walls have been removed.
Means, Tools, Materials
■
■
■
B836en
Indoor crane or mobile crane.
Chains or transport belts.
Pallet jack or forklift truck with minimum carrying capacity of
8 MP.
Transport - Version 4
2‐63
Note
When transported with a forklift truck, the rotary indexing table is
transported on the wooden pallet.
1
3 securing points, attachment eye threading M20
Transporting rotary indexing table
Fig. 73825
1. When the rotary indexing table is transported with a crane:
− Attach transport belts or chains to the three securing
points on the rotary table.
− Raise rotary indexing table.
− Remove the wooden pallet.
− Transport rotary indexing table to the installation site with
crane or crane truck.
2. When the rotary indexing table is transported with the forklift
truck.
− Grab the wooden pallet from the narrow side and transport it to the installation site.
− Remove the wooden pallet at the installation site.
Transporting the safety cabin
The modules of the safety cabin are transported on a total of
three wooden pallets.
When transporting pallet 1 with 5.7 m in length using forklift
truck the following applies: The pallet may only be grabbed longitudinally by the forklift truck. The required fork length is at least
3.5 m.
2‐64
Transport - Version 4
B836en
Means, Tools, Materials
■
■
■
Indoor crane or mobile crane.
Transport belts.
Pallet jack or forklift truck.
Ø Transport the wooden pallets individually to the installation
site using a crane, a crane truck or a forklift truck.
Transportation of scrap conveyor
The rotational changer is transported completely mounted on a
wooden pallet. Ideally it should be transported with a crane.
When the scrap conveyor is transported with a forklift truck, grab
the wooden pallet crosswise if possible.
Means, Tools, Materials
■
■
■
Indoor crane or mobile crane.
Transport belts.
Pallet jack or forklift truck.
Ø Lift scrap conveyor with load straps at the 4 marked securing
points (2 bollards in the high-angle piece and 2 eye bolts in
the straight piece) and transport.
Transporting the compact dust extractor
(Herding)
The compact dust extractor has four flanges on the upper collar
/ on the sound proofing cover for attaching chains or transport
belts.
The device is transported horizontally on a wooden pallet and
only set upright once it is at the installation site and lifted off the
pallet afterwards.
Means, Tools, Materials
■
■
■
B836en
Indoor crane or mobile crane.
Transport belts.
Forklift truck
Transport - Version 4
2‐65
NOTICE
Damage due to improper transport!
Ø
Ø
Transport the compact dust extractor from the pallet to the
installation site.
At the installation site, only set the compact dust extractor
upright using a crane or crane truck.
1. Transport the pallet to the installation site with the forklift
truck.
2. Attach transport belts or chain slings to the securing points
and slowly set the device upright.
3. Only lift the device off the pallet when it is vertical.
Transporting process cooler
Means, Tools, Materials
■
■
Indoor crane or mobile crane.
Transport belts.
Ø Lift process cooler with chains or load straps at the
four marked securing points and transport.
Transporting the safety cabin
The modules of the safety cabin are either supplied on wooden
pallets or in a separate container directly from the supplier.
Ø Transport the wooden pallets to the installation site using a
crane, a crane truck or a forklift truck.
7.3
Installing the system
Preparing the factory floor
The factory floor must be prepared by the user in accordance
with the machine's foundation plan before the machine is delivered. The machine body is lowered onto the foundation by the
service engineer and secured and leveled.
2‐66
Transport - Version 4
B836en
Conditions
■
■
■
■
■
The foundations have been prepared. Holes and cut-outs
have been made in the factory floor in accordance with the
foundation plan.
The floor requirements at the installation site must comply
with the installation requirements. No expansion joints in the
factory floor are permitted inside the installation surface.
Any floor paint or screed which is available in the area of
the cast surfaces of the bore anchors must be removed.
The cast surfaces must be free of dust and grease.
Gas, air and power connections must be installed at the site
of the machine in accordance with these installation conditions.
Note
When using rotational moving devices, keep the machine body
or platform on the rotational moving device and armored rollers.
Have four hydraulic hoisting jacks readily available.
1. Clean the surface thoroughly. Remove any loose and nonadhesive coats of paint, laitance or screed from the area of
the cast surfaces.
2. Draw the zero point lines for the X and Y axes on the factory
floor.
3. Mark the bore holes to be used to anchor the machine body
on the factory floor.
4. Drill holes into the factory floor.
B836en
Transport - Version 4
2‐67
2‐68
Transport - Version 4
B836en
Chapter 3
Description
1
Machine concept
3‐3
2
Coordinate system and working range
3‐4
2.1
Coordinate system
3‐4
2.2
Working range
3‐6
3
Machine components
3‐8
3.1
Sub-assemblies of the basic machine
Machine body
3‐11
Motion unit
3‐11
Hydroforming package (option)
3‐11
Beam guidance
3‐12
Dynamic cutting optics
3‐13
3.2
Laser protection device
3‐19
3.3
Exhaust system and filtering installation
3‐21
3.4
Workpiece changer
3‐25
3.5
Clamping fixture
3‐29
Clamping fixture for hot-formed parts
B836en
2017-11-17
3‐10
Description
3‐34
3‐1
Clamping fixture for inner high-pressure
(IHU) formed workpieces
3‐2
Description
3‐37
3.6
Solid-state lasers
3‐43
4
Technical data
3‐45
2017-11-17
B836en
1.
Characteristics
Machine concept
The laser processing machine TruLaser Cell 8030 is a productive
machine which is ideally suited for the batch production of
formed sheet metal parts. It features standardized components
and compact installation.
The features are:
■
■
■
■
■
■
Solid-state lasers
B836en
2017-11-17
Suitable for laser cutting high-strength components with high
dynamics.
Using the solid-state laser TruDisk as a beam source allows
the machine to be integrated into a laser network.
Quick rotational changer with matching fixture system, including control.
Highly productive rotary indexing table (option) with 3 production places, including fixture equipment and a control.
Optional safeguarding of the danger zone around the workpiece changer outside of the safety cabin.
Scrap conveyor for continuous removal of cut-outs and sheet
skeletons.
The machine comes standard-equipped with a solid-state laser of
the TRUMPF TruDisk series, with a laser power of 2000 W,
3000 W or 4000 W.
Machine concept
3‐3
2.
Coordinate system and working
range
2.1
Coordinate system
The standard equipment for the system includes 5 NC axes. The
integration of additional NC axes is possible.
Coordinate system
Fig. 88769
X axis
Horizontal movement of the cantilever lengthwise in relation to the machine body
Y-axis
Horizontal travel movement of the Y carriage
Z axis
Vertical travel movement of the Z barrel
B axis
Swivel movement of the processing optics around the Y axis (±135°)
C axis
Rotary movement of the processing optics around the Z axis (n*x 360°)
NC axes of the machine
3‐4
Coordinate system and working range
Tab. 3-1
2017-11-17
B836en
Kinematic transformation
The machine has two coordinate systems:
■
■
Machine coordinate system (MKS): Kinematic transformation is activated. The path information for the X, Y and Z
axes refers to the coordinates of the pivot of the B/C axis in
the angular gear.
Workpiece coordinate system(WKS): Kinematic transformation is active. The path information for the X, Y and Z axes
refers to the coordinates of the tool tip (Tool Center Point).
The B and C axes perform compensating movements during
linear axes positioning.
Note
The kinematic transformation is activated with the
TC_TRAFO_ON command and deactivated with the
TC_TRAFO_OFF command.
Joint offset
The offset value for the X, Y and Z axes between the beam center of the pivot of the B/C angular gear and the beam center of
the focus point (Tool Center Point) is referred to as the joint offset.
1
Beam center of B/C gear pivot
2
Beam center (TCP)
Y
Joint offset of the Y axis
Z
Joint offset of the Z axis
Joint offset
B836en
2017-11-17
Fig. 37800
Coordinate system and working range
3‐5
2.2
Working range
Working range
Fig. 58690
X axis in mm
Y axis in mm
Z axis in mm
3000
1300
600
Working range
Tab. 3-2
X axis in mm
Y axis in mm
Z axis in mm
3000
1300
600
Working range
3‐6
Coordinate system and working range
Tab. 3-3
2017-11-17
B836en
The 3D working range (core range) depends on the processing
optics used.
3D working range
The zero point of the Z axis refers to the center of rotation in the
B/C gear (see Fig. 37800, pos. 1).
1
Working height
2
3D core range
3
Processing optics
3D working range
Fig. 28857
Core range
The core range is the 3D working range that can be used without restrictions, regardless of the position of the B and C axes.
The core range is calculated as follows:
B836en
2017-11-17
■
X3D = X2D - (2 x Zoffset)
■
Y3D = Y2D - (2 x Zoffset)
■
Z3D = Z2D - Zoffset
Coordinate system and working range
3‐7
3.
Machine components
1
Cooler (optional)
5
Instrument panel
8
Control panels
2
Basic machine
6
Scrap conveyor
9
Rotational changer
3
Switch cabinets
7
Control panel
10 Safety cabin
4
Compact dust extractor
Standard variant, machine with rotational changer
Fig. 71418
Components
Function
Documentation
Basic machine
Machining workpieces
Operator's manual
TruLaser Cell 8030
Spare parts catalogue
TruLaser Cell 8030
Control panel
Operation of the machine
Creation of NC programs
TruDisk laser device
Operator's manual
TruLaser Cell 8030
Data management
Programming manual
TruLaser Cell 8030
Generation of laser radiation
Operator's manual for TruDisk Laser
Spare parts catalogue for the TruDisk laser
Laser light cable (LLK)
Beam guidance from the laser
device to the basic machine
-
External process cooler for TruDisk
Cooling the laser unit and optical
components of the machine
Operator's manual for the process
cooler
Chiller for basic machine
(optional)
Cooling the optical components of
the machine
Operator's manual
TruLaser Cell 8030
3‐8
Machine components
2017-11-17
B836en
Components
Function
Documentation
Switch cabinet
CNC control for machine
Electrical circuit diagram
Electrical supply to drives
Logic and performance section
Safety cabin
Shield against laser radiation
-
Securing the danger zone
Compact dust extractor
Extraction of fumes and airborne
particles in the working room
Operator's manual for the compact
dust extractor (filtering installation),
Herding
Rotational changer
rotary indexing table (option)
Holding and fixing the workpieces
during processing
Operator's manual
TruLaser Cell 8030
Scrap conveyor
Collection and removal of waste
parts and sheet skeletons from the
work area
Operator's manual for the Kabelschlepp scrap conveyor
Components of the laser processing machine
Nameplate
Tab. 3-4
The nameplate is located next to the main switch.
Video monitoring (option)
Fig. 78933
Camera for work area monitoring
The machine can be optionally equipped with a video camera for
work area monitoring and with a monitor.
Software is protected by
copyright
B836en
2017-11-17
The software installed on the machine, including any storage
media and documentation supplied may only be used for this
machine. The software may only be copied to make a backup.
The software may not be sold or passed on without the
machine. If the machine is sold, the buyer must assume a corresponding obligation to this effect.
Machine components
3‐9
3.1
Sub-assemblies of the basic machine
1
Z barrel
5
Machine body
2
Y axis drive
6
B- and C-axis drive
3
X-axis drive
7
Extension arm
4
Z-axis drive
8
Processing optics
Basic machine modules
Fig. 75192
Assembly
Function
Machine body
Tool holder of the motion unit and all functional
components.
Motion unit
Tool holder X-, Y- and Z- carriageBeam guidance components and media feed.
Z barrel
Laser beam guidance and media feed.
Drives for B and C axis.
Collimation
Coupling of laser light cable in the barrel.
Processing optics
Focuses the laser beam on the workpiece.
Basic machine modules
3‐10
Machine components
Tab. 3-5
2017-11-17
B836en
Machine body
The machine body is a torsion-resistant welded construction. It
includes all basic functions that are relevant to the machine's
accuracy. These include:
■
■
Motion unit holder.
Fixation of the safety cabin, energy supply, suction system
and all technical functions concerning gases and devices.
The solid anchoring with cast wedge mounts provides optimum
rigidity and the long-term alignment of the machine.
The two switch cabinets are mounted on the rear side in the
machine body; the device panel is on the front side in the
machine body.
Motion unit
The motion unit consists of a cantilever extension arm and the
attached Y slide with integrated Z axis. The extension arm is
connected to the machine body via guide rails (X slide). The
most important modules of the motion unit include:
■
■
Cantilever with Y slide and X drive.
Z axis drive and guide (barrel).
The following are integrated in the barrel:
■
■
■
■
Drives for B and C axis.
B/C gear and angular gear.
Magnetic coupling and processing optics.
Collimation: input coupling of the laser beam in the barrel.
The travel ranges of the X, Y, and Z axes are limited by software
limit switches.
Hydroforming package (option)
The hydroforming package is a machine option. It is normally
used on machines primarily used to process workpieces formed
with high internal pressure (IHU).
The hydroforming package protects the motion unit from dirt and
wear. The following components belong to the hydroforming
package option:
■
■
B836en
2017-11-17
Protective hoods for the motors of the X, B and C axes.
Metal fins for protecting the Y axis bellows.
Machine components
3‐11
■
■
Cover for protecting the Z axis rack.
Various protective plates.
Beam guidance
Optical components
The laser beam is directed through the barrel to the deflection
mirror in the B/C gearbox and channeled to the processing
optics. Quartz lenses in the processing optics focus the beam
through the nozzle onto the workpiece.
The laser light is coupled with a laser light cable (LLK), coming
from the beam source, from above via the cable carrier into the
Z barrel in the collimation.
The collimation has a quartz lens. The beam diameter is
adjusted in the factory using this lens.
In addition to the beam source, the LLK, the collimation, as well
as the processing optics are among the optical components of
the machine. The laser light cable, collimation and optics form
an optical unit and depend on the beam quality.
Laser device
LLK diameter
Focal length
collimation
Focal length
processing
optics
TruDisk 2000
75 μm
f = 100 mm
f = 200 mm
TruDisk 3001
100 μm
f = 89 mm
f = 150 mm
TruDisk 4001
Optical configuration depending on the beam quality
Tab. 3-6
Notes
■
The laser light cable and collimation may only be replaced
together. The replacement may only be performed by
TRUMPF service engineers. After replacement, a basic
adjustment of the beam is required.
Improper replacement will lead to the destruction of the
collimation and laser light cable!
■
Notice! The new generation of cutting optics for the TruLaser
Cell 8030 (L60) may not be used on the predecessor
machine TruLaser Cell 8030 (L45) or on a machine of the
TruLaser Cell 7000 series (L31).
The raw beam diameter is too large for the focusing lens
and will lead to the thermal destruction of the optics.
■
3‐12
Machine components
On the TruLaser Cell 8030 (L60) machine with a LLK diameter of 100 μm, it is possible and permissible to use dynamic
cutting optics of the predecessor machine TruLaser Cell 8030
(L45) or the TruLaser Cell 7000 series (L31).
2017-11-17
B836en
Collimation cooling
The collimation and the connection of the laser light cable is
cooled via the cooling circuit of the laser device (laser recooling
unit) as standard. Optionally, the machine can be used with a
recooling unit (machine cooler) for cooling the optical components.
Deflection mirror in the B/C
gearbox
The deflection mirror in the B/C gearbox directs the laser beam
to the processing optics. The deflection mirror is air-cooled.
Option FocusLine: The deflection mirror is an adaptive mirror,
which controls the focal position with compressed air.
FocusLine
With the FocusLine option, the focal position is automatically
adapted to the type of material and sheet thickness during processing. The focal position is controlled via the laser technology
table (LTT) and the FocusLine mirror in the B/C gearbox.
FocusLine has the following advantages:
■
■
■
A utility program is used to exactly determine the focal position.
The focal position is automatically adjusted to the respective
sheet thickness and type.
The focal position can vary during processing.
The following applies to machines without FocusLine:
■
■
Before the beginning of processing, the focal position must
be adjusted manually depending on the type of material and
sheet thickness.
The focal position is not determined using a utility program.
The required focal position must be determined by means of
tests.
Dynamic cutting optics
Notes
■
■
B836en
2017-11-17
Operation of the "dynamic distance regulation": refer to the
"TruLaser Cell series operator's manual", chapter
"Operation", section "Working with dynamic distance regulation".
Programming the "dynamic distance regulation": refer to the
"TruLaser Cell programming manual", chapter "Cycles for
laser processing", section "Dynamic distance regulation".
Machine components
3‐13
NOTICE
Thermal destruction of the optics if used on a predecessor
machine TruLaser Cell 8030 (L45) or on a machine of the
TruLaser Cell 7000 series (L31)!
Ø
These cutting optics of the new generation may only be
used on a TruLaser Cell 8030 (L60).
1
Catch strap
5
Additional axis drive
2
Magnetic coupling
6
Cutting insert
3
Housing
7
Sensor body and nozzle
4
LED display
Dynamic cutting optics
Fig. 75193
The dynamic cutting optics is equipped with an additional axis
for dynamic distance regulation (ADC).
The cutting optics are marked laterally with the material number,
serial number as well as a product code. The machine control
recognizes the product code automatically.
The optical components are made of silica glass, they are not
cooled.
Technical data
3‐14
Machine components
Dynamic cutting optics
F150 D30 R230
F200 D25 R230
Focal length
f =150 mm
f = 200 mm
X axis joint offset
0 mm
0 mm
Y-axis joint offset with magnetic
coupling
-158 mm
-158 mm
Y-axis joint offset without magnetic coupling
-112 mm
-112 mm
2017-11-17
B836en
Technical data
Dynamic cutting optics
F150 D30 R230
F200 D25 R230
230 mm
230 mm
Stroke of ADC additional axis
±10 mm
±10 mm
Weight with yoke plate
Approx. 5 kg
Approx. 5 kg
Theoretical focal position for collimated beam
Nozzle distance
1 mm
Nozzle distance
3 mm
Permissible focal position adjustment range
-5.25 mm to
+5.25 mm
-12.5 mm to
+8.0 mm
Z axis joint
offset13
Technical Data
Sensor system
Tab. 3-7
The sensor system of the cutting optics features dedicated software which is checked when the optics are set up and automatically updated if required.
The software consists of two components: the bootloader to load
the software and the software program itself. The electronics of
the cutting optics use this software to communicate with the distance regulation (ControlLine) of the machine.
The current operating status of the sensor system is displayed
using LEDs.
Fig. 51640
LED display
Display
Normal
mode
Update
Error
Error
Error
POWER (green)
Power supply present
Illuminated
Illuminated
Illuminated
Illuminated
Illuminated
ONLINE (orange)
Connection to ControlLine active
Illuminated
Illuminated
off
off
off
13 Nominal tool length, corresponds to the swivel radius at 1 mm nozzle
distance in the neutral position of the additional ADC axis.
B836en
2017-11-17
Machine components
3‐15
Display
Normal
mode
Update
Error
Error
Error
BOOT (red)
Bootloader active
off
Illuminated
flashes
off
Illuminated
RUN (yellow)
Software program active
Illuminated
flashes
flashes
off
off
Measures required
-
-
Electronics
defective.
Send the
cutting
optics to
TRUMPF for
repair.
Electronics
defective.
Send the
cutting
optics to
TRUMPF for
repair.
Communication with
ControlLine
interrupted:
contact
TRUMPF
Technical
Service.
Sensor operating status display
Magnetic coupling
Tab. 3-8
The processing optics are held by a magnetic coupling. The
magnetic coupling consists of an overload flange, mounted on
the barrel, and an overload plate at the processing optics. The
holding force is generated by permanent magnets. The overload
flange is the primary part (permanent magnet). The overload
plate is the anchor part.
In case of a collision of the processing optics with workpieces or
objects in the work area, the electrical monitoring circuit between
the primary part and the anchor part is interrupted; the processing optics are released from the flange.
Note
The green LED on the magnetic coupling lights up when the
processing optics are docked correctly on the magnetic coupling.
3‐16
Machine components
2017-11-17
B836en
1
Catch strap
5
Foam rubber
2
Bellows
6
LED magnetic coupling
3
Metal cable ties
7
Knurled screw
4
Sleeve
Magnetic coupling with bellows
Fig. 60955
Damage to the processing optics when torn from the
magnetic coupling!
NOTICE
Ø
Ø
Ø
Ø
Ø
Replace the banjo screws whenever the processing optics
are dropped.
Properly mount the catch strap.
Replace damaged catch strap.
Replace damaged bellows.
Set the B and C axes to 0° before switching off the
machine.
The processing optics are secured against uncontrolled ejection
when there is a collision with the following securing elements:
■
■
B836en
2017-11-17
With the catch strap, as far as it is mounted.
With bellows. The bellows "open" in the event of a collision.
Here, the bellows on the yoke plate of a bushing are held
onto the flange with 3 knurled screws. In the event of a collision, the bellows protect the optics as well as the beam guidance from dirt.
Machine components
3‐17
Securing element, bellows
Fig. 60957
Notes
■
■
■
3‐18
Machine components
Catch-ropes can be used in combination with a bellows.
The foam rubber in the yoke plate seals and protects against
dirt. If damaged, the foam rubber must be exchanged.
When exchanging the bellows, the two metal cable ties
(inside and out) for fastening the bellows must be
exchanged.
2017-11-17
B836en
3.2
Laser protection device
In order to protect the operator against laser radiation, the work
area of the system is equipped with an encapsulated safety
cabin with a roof and lateral service doors. The safety cabin is
comprised of sheet elements. The window in the service door is
a special laser protection window.
Doors and laser light-relevant cover plates are monitored with
the use of safety locks. The laser beam is only ignited if the
doors are closed.
The interface between the workpiece changer and the safety
cabin is protected by partition walls and sealing strips. Partition
walls and sealing strips are part of the laser protection device of
the machine.
1
2
Safety cabin sealing strips
(green)
3
Rotational changer partition wall
4
Laser protective window
5
Conveyor/safety cabin interface
Partition wall sealing strips (red)
Overview of the safety cabin with a rotational changer
B836en
2017-11-17
Fig. 71420
Machine components
3‐19
1
Conveyor/safety cabin interface
3
Partition wall sealing strips (red) 5
2
Safety cabin sealing strips
(green)
4
Rotary indexing table partition
wall
Laser protection window
Overview of the safety cabin with a rotary indexing table
3‐20
Machine components
Fig. 71421
2017-11-17
B836en
3.3
Exhaust system and filtering
installation
The aerosols and dust emitted when laser cutting metal are
extracted from the working range of the machine and directed to
a suction and filtering system (compact dust extractor) via a pipe
system, where they are separated efficiently.
The work area of the machine is vacuum-cleaned through the
open surface of the scrap conveyor. The suctioned air is guided
to the compact dust extractor via 2 connection sockets and a
piping system.
When the exhaust system is in operation, there is underpressure
inside the safety cabin.
During machining, a cyclone arises around the workpiece and
the fixture. The airflow must be permitted to flow unimpeded so
that the work area can be vacuum-cleaned effectively. This is to
be observed in the constructive design of the fixtures and fixture
holders.
In order to guarantee the full efficiency of the exhaust system,
pay attention to the following:
■
■
■
■
■
B836en
2017-11-17
Fixtures and fixture holders must be permeable for the circulating air.
The slottings in the front side of the safety cabin must not be
sealed.
The service door is sealed with foam rubber. The door must
be fit closely so that it is air-tight. If there is even a small
amount of damage, the foam rubber must be replaced.
The guide plates (see the following figures), which effectively
support air circulation, must not be dismounted. The lateral
guide plates must be closed during processing.
The grids in the exhaust piping to the left and right on the
scrap conveyor must be checked daily and cleaned weekly.
Machine components
3‐21
1
Guide plate, machine body
2
Lateral guide plates, front and
rear
3
Guide plates, scrap conveyor
Exhaust system, machine with rotational changer
1
Guide plate on the machine
body
2
Lateral guide plate, rear
3
Hinged guide plate
4
Lateral guide plate, front
5
Guide plate, scrap conveyor
Exhaust system, machine with rotary indexing table
3‐22
Machine components
Fig. 75194
2017-11-17
Fig. 75195
B836en
Arrangement of fixtures
During machining, a cyclone arises around the workpiece and
the fixture. The airflow must be permitted to flow unimpeded so
that the work area can be vacuum-cleaned effectively. For this
reason, the following should be observed when arranging the fixtures and fixture holders during construction:
■
■
■
■
The fixture or fixture holder must be permeable for the circulating air.
The plane between the rotational changer and the fixture or
fixture holder (section B, Fig. 61680), including the workpiece, must allow air to permeate over the whole cross-section in a section of at least 200 mm.
The clearance at the cantilevered end of the fixture or fixture
holder must be at least 200 mm over the whole cross-section
(section A, Fig. 61680).
The maximum fixture height is 600 mm, starting from
Z = 0 mm.
Note
Recommendation for the design of cutting fixtures: see "Cutting
fixture" section.
1
Fixture/workpiece
A
Clearance
2
Scrap conveyor
B
Air-permeable section
3
Rotational changer
Arrangement of fixtures
Compact dust extractor
Fig. 61680
The machine is equipped as standard with a compact dust
extractor (synonym: filtering installation) with a spark arrester.
The dust container is equipped with a special non-flammable,
replaceable fine dust bag for collecting the extracted dust . The
extracted dust is collected and disposed of in the dust bag.
The compact dust extractor can optionally be equipped with the
following components:
■
■
B836en
2017-11-17
Fire extinguisher with argon or CO2 as inert extinguishing
gas for fighting fires in the compact dust extractor.
Soundproofing cover for reducing the sound pressure level
by 3 dB at the workplace (see the "Noise level test certificate" chapter.
Machine components
3‐23
■
■
MultiCoater for preventive fire protection ("inertization") or for
protecting the filter elements ("Precoating").
The fill level sensor signals when the maximum permissible
fill level has been reached. In this case, the control issues a
message.
The suction power inside the safety cabin is 4000 m3/h. The air
suctioned in the work area is separated and cleaned in the compact dust extractor. The cycles for purging the filter elements are
controlled according to the jet-pulse principle (depending on the
differential pressure).
Extinguisher system
(optional)
If the compact dust extractor is equipped with an automatic
extinguisher system, an acoustic alarm is triggered if a fire is
detected. The gate valves of the air supply and exhaust air system are immediately closed. The complete interior space of the
compact dust extractor is flooded (gaseous) CO2 or argon.
MultiCoater
The (optional) MultiCoater is an autonomous device that is connected to the control and supply ports of the compact dust
extractor. The compact dust extractor must be prepared for the
use of an MultiCoater.
The MultiCoater blows dispensing material (calcium carbonate or
trass powder) onto the filter elements of the compact dust
extractor in the clean gas space.
During start-up of the laser processing machine, the MultiCoater
is normally parameterized for a use case or operating mode. A
distinction is made between the following operating modes:
■
■
"Inertization": means minimizing the risk of fire. A large
amount of dispensing material is continuously blown into the
clean gas space of the compact dust extractor and thus
added to the discharged dust.
"Precoating": After the cyclic purging of the filter elements,
dispensing material is applied to the filter elements for protection. Pre-coating can be used for processing oily sheets.
The filling level of the storage container is monitored. If the permissible minimal filling level has been reached, a message will
be issued.
The MultiCoater's cover is monitored by a proximity switch. If the
cover is opened while the red lamp is lit, the pre-coating procedure is interrupted. After the cover is closed, the pre-coating procedure will continue after 5 seconds. While the pre-coating procedure is active, the red signal light next to the cover is lit.
Signal light is lit
Pre-coating procedure is active.
Do not open the cover from the
storage container.
Signal light flashes
Compressed air supply is insufficient.
Check why either no or too little
compressed air has been provided.
Red signal light
3‐24
Machine components
Tab. 3-9
2017-11-17
B836en
3.4
Workpiece changer
The workpiece changer is the work station at which the workpieces are clamped in a fixture during machining.
The components are set up outside of the safety cabin. Afterwards, the workpiece changer rotates the clamped component
into the machining position. After the end of machining, the workpiece changer rotates into the unloading position. Afterwards, the
finished machined workpiece can be removed and a new unprocessed part set up.
1
Device box fixture
3
Slot number
5
Workpiece
2
Production place number
4
Fixture interface
6
Fixture
Workpiece changer with fixture and workpiece
Components
Each workpiece changer consists of standard modules and fixtures (optional). The changer consists of the following assemblies:
■
■
■
■
B836en
2017-11-17
Fig. 74470
Drive with rotary plate and partition wall(s).
Fixture interface:
− Rotary plate for mounting a maximum of 2 fixtures per
production place.
− Media connections for electrics, pneumatics and vacuum
(optional) for the connection of the fixtures.
Horizontal fixture carrier (option): 2 carriers for each production place for accommodating the fixtures.
Project-specific TRUMPF fixtures or customer-provided fixtures.
Machine components
3‐25
Loading and unloading the
workpieces
Operating production places as well as workpiece changer: (see
"Operating the workpiece changer", pg. 4‐57)
Workpieces can be loaded and unloaded in different ways.
Machine with rotational changer and Basic Loading safeguarding
device (standard):
Fig. 71178
The loading and unloading area is located at the front in front of
the safeguarded danger zone.
3‐26
Machine components
2017-11-17
B836en
Machine with rotational changer and Comfort Loading safeguarding device (option):
Fig. 71179
All 4 sides around the safeguarded danger zone can be used for
loading and unloading.
B836en
2017-11-17
Machine components
3‐27
Machine with rotary indexing table (option) and safeguarding
device:
Fig. 75196
The rotary indexing table has 3 production places, which can be
used for either loading or unloading. The user can configure the
loading and unloading area himself. The rotary indexing table
moves by 120° for each step.
Scrap conveyor
Waste parts or scrap skeletons are collected on a scrap conveyor and transported out of the work area with a conveyor belt.
The lag time of the scrap conveyor is 90 seconds.
NOTICE
Property damage caused by a scrap skeleton or waste parts
which are too large or too small.
Scrap skeleton and waste parts block the conveyor belt.
Ø
Ø
Ø
3‐28
Machine components
Scrap skeleton or waste parts may not exceed the minimum
and maximum dimensions.
Set parting cuts.
Before entering reverse mode, remove the waste parts from
the conveyor belt.
2017-11-17
B836en
3.5
Clamping fixture
The workpieces are fixed in a correct position with high repetition
accuracy and clamped in a clamping fixture during processing.
A maximum of four fixtures (two for each production place) can
be mounted per production place on the workpiece changer.
Each fixture can have at most 4 pneumatic clamps plus 2 parallel clamps (standard). Project-specific solutions might deviate
from this.
Depending on the workpiece, the following fixture types are differentiated:
■
■
Set of drawings
The clamping fixture's scope of delivery includes a set of drawings in the device's terminal box:
■
■
■
■
■
Fixture port
Clamping fixtures for workpieces formed by internal high
pressure.
Clamping fixtures for hot-formed workpieces.
Fixture with identification of the clamping units, clamping cylinders and sensors (Bero) as well as the fixture dimensions.
Identification of the measuring points and fixture reference
point run on the workpiece changer.
Measurement data table: The measurement data table contains the reference values determined during start-up of the
fixture, which establish the reference to the machine zero
point (G500).
If available: Fixture-specific transport regulation.
Optional documentation:
− Pneumatic schematic and electrical schematic.
− Layout, input and output addresses of the KSS.
− If required, fixture-specific transport regulation.
The fixture is mounted on the workpiece changer at the prescribed fixture place and is connected to the fixture interface pneumatically and electrically.
All actuators of the fixture, such as clamping devices, sensors or
positioner, are configured, controlled and operated via the configurable control interface.
The actuators are program-controlled opened and closed in automatic mode. In setup mode, the clamps are operated via switch
elements or via manual functions.
Note
Fixture interface: See "Supplement to operator's manual", "Configurable control interface (KSS)", chapter "Interface description".
B836en
2017-11-17
Machine components
3‐29
Actuation via KSS
The cylinder in the positioner as well as the clamping devices
are controlled via the configurable control interface from the NC
program with the TC_ELEMENT_STATE NC cycle. The programming is done via configurable KSS elements, such as "cylinder"
and "clamping device".
■
■
Sample configuration for the pneumatic cylinder in the positioner:
− The cylinder should run in (actual position); this corresponds to status 2 "run in", for example, for the KSS element, "cylinder".
− The cylinder should extend (required position); that corresponds to the status 1 "extend" for the KSS element,
"cylinder".
Sample configuration for a clamping device:
− The clamping device should be opened, which corresponds, for example, to the status 2 "Open" for the
"clamping device" KSS element.
− The clamping device should be closed, which corresponds, for example, to the status 1 "Closed" for the
"Clamping device" KSS element.
Note
KSS configuration and operation: see "Supplement to operator's
manual", "Configurable control interface (KSS)".
Workpiece recognition
Check workpiece sensors to see if the workpiece is correctly
inserted in the clamping fixture. Only when all sensors detect the
workpiece and loading acknowledgement has taken place by the
operator or by an external automation, will the clamping devices
be closed in the configured clamping sequence.
The workpiece query is visualized on the terminal box with
LEDs. The visualization is optional.
■
■
3‐30
Machine components
If the workpiece has been detected, the LED will lit up green.
If the workpiece has not been detected, the LED will not light
up.
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1
LED display
Workpiece query display
Fig. 65651
Usually, there is a maximum of four workpiece sensors on one
fixture. The inputs E1 to E4 identify the individual sensors. The
input E1 corresponds to the first sensor when starting from the
left. The sensors are always counted from left to right.
Reference point run to the
machine zero point
Every fixture has a mechanical, fixed zero point (B1) that is
measured at the factory during start-up of the fixture and entered
in a measurement data table. The mechanical zero point may be
a measuring ball, a RPS bolt, a cross-hairs or another mechanical component on the fixture.
The fixture zero point B1 always refers to the reference point A1
on the workpiece changer.
B836en
2017-11-17
Machine components
3‐31
Zero point (B1) of the fixture, example
Fig. 86289
Referencing the fixture to the workpiece changer: For the
commissioning of the clamping fixture at the machine, the zero
point of the fixture B1 is measured to the reference point A1 on
the workpiece changer. B1 is referenced to A1 by determining
the deviation (offset). The measured offset values are entered in
the measurement data table.
Referencing the fixture to the machine zero point (G500):
During start-up of the clamping fixture at the machine, the measured reference values are transferred to the machine control.
Start-up of the fixture on the machine is normally performed by a
TRUMPF employee.
Notes
■
■
■
■
■
3‐32
Machine components
Do not change the mechanical zero point of the fixture.
Reference point run of the fixture, reference points, zero
points and measuring points (C and D): see Set of drawings
for the fixture, sheet 3.
Reference point run to reference point A1 on the workpiece
changer: see set of drawings for the fixture, sheet 3.
In the program, the fixture zero point B1 usually corresponds
to the programmed workpiece zero point.
Project-specific solutions may deviate from the default specifications.
2017-11-17
B836en
Each clamping fixture is marked as follows:
Identification
■
Fixture number (coding).
Number of the fixture place on which the fixture is mounted.
Nameplate.
CE marking.
2
Fixture place number
■
■
■
1
Fixture number (coding)
3
Nameplate
Identification
Fig. 86288
The nameplate contains the following information:
■
■
■
■
■
■
■
■
B836en
2017-11-17
Product classification.
Machine number and year of manufacture.
Workpiece number and workpiece designation.
Approved operation for a machine or for a machine type.
Pneumatic and electric connected loads.
Weight and bushing position on the workpiece changer.
TRUMPF drawing and material number.
Manufacturer.
Machine components
3‐33
Clamping fixture for hot-formed parts
In this type of clamping fixture, hot-formed, three-dimensional
sheets are generally inserted and fixed with clamping elements.
Assemblies
A clamping fixture of this type generally consists of the following
assemblies, which are structurally adapted to the workpiece:
■
Carrier frame with mounting mandrel as well as full and pass
fitting pins for positioning the fixture in the centering bushings
on the workpiece changer. So-called clamping nests are on
the carrier frame that consist of clamping and support units.
Cover sheet for protecting the workpiece changer.
Pneumatic clamping units for clamping the workpiece.
Support units and sensors for fixing the workpiece and
detecting its position.
Protective plates for protecting the fixture from laser radiation
and slag.
Terminal box with supply connections.
■
■
■
■
■
1
Terminal box
4
Carrier frame
7
Full and pass fitting pins
2
Cover plate
5
Guard plate
8
Mounting mandrel
3
Clamping unit
6
Support unit
9
Fixing screws
Clamping fixture for hot-formed parts
3‐34
Machine components
Fig. 65645
2017-11-17
B836en
Clamping unit
Every clamping unit consists of a clamping cylinder and a clamping arm.
1
Display
2
Clamping arm
3
LED indicator, clamping cylinder
Clamping unit
Fig. 65649
You can monitor the clamps for proper clamping at the display
on each of the clamps:
■
■
The clamp is clamped correctly when the display is extended
and the LED for the clamping cylinder lights up in green.
If the display is not extended, the clamp is either open or not
clamped correctly.
Note
Emergency triggering: In an emergency, the clamp can be
opened manually by pushing the display down on the clamp.
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Machine components
3‐35
Support unit
The workpiece is loaded in the loading position in the open
clamping fixture; when this is done, the workpiece is inserted in
the correct position into the support units with light pressure.
Support unit
Fig. 65650
Every index pin is adjusted to the workpiece geometry when the
fixture is commissioned. Due to the manufacturing tolerances of
the formed workpiece, it might be necessary to readjust the
index pins.
The position of the support points on the fixture is corrected by
adding adjusting shims of different sheet thickness to the index
pins.
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Machine components
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B836en
Clamping fixture for inner high-pressure
(IHU) formed workpieces
In this type of clamping fixture, hollow profiles are generally
inserted and fixed with clamping elements.
The hollow profiles are workpieces which have been formed by
the "internal high pressure forming" (hydroforming) process.
These workpieces will be referred to below as "IHU workpieces".
Every clamping fixture of this type consists of a carrier frame
and at least one swivel frame. The positioning unit and so-called
clamping nests are located on the swivel frame.
Assemblies
1
Clamping nest
4
Terminal box
7
Fixture interface
2
Positioner
5
Cover plate
8
Carrier frame
3
Swivel unit with swivel frame
6
Mounting mandrel
Assemblies, IHU clamping fixture
Fig. 86285
A clamping fixture consists of the following assemblies, which
can vary in detail, depending on the workpiece:
■
■
■
B836en
2017-11-17
Carrier frame with mounting mandrel as well as full and pass
fitting pins for positioning the fixture in the centering bushings
on the workpiece changer.
Cover sheet for protecting the workpiece changer.
Clamping nests consisting of pneumatic clamping units as
well as support units and workpiece sensors for fixing the
workpiece.
Machine components
3‐37
■
■
■
■
■
Swivel unit
1
Swivel unit
2
Positioner
Swivel unit, consisting of swivel frame and swivel axis for
swiveling the workpieces during the processing.
Positioner for positioning the raw parts (optional).
Terminal box with supply lines.
Fixture interface for pneumatic and electric connections.
Protective plates for protecting the fixture from laser radiation
and slag.
In the following example, two swivel units are mounted opposing
each other on the support frame of the clamping fixture.
3
Swivel frame
4
Clamping and support unit
Swivel unit
Fig. 86279
The swivel unit swivels the swivel frame each by 180° with the
clamped workpiece during machining into the end position. The
swivel axis is actuated via the KSS.
The positioner as well as the clamping nests are firmly connected to the swivel frame.
3‐38
Machine components
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B836en
Clamping unit
Every clamping unit consists of a clamping cylinder and a clamping arm.
1
LED indicator, clamping cylinder 3
2
Display
Clamping arm
Clamping unit
Fig. 86287
You can monitor the clamps for proper clamping at the display
on each of the clamps:
■
■
The clamp is clamped correctly when the display is extended
and the LED for the clamping cylinder lights up in green.
If the display is not extended, the clamp is either open or not
clamped correctly.
Emergency triggering: In an emergency, the clamp can be
opened manually by pushing the indicator down on the clamp.
The middle clamping units can have a ball roller (optional)
instead of the thrust piece. These clamping devices close first.
B836en
2017-11-17
Machine components
3‐39
The ball roller allows the workpiece to be moved into the
required position by the positioner later on.
1
Ball roller
2
Loaded bearing
Workpiece fixing
Support unit
Fig. 86280
The support unit consists of index pins and slats. For insertion of
the raw part into the clamping fixture, the workpiece is placed in
the correct position in the index pin.
1
Support bolt
Support unit
Fig. 86904
Every index pin is adjusted to the workpiece geometry with
shims when the fixture is commissioned. Due to the manufactur-
3‐40
Machine components
2017-11-17
B836en
ing tolerances of the formed workpiece, it might be necessary to
readjust the index pins.
The position of the support points on the fixture is corrected by
inserting shims of different sheet thickness under the index pins.
Positioning unit (optional)
Each positioner includes a pneumatic cylinder, a positioning bolt
and a fork for positioning the workpiece.
1
Positioner
2
Positioning bolt
3
Fork
Positioner
Fig. 86284
The fork is pressed forward during positioning via the geometry
of the cone at the end of the workpiece. Once the sensor for the
fork query signals that the required fork position is reached, the
pushing movement of the positioner ends.
The required position of the fork is measured and adjusted to
the zero point of the fixture at the factory. When the pneumatic
cylinder retracts, the fork is spring-loaded back into the starting
position.
Notes
■
■
B836en
2017-11-17
The fork depends on the workpiece. The fork may also have
to be replaced when the workpiece is changed.
Run in the positioner again only after the separating cut at
the end of the processing. If the positioner is run in too early,
damage (deformation or breakage) to the workpiece can
result.
Machine components
3‐41
Insert and position the
workpiece
Insertion position
The cylinder is retracted in the insertion position. The cylinder is
extended in the required position.
Required position
Position the workpiece
Fig. 86905
The workpiece is placed down with the smallest funnel crosssection from above onto the conical surfaces on the fork.
The middle clamping devices with the pressure roller close first
in the clamping sequence. After these clamping devices are
closed and the workpiece is fixed in the insertion position, the
positioning bolt presses the workpiece into the required position.
Once the workpiece is in the required position, the rest of the
clamping devices close.
Fig. 86905
3‐42
Machine components
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B836en
3.6
Solid-state lasers
The system comes equipped with a solid-state laser from the
TruDisk Series from TRUMPF as standard. Lasers with a laser
power of 2000 W, 3000 W or 4000 W are used.
Fig. 90041
Notes
■
■
Optical laser cable
TruDisk laser device: see "TruDisk operator's manual".
For processing with the solid-state laser: see "Technical information on solid-state laser".
The machine is shipped standard-equipped with a laser light
cable ((LLK) permanently installed between the laser device and
the machine.
The laser light is coupled to and routed in an optical fiber. The
optical fiber is a thin thread of silica glass.
Note
A renewed basic adjustment of the beam guidance is required
after the LLC has been replaced, which may not be performed
by anyone other than trained specialists.
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2017-11-17
Machine components
3‐43
Laser network
The solid-state laser has a maximum of 6 Profibus interfaces.
The machine is assigned a Profibus interface, a hardware interface and a light path no. at the time the laser processing system
is commissioned.
The operator must know the number of the Profibus interface of
the laser device assigned at the time of the commissioning of
the machine if the machine is operated in a laser network.
If the laser is shipped with 2 or more light path couplings, then
the scope of delivery of the laser will also include:
■
■
Control panel and panel computer.
"Interface description TruDisk" manual.
Note
Laser device control interfaces: See "Interface description TruDisk" manual.
Remote diagnostics
The remote diagnostics for the laser device take place through
the remote diagnostics port on the machine.
Cooling system
The laser device has an internal cooling circuit which is usually
connected to an external cooling unit or a domestic water installation.
Pilot laser
The system is standard-equipped with a pilot laser (synonym:
alignment laser). The pilot laser is a laser diode which emits light
at the wavelength of 635 nm. The light beam of the laser diode
is coupled into the beam guidance of the machine through the
laser light cable.
The pilot laser projects a small red spot of light (diameter
approx. 2 mm) on to the workpiece. This means the processing
optics can be positioned quickly and easily. The pilot laser is
used as follows:
■
■
■
■
3‐44
Machine components
For aligning and adjusting the laser beam.
For approaching a start position.
For recording the contour during teaching.
For moving along the 3D contour of a workpiece, e.g. in
order to check a taught NC program.
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B836en
4.
Working range
Technical data
X axis
3000 mm
Y-axis
1300 mm
Z axis
600 mm
B axis
±135°
C axis
n*360°
Horizontal top edge of the fixture
interface
650 mm
Center of the socket fitting on the
rotary plate
650 mm
Workpiece changer swiveling
range
Rotational changer
180° forward/backward
rotary indexing table
n*120°
Maximum axis speed
Simultaneous
173 m/min
X axis
100 m/min
Y-axis
100 m/min
Z axis
100 m/min
B axis
90 rpm
C axis
90 rpm
Smallest possible increment
0.001 mm
Workpiece changer working
height
Accuracy14
Maximum repeatability:
- Linear axes: X, Y, Z
0.03 mm
- Rotary axes: B, C
0.005°
Maximum positioning
CNC control
deviation15:
- Linear axes: X, Y, Z
0.08 mm
- Rotary axes: B, C
0.015°
Hard drive with RAID controller
USB port
Base:Siemens 840D Solution Line
Platform
2x SSD with 128 GB MLC flash
memory
Color monitor
19" TFT display
Processor: Prozessor Intel® Celeron® 2000E 2,2 GHz, 2 Cores
Technical data
Tab. 3-10
14 The part precision that can be achieved depends, among other things,
on the type of workpiece, its pre-treatment, the sheet size, the material
and its position within the working area. The technical specifications
are based on different component variants, due to the modular program of the TruLaser Cell. They depend on the options in use.
15 Purely mechanical accuracy without control compensation, measured
over the entire travel distance of the axis in accordance with VDI 3441.
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2017-11-17
Technical data
3‐45
Network connection
Network card (Ethernet)
100 Mbit/s
Connection
RJ 45 plug
maximum cable length 100 m
Supported network protocols
NET BEUI, TCP/IP, Novell server,
NTFS file system
Required line pressure
(without options)
min 6 bar
max. 14 bar
Compressed air consumption
see the "Installation conditions"
chapter (see "Compressed air supply", pg. 2‐43)
Electrical connection
Connected loads
see the "Installation conditions"
chapter (see "Connected load and
fuse protection", pg. 2‐37)
Permissible beam source
Laser device
TruDisk 2000
TruDisk 3001
TruDisk 4001
Pneumatic connection
Technical data
Tab. 3-11
The following technical data is valid for a symmetrical loading of
the workpiece changer:
Rotational changer
rotary indexing table
Rotary plate diameter
4000 mm
4800 mm
Maximum permissible load per
production place without horizontal fixture port
300 kg
300 kg
Maximum permitted load per production place with horizontal fixture port (for one fixture per production place)
260 kg
260 kg
Maximum permissible moment of
inertia
1270 kgm2
2700 kgm2
Rotation time
2.1 s (180°)
2.3 s (120°)
Effective width of scrap conveyor
650 mm
Permissible outer circle diameter
of the waste parts
maximum diameter: 500 mm
Permissible bend height of waste
parts
maximum of 50 mm related to the outer circle diameter level
Permissible sheet thickness of
waste parts
maximum: 3 mm
minimum: 1 mm
Rotational changer, rotary indexing table and scrap conveyor.
3‐46
Technical data
Tab. 3-12
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Chapter 4
Operation
B836en
2017-11-17
1
Description of the controls and indicators
4‐8
1.1
The machine's main switch
4‐11
1.2
Control panel
4‐14
1.3
MobileControl
4‐19
Installing the MobileControl app
4‐22
Activate MobileControl at the machine.
4‐23
Switching between control and observation
mode
4‐27
Exiting MobileControl
4‐28
1.4
Access Control Key System user management
4‐29
1.5
Decentral control panel
4‐34
1.6
Status indicators
4‐37
1.7
Scrap conveyor
4‐38
1.8
Compact dust extractor
4‐40
1.9
Acknowledge the danger zone
4‐41
1.10
Mechanically lock the door
4‐42
Operation
4‐1
2
Operating modes of the machine
4‐43
3
Operating the machine
4‐44
3.1
Entering the work area
4‐45
3.2
Switching the machine on and off
4‐46
3.3
3.4
3.5
3.6
3.7
4‐2
Operation
Switching on the machine
4‐46
Switching off the machine
4‐48
Shutting down the machine in the event of a
malfunction/emergency
4‐50
Tripping the EMERGENCY STOP
4‐50
Cancelling the EMERGENCY STOP
4‐50
Trip the extinguisher with a manual alarm
4‐50
Check safety functionality
4‐52
Manually start the safety test
4‐53
Issue user consent
4‐54
Eliminate malfunction
4‐55
Triggering FEED HOLD
4‐55
Acknowledging FEED HOLD after opening
the door
4‐55
Acknowledging FEED HOLD after a collision involving the nozzle
4‐55
Restarting processing after knocking off the
processing optics
4‐56
Operating the workpiece changer
4‐57
Manual functions
4‐59
Rotating workpiece changer in setup mode
4‐59
RSTAcknowledge the loading operation in
automatic mode
4‐60
RW: Acknowledge the loading operation in
automatic mode
4‐60
Acknowledging malfunction
4‐61
Acknowledging clamping error
4‐61
Operate scrap conveyor
4‐62
Starting the conveyor belt
4‐63
Stopping the conveyor belt
4‐63
Starting the conveyor belt in reverse mode
4‐64
Eliminate malfunction
4‐64
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4
Description of the user interface
4‐65
5
System settings
4‐71
5.1
Setting data and time
4‐71
5.2
Selecting language and measuring system
4‐71
5.3
Activate the on-screen keyboard
4‐72
5.4
Open TRUMPF Operating System (TOS)
4‐73
5.5
Close user interface
4‐73
5.6
Switching to the TruControl interface
4‐74
6
User administration
4‐75
6.1
Log on user group
4‐76
6.2
Change password
4‐77
6.3
Deleting the password
4‐77
7
Production plan
4‐78
7.1
Creating and editing a production plan
4‐81
Creating a new production plan
4‐82
Editing job data
4‐84
Disable job
4‐84
Delete the order in the production plan
4‐84
Delete programs and orders
4‐85
Deleting a production plan
4‐85
7.2
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2017-11-17
Production with the production plan
4‐86
Starting a production plan (manual loading)
4‐87
Starting a production plan (automatic loading)
4‐89
Changing the program sequence
4‐90
Modifying the number of program runs
4‐91
Stopping the production plan with "Stop
after cycle end"
4‐92
Starting to run empty, ending the production
plan
4‐93
7.3
Exporting order
4‐93
7.4
Starting step-by-step cycle
4‐94
7.5
Loading and workpiece status
4‐94
Displaying the loading and workpiece status
4‐96
Changing the loading and workpiece status
4‐98
Acknowledging workpiece status with manual loading
4‐99
Operation
4‐3
Acknowledging the workpiece status with
automatic loading
7.6
Remaining time display
Configuring the remaining time display
4‐105
Production
4‐115
8.1
Current program
4‐115
Start program
4‐115
Pause program
4‐116
Aborting a program
4‐116
Switch screen view
4‐116
Display Switching over the axis positions
4‐117
Display NC simulation
4‐117
8.3
8.4
Preparing programs
4‐118
Import master file
4‐118
Prepare program
4‐119
Manual functions
4‐120
Call manual functions
4‐122
Activating marking test mode
4‐123
Activating STOP after single contour
4‐124
Display the workpiece counter
4‐124
Resetting the workpiece counter
4‐124
Utility tools
4‐125
Starting utility programs
4‐125
9
Setup
4‐126
9.1
Moving the axes manually
4‐126
9.2
Operation
4‐101
8
8.2
4‐4
4‐99
Moving the axis continuously
4‐126
Moving the axis incrementally
4‐126
Manual functions
4‐127
Call manual functions
4‐130
Requesting the laser in the laser network
4‐131
Enabling the laser in the laser network
4‐131
Enabling the dynamic distance control system
4‐132
Deactivating the dynamic distance control
system
4‐132
Positioning the additional axis
4‐133
Activating distance regulation
4‐133
ControlLineRecord characteristic curve
4‐134
Switching the kinematic transformation on
or off
4‐134
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9.3
9.4
Displaying and resetting workpiece counter
4‐135
Running a warm start
4‐136
Focal position without FocusLine setting
4‐136
MDA
4‐138
Execute the NC blocks in the following
block
4‐138
Execute the NC blocks in a single block
4‐138
Configuration
4‐139
Configure loading and unloading place
4‐141
Configure loading and unloading place
4‐141
Programming
4‐144
10.1
Program management
4‐144
10.3
10.4
10.5
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4‐135
10
10.2
B836en
Park axes
Selecting program
4‐146
Creating a new program
4‐146
Copying a program
4‐147
Editing a program in the text editor
4‐147
Create subroutine
4‐148
Number program
4‐150
Exporting program
4‐150
Importing program
4‐151
Delete program
4‐151
Show setup plan
4‐152
Show PDF file
4‐152
Creating and managing subroutine macros
4‐153
Creating a subroutine macro
4‐154
Processing a subroutine macro
4‐155
Deleting the subroutine macro
4‐156
Inserting the Subroutine macro
4‐156
Transformation
4‐159
Applying the actual position as the zero
point
4‐161
Moving zero point incrementally
4‐162
Select Frame and fill transformation accumulator
4‐162
Deleting transformation accumulator
4‐163
Operate KSS
4‐163
Start KSS configuration
4‐163
Activate module and load module data
4‐164
Deactivating the module
4‐164
Programming system
4‐165
Operation
4‐5
Starting TruTops Cell Basic
4‐165
Call up advanced shop floor programming
4‐165
11
Technology
4‐166
11.1
Laser cutting
4‐167
11.2
Selecting the setting for the "Table" selection field
4‐168
Creating a cutting table
4‐168
Edit the cutting table
4‐169
Ramp cycles
4‐170
Programming ramp cycles
11.3
Managing the tooling status
4‐172
Creating a new setup state
4‐173
Editing the tooling level
4‐174
Deleting a setup state
4‐175
12
Maintenance
4‐177
12.1
Manual functions
4‐177
12.2
Partial backup
4‐177
12.3
4‐177
File manager
4‐178
Edit and save file
4‐179
13
Diagnostics
4‐180
13.1
Displaying all messages
4‐180
13.2
Displaying all messages
4‐180
13.3
Displaying the software version
4‐181
13.4
Display I/O monitor
4‐181
13.5
Logging the process data for service purposes
4‐182
13.6
Starting Teleservice
4‐182
13.7
Visual Online Support (VOS)
4‐184
Starting Visual Online Support
Operation
4‐171
Activate setup state
Backing up data
4‐6
4‐170
4‐185
14
Help
4‐189
14.1
Starting online help
4‐190
14.2
Editing bookmarks
4‐190
14.3
Starting context-sensitive help
4‐191
15
Teachen
4‐192
15.1
Teach panel
4‐194
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15.2
Description of the user interface
4‐201
15.3
Activating TEACHIN operating mode
4‐203
15.4
Starting online help
4‐204
15.5
Setting basic functions
4‐204
15.6
15.7
15.8
15.9
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2017-11-17
Automatically replacing the zero point
4‐204
Activate the imperial (inch) measuring system
4‐205
Activate and set the NC axes
4‐205
Setting threshold values for determination of
the geometry deviation
4‐206
Configure the function for F1 and F2 buttons
4‐208
Configure the cycle selection for the F1 key
4‐209
Delete the configuration for the F1 key
4‐210
Recording teach points
4‐211
Teaching a straight line
4‐211
Teaching the arc with CIP
4‐212
Teaching the macro center
4‐213
Teaching macro help point
4‐213
Teaching circular contour
4‐214
Teaching a rectangle contour (square)
4‐215
Teaching oblong hole
4‐217
Creating new program
4‐219
Creating a new program
4‐219
Setting the zero point
4‐220
Approach edge incrementally.
4‐220
Incorporating the contour
4‐223
Editing a program
4‐224
Searching and replacing NC text
4‐225
Insert and process cycles
4‐225
Select value for the name variable laser
technology table.
4‐226
Selecting the laser technology table
4‐227
Inserting block numbering
4‐227
Testing and correcting the program
4‐227
Correcting the zero point
4‐228
Inserting H word
4‐228
Correct path
4‐229
Testing the program
4‐230
Operation
4‐7
1.
1
Decentral control panel
2
Control panel
3
Description of the controls and
indicators
Scrap conveyor control panel
4
Main switch
Rotational changer with Basic Loading safeguarding device
1
Decentral control panel
2
Control panel
3
Scrap conveyor control panel
Fig. 71412
4
Main switch
Rotational changer with Comfort Loading safeguarding device
4‐8
Description of the controls and indicators
Fig. 74465
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B836en
1
Scrap conveyor control panel
2
Decentral control panel
3
Control panel
4
Main switch
Machine with rotary indexing table (option)
Operating element
Requirement
MAIN SWITCH
EMERGENCY
STOP push-button
B836en
Fig. 71413
Explanation
-
The main switch is a power isolation device.
No
■
ON: The electrical power supply is switched on.
■
OFF: The electrical power supply is switched off.
The following functions are triggered by pressing the
EMERGENCY STOP push-button:
■
All axes motions stop at maximum braking power.
■
The drives are switched off.
■
Gas supply is interrupted.
■
The power supply for the machine (except the 24 V
voltage to the control system) will be interrupted.
■
An active program is aborted and must be restarted,
if required.
■
The installed light path is interrupted. The absorber
(beam trap) closes.
WLAN tablet PC
(option)
The tablet PC is
switched on
Operating the machine.
Teach panel(see
"Teach panel",
pg. 4‐194)
TEACHIN key
switch in ON
position
Teach panel for TEACHIN operating mode.
Scrap conveyor
control panel
MAIN SWITCH
Machine in ON
position
Operate scrap conveyor:
2017-11-17
■
Acknowledge malfunction.
■
Switch off the power to the drive motor.
■
Start the reversing operation.
Description of the controls and indicators
4‐9
Operating element
Requirement
Explanation
-
No persons are
inside the safety
cabin.
By pressing the button, the danger zone inside the
safety cabin is acknowledged when exiting the safety
cabin.
ACKNOWLEDGE THE
DANGER ZONE
Control elements not on the control panel
Tab. 4-1
Operating element
Requirement
Explanation
Main switch
Process cooler is
switched on
Operating the laser: See the "TruDisk" manual.
Key-operated switch
Control panel
(option)
Note:
All operations required for operating and programming the laser
processing system are done from the user interface of the
machine control, with the exception of laser diagnostics and the
"Show laser device" maintenance wizard.
Computer panel
(option)
EMERGENCY
STOP push-button
For information regarding the operation of the laser control system,
see the "TruControl 1000" software manual.
The button is not
encapsulated.
The EMERGENCY STOP push-button on the laser device triggers
an EMERGENCY STOP only for the laser device.
Note:
If the EMERGENCY STOP push-button on the laser device is
encapsulated and therefore not operable, the EMERGENCY STOP
of the machine also affects the laser device.
Controls for the TruDisk laser device
4‐10
Description of the controls and indicators
Tab. 4-2
2017-11-17
B836en
1.1
The machine's main switch
Note
If the main switch is switched off, the illumination inside the
safety cabin will also be switched off.
The MAIN SWITCH is on the front of the machine's body.
1
MAIN SWITCH
Machine main switch
B836en
2017-11-17
Description of the controls and indicators
Fig. 73840
4‐11
Machine main switch
Requirement
Explanation
Decentralized electrical power supply
(standard)
Switch on: The laser
device and the laser
cooler are switched
on.
The machine, the laser device and the
process cooler each have their own electrical connection.
Switch off: The
machine control system will be shut
down.
Central electrical power supply (option)
Switch on: none
Switch off: The laser
and machine control
systems have been
shut down.
The machine's main switch only switches
the electrical power supply to the machine
on and off.
The laser device and the process cooler
(laser heat exchanger) each have their own
main switches (mains disconnector). For
the machine to be ready for use, all 3 main
switches must be switched on.
The machine, the laser device and the
process cooler each have their own electrical connection. The machine's main switch
switches the electrical power supply to all
components on and off.
The laser device and the process cooler
(laser heat exchanger) also each have their
own main switches. These components can
be switched on or off independently from
the machine's main switch.
Machine main switch
Tab. 4-3
Under Voltage Trip key
switch
1
MAIN SWITCH
2
Key switch Under Voltage Trip
Fig. 59607
4‐12
Description of the controls and indicators
2017-11-17
B836en
If the Under Voltage Trip key-operated switch is at inactiv,
the machine's safety circuit is bypassed. There is
dangerous voltage at all live components.
DANGER
Risk of fatal injury due to electric shock!
Ø
Ø
Ø
Observe the warning signs.
Do not touch live parts.
Only qualified electricians may work on the machine's electrical equipment.
Key-operated switch
inactiv
activ
Under Voltage Trip
The undervoltage trip is
bypassed. If the switch cabinet
door to the machine's main
switch is opened, there is still a
dangerous voltage on all of the
electrical components.
If the switch cabinet door to the
machine's main switch is closed
then there will be voltage on all of
the components. As soon as the
switch cabinet door is opened, the
undervoltage trip is used to switch
off the mains disconnector.
This state may only be activated
for fault-finding by properly qualified electricians.
If the switch cabinet doors or the
switchboxes are opened with the
MAIN SWITCH ON, then there is
still a dangerous voltage. These
doors and switching devices are
labelled with warnings.
Tab. 4-4
Under Voltage Trip key-operated switch
B836en
2017-11-17
Description of the controls and indicators
4‐13
1.2
Control panel
The machine is operated via the control panel.
1
User interface
4
Operating panel
2
Teach panel
5
TEACHIN key switch
3
USB connection
6
Keyboard
Control panel
Fig. 74469
Operating element
Explanation
Operating panel with display
Operation of machine and laser
device
Keyboard
Text input for user interface
TEACHIN KEY SWITCH
Activation of TEACHIN operating
mode
USB port
Connection of peripheral devices,
e.g. for data transmission
Control panel
4‐14
Description of the controls and indicators
Tab. 4-5
2017-11-17
B836en
Operating element
Name
Requirement
Status
Description
NUMBER PAD
-
-
Number input for the user
interface.
CHANGE OF
SIGN
-
-
Changes the operational
sign in input fields without
deleting the previously
entered value.
BACKSPACE
-
-
Moves the cursor one
character to the left each
time it is pressed. The
character to the left of the
cursor is deleted.
ESCAPE
-
-
Undoes any entries that
were started but not completed.
ENTER
-
-
Confirms values that have
been entered.
TOUCHSCREEN
-
-
Locks touch-screen operation, e.g. to clean the
screen.
On machines with the
MobileControl option:
unlock the screen.
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CHANGE OF
APPLICATION
-
-
Switches between applications, e.g. between the
TRUMPF Operating System (TOS) and the user
interface.
PAGE UP/
PAGE DOWN
-
-
Scrolls a list up/down.
MAGNIFYING
GLASS
-
-
Increases/decreases the
view.
TAB
-
-
Moves the cursor to the
next input field.
2017-11-17
Description of the controls and indicators
4‐15
Operating element
Name
Requirement
MACHINE
ON/OFF
■
■
The control
system is
ready for
operation.
Status
■
Illuminates: The
machine is ready to
operate.
■
Flashes: Power supply
to drives.
The power supply of
the drives is switched
on with MACHINE ON.
Test cycles are performed for monitoring
the supply devices
(compressed air, axes,
etc.).
■
Or: An error is pending
(e.g. emergency stop),
drives cannot be
switched on.
The drives are
switched off in the
event of EMERGENCY
STOP.
■
After the releasing the
EMERGENCY STOP
push-button, the drive
must be switched back
on.
■
The button is illuminated: LASER TEST
mode is active.
LASER TEST operating
mode will be activated or
deactivated.
■
Off: LASER TEST
mode is deactivated.
■
In LASER TEST mode,
the laser beam and the
gas supply will be
switched off.
■
A program can be run
without a laser beam.
EMERGENCY
STOP is not
active.
LASER ON/OFF
RESET
FEED HOLD
4‐16
-
Laser device is
ready for operation: The
ON/OFF button
on the laser
device is lit up
in blue.
-
-
Switches the machine
drives on or off.
■
■
LASER TEST
Description
−
Slow: Drives are
ready to be
switched on.
−
Fast: Drives have
been switched on.
Off: Drives are
switched off.
■
Illuminated: Laser is
switched on.
The laser is being
switched on or off.
■
Off: Laser is not
switched on.
■
■
Flashing slowly: Laser
is switched on or is in
standby mode.
Pressing briefly
switches the laser on
or switches the laser to
standby mode.
■
■
Flashing quickly: Laser
control is being shut
down.
Pressing for longer
switches the laser off
and shuts down the
laser control.
■
Flashes: An error is
pending.
■
Cancels the running
program.
■
Off: No errors pending.
■
Immediately ends the
production plan.
■
Acknowledges error.
■
Acknowledges EMERGENCY STOP after
unlocking the push-button.
■
Description of the controls and indicators
Illuminates: FEED
HOLD is pending.
2017-11-17
Stop all machine movements. The laser beam
and the gas supply are
being switched off.
■
No axis movements
are possible while
FEED HOLD is active.
■
No beam enable for
the installed light path.
B836en
Operating element
Name
Requirement
Status
Description
ACKNOWLEDGING
FEED STOP
Feed hold is
active.
-
Acknowledges FEED
HOLD.
START
■
FEED STOP
is not active.
■
Illuminates: Program is
active.
■
The machining program
has been
selected.
■
Off: The program has
been ended.
■
Flashes: the light barThe status display is valid
rier is interrupted, wait for a machine with a rotafor loading acknowledg- tional changer.
ment.
■
Off: the light barrier
has been acknowledged.
■
Status display,
light barrier
-
LEFT and
RIGHT navigation buttons
-
PLUS and
MINUS button
■
■
FEEDRATE
POTENTIOMETER
EMERGENCY
STOP is not
active.
Note:
The potentiometer only works at
0% or 100% in
the "Production"
user group; an
infinitely variable
setting is not
possible.
Starts the selected
machining program.
-
Have no effect.
-
Move the axes in jog
mode.
Manual function of the
switch: increase or reduce
value.
FEED STOP
is not active.
"Standard" user
group is active.
-
Controls the speed of
movement of the NC axes
between 0 - 120 %:
■
2017-11-17
In setup mode: Feed
speed between 0 4 m/min (without
simultaneous mode).
In teach mode, the
maximum speed corresponds to the safe
speed.
■
B836en
Continues an interrupted machining program.
In automatic mode:
The feed rate with
simultaneous axis
motion is between 0 85 m/min.
Description of the controls and indicators
4‐17
Operating element
Name
Requirement
Status
Description
EMERGENCY
STOP push-button
-
-
■
Stops the movement of
all axes at maximum
braking power.
■
Switches the drives off.
■
Interrupts the gas supply.
■
Aborts the active
machining program. It
will have to be
restarted.
■
Interrupts the installed
light path. Closes the
absorber.
■
Interrupts the electrical
power supply to the
process cooler and
compact dust extractor.
Note:
After unlocking the EMERGENCY STOP push-button, the drives must be
switched on again: Press
the RESET button and
then the
MACHINE ON/OFF button.
Tab. 4-6
Operating elements
4‐18
Description of the controls and indicators
2017-11-17
B836en
1.3
MobileControl
The MobileControl function is a machine option. Using the MobileControl app, the live image of the user interface of the
machine is transferred to a mobile terminal. The MobileControl app allows the user to control the machine remotely (in control mode) or to monitor it (in observation mode).
Fig. 73679
Observation mode: The user interface of the machine is transferred to the tablet or smartphone as a live image. The machine
is still operated via the control panel. Observation mode is
visualized on the control panel as a blue-green bar at the upper
edge of the display.
Control mode: If the MobileControl function is active in control
mode on the machine, then the machine can only be operated
via the tablet or smartphone. Control mode is visualized on the
user interface on the control panel with a yellow-red control
frame.
Note
The TEACHIN operating mode as well as the teach panel can
be operated in control mode.
B836en
2017-11-17
Description of the controls and indicators
4‐19
MobileControl App
Remote control of the machine is carried out using a tablet PC
or smartphone and the MobileControl app supplied by TRUMPF.
Here, the MobileControl app is connected to the local WLAN network of the machine.
The MobileControl app can be downloaded free of charge
from Google Play or in the Apple App-Store.
Tab. 4-7
Note
The MobileControl app has an online help. When the app is
open, it is called up via the lower button bar with the "Question
mark" button.
MobileControl software
The MobileControl software is licensed and enabled by the service engineer when the machine is commissioned or retrofit on
the machine.
The user connects the MobileControl app to the machine control
using the MobileControl Manager.
Note
If the MobileControl software is activated via the TRUMPF Telepresence Portal, the connection to the Telepresence Portal must
be ended before the MobileControl function can be activated on
the machine.
Wireless Operating Point
Wireless Operating Point (WOP) is the router for the local WLAN
of the machine.
The MobileControl app and the machine control are connected
via the WLAN router in the electrical cabinet of the machine.
Note
The Wireless Operating Point has no connection to the
machine's network drives or to the customer's network.
Local WLAN of the machine
The user interface as well as the live image of the observation
camera (option) are transmitted to the mobile terminal via the
local wireless network (WLAN) of the machine.
The WLAN connection between the MobileControl app and the
machine control is started after entering a password or PIN.
WPA key
4‐20
In the MobileControl manager, a WPA key is generated at the
machine once or for every new activation. The WPA key (QR
code) contains the access data for the WLAN connection: password (WPA2-Key) and network name (SSID).
Description of the controls and indicators
2017-11-17
B836en
The automatically generated network name corresponds to the
following scheme: "TRUMPF_machine_number (or
alias)_MCA". Instead of the machine number, the user can
assign an individually chosen network name (Alias).
Notes
■
■
Prerequisites
If a mobile terminal is used for multiple machines, a new
WPA key must be generated for every new activation of
MobileControl on a machine.
If a new WPA key is generated, all previously connected
mobile terminals must be reconnected with the WLAN of the
machine afterwards.
The following conditions must be met in order for the MobileControl function to be able to be used on the machine:
■
■
■
The machine is equipped with the TRUMPF Wireless Operating Point (WOP).
The MobileControl software is activated on the machine.
The MobileControl app is installed on the mobile terminal.
The user requires a tablet PC with a camera or a iPhone. The
following devices are supported:
■
■
Restrictions
iPad Tablet with camera (minimum requirement: iOS version 7.0).
iPhone (minimum requirement: iOS version 7.0).
Remote control via MobileControl cannot be used under the following conditions:
■
■
In service mode.
If the machine control is connected with the TRUMPF Telepresence Portal.
Note
If the MobileControl software is enabled via the Telepresence Portal, the connection with the Telepresence Portal must
be ended before remote control via MobileControl can be used.
B836en
2017-11-17
Description of the controls and indicators
4‐21
Installing the MobileControl app
The MobileControl app must be installed on the mobile terminal.
Condition
■
Downloading the
MobileControl app
Internet connection is active.
1. Open the app store and tap on the TRUMPF icon.
2. Select the MobileControl app.
− Tap on Load.
− Tap on Install.
Once the icon of the app is displayed on the tablet, the app
is downloaded and installed.
Adapting the configuration
3. Tap on the "Settings" icon.
The "Configuration" menu is opened.
MobileControl app, "Configuration" menu
Fig. 86901
4. Activate the following function: Under "General Settings":
"Deactivate idle mode".
5. Tap on Save.
4‐22
Description of the controls and indicators
2017-11-17
B836en
Activate MobileControl at the machine.
Conditions
■
■
■
Starting the
MobileControl app
Opening the MobileControl
Manager
The machine is ready for operation.
TRUMPF MobileControl app is installed on the tablet PC.
MobileControl software is enabled.
1. Switch on the mobile terminal.
2. Start the MobileControl app.
3. At the machine's control panel: open TRUMPF Operating System (TOS):
− Press the CHANGE APPLICATION button.
− Select TRUMPF Operating System (TOS).
4. Press Operator.
5. Press Network ....
6. Select MobileControl Manager and press Start.
The MobileControl Manager is opened.
MobileControl Manager
Fig. 86052
Note
The presettings in MobileControl Manager usually do not
have to be changed.
7. Activate the following functions, assuming they are not
already activated automatically:
− "MobileControl enabled": activate or deactivate MobileControl.
− "MobileControl Input Allowed": Operation should be done
using the mobile terminal. If MobileControl is deactivated,
B836en
2017-11-17
Description of the controls and indicators
4‐23
the remote control cannot be activated in the MobileControl app.
− "MobileControl enabled on startup" (optional): MobileControl should be active when the machine is switched on.
8. If the network name (SSID) is to be changed:
− Enter the network name in the Machine Alias field and
press Set Alias.
A network name defined by the user is generated instead of
the "machine number".
Generating or displaying the
WPA key
Note
If a new WPA key is to be generated, the current WPA key
must be deleted first (see online help for the MobileControl app).
9. Either
Ø To show the current WPA key: press Show WPA2-Key.
or
Ø If a new WPA key should be generated:
− Press Generate new WPA2-Key.
− To show the WPA key: press Show WPA2-Key.
10. Press OK.
The generated WPA key, consisting of the QR code, password (WPA2-Key) and network name (SSID), is shown.
Fig. 73680
11. Tap on the button with the "QR code" in the lower button bar
on the tablet.
The tablet camera will start.
12. Scan the QR code on the machine with the tablet.
The password is saved to the clipboard and can be pasted
to the tablet from there later. The network name is saved in
the app.
4‐24
Description of the controls and indicators
2017-11-17
B836en
Connecting the
MobileControl app with the
machine control
13. Tap on the "Settings" icon (gearwheel) on the tablet in the
lower button bar.
1
WLAN status
2
Network name (SSID)
Fig. 86903
14. In the "Settings" column, tap on "WLAN".
15. In the "WLAN" column, tap on the network name (SSID) of
the machine.
16. Paste the password from the clipboard:
− Tap on "Password".
− Tap on Insert.
The password is pasted from the clipboard.
17. Tap on Connect.
The WLAN connection is set up. If the status of the WLAN
connection shows a green checkmark, the tablet is con-
B836en
2017-11-17
Description of the controls and indicators
4‐25
nected to the WLAN of the machine. Observation mode is
active.
1
Observation mode bar
Fig. 86900
Activating control mode
18. Show the MobileControl app again.
Note
Input via PIN or QR code can be selected by tapping the
Change method button. The selected method is self-holding.
19. On the tablet under "Settings", tap the Activate Remote Control button.
A QR code or, alternatively, a 4-digit PIN (depending on the
selected method) is displayed.
20. Scan the QR code or PIN.
Control mode is activated. A yellow/red control frame
appears on the user interface. The machine can now be
operated exclusively via the mobile terminal. The
4‐26
Description of the controls and indicators
2017-11-17
B836en
touchscreen as well as the buttons on the control panel are
disabled.
1
Control frame
Fig. 86902
21. On the mobile terminal: To change from the TOS to the HMI,
tap on the "change of application" icon.
Switching between control and observation
mode
If control mode is active, the operator can switch between
control mode and observation mode via the yellow "control
mode" and "observation mode" buttons on the upper edge of the
touchscreen on the control panel. MobileControl remains activated here and the WLAN connection is maintained.
B836en
2017-11-17
Description of the controls and indicators
4‐27
Conditions
■
■
MobileControl is active.
Control mode is active.
"Control mode" button
"Observation mode" button
Tab. 4-8
1. At the control panel: press the TOUCHSCREEN button.
The touchscreen is enabled.
2. In order to switch to observation mode, press the "observation mode" button.
Observation mode is active.
3. To switch back to control mode, press the "control mode"
button.
Control mode is active again. The machine can now be operated via the mobile terminal again. The touchscreen on the
control panel is disabled again.
Exiting MobileControl
The WLAN connection is only broken once remote control is
deactivated.
Note
If the WLAN connection is broken unintentionally, control mode
can be ended at any time with the "observation mode" button on
the touchscreen.
1. At the control panel: press the TOUCHSCREEN button.
The touchscreen is enabled.
2. Tap on "Settings" (gearwheel) on the tablet.
3. Tap on the Deactivate Remote Control button.
The WLAN connection is broken.
4. Close the MobilControl app.
4‐28
Description of the controls and indicators
2017-11-17
B836en
1.4
Access Control Key System user
management
Access Control Key System is an option for the laser machine.
The electronic user management system from Euchner of the
Electronic-Key-System EKS Light type is an electronic access
control.
With a hardware ID key (RFID chip), the user can assign userspecific rights to the personnel (operator, person doing set-up
work, etc.) for the machine control.
Prerequisites:
■
■
■
The option is applied on the machine.
The reading device for the RFID chips is mounted on the
control panel.
Before use, the user wrote the user ID as well as the "User
group" (user rights) to the chip.
Note
If the Access Control Key System is applied at the machine,
then user management by issuing passwords (standard) does
not work.
TRUMPF scope of delivery
The scope of delivery of the Access Control Key System option
by TRUMPF includes the following components:
■
■
■
User scope of delivery
The following Electronic-Key-System EKS Light components do
not belong to the TRUMPF scope of delivery. The user must
procure these components from Euchner:
■
■
■
■
B836en
2017-11-17
Interface adapter (analysis device) mounted in the machine's
control panel housing.
Reading device (key adapter) for RFID chips is mounted on
the control panel.
User management and assigning rights in the machine control.
Electronic-Key-Manager - EKM management software (including the supplementary software adapted to TRUMPF) from
Euchner for programming the RFID chips.
Electronic keys, RFID chips (with 116 bytes of read/write
memory).
Key adapter with USB interface and connection cable for the
USB interface.
Optional: EKS table housing for installing the key adapter.
Description of the controls and indicators
4‐29
Components
Euchner order number
Euchner item number
Management software Electronic-Key-Manager - EKM:
"EKM-Light Version" or "EKM single-user version"
-
-
Management software "EKM single-user version" on
CD ROM
098578
EKM single-user version
Management software "EKM-Light Version" on
CD ROM
111410
Light Version
Supplementary software with TRUMPF input dialog box
German: 099972-600
-
Note: this software must be ordered and activated in
consultation with the Euchner.
English: 099972-610
Compared to Light Version, the management software
"EKM single-user version" also has a database viewer
for managing the user rights.
French: 099972-620
Spanish: 099972-630
Italian: 099972-640
Electronic keys, RFID chips (with 116 byte write and
read memory)
Red: 077859
EKS-A-K1RDWT32-EU
Black: 084735
EKS-A-K1BKWT32-EU
Blue: 091045
EKS-A-K1BUWT32-EU
Green: 094839
EKS-A-K1GNWT32-EU
Yellow: 094840
EKS-A-K1YEWT32-EU
White: 123097
EKS-A-K1WHWT32-EU
Orange: 123098
EKS-A-K1OGWT32-EU
EKS key adapter with USB interface
092750
EKS-A-IUX-G01-ST01
Manual for EKS key adapter, can be ordered or downloaded free of charge
German and English:
094485
USB & USB FSA
USB driver EKS: includes a driver for the key adapter
with USB interface and a driver for the virtual serial
COM port for the Windows operating system.
094376
EKS USB Driver
USB 1.1 or USB 2.0 connection line for the EKS key
adapter
-
-
Optional: EKS table housing for the key adapter
113106
EKS DESKTOP CASE
Tab. 4-9
Notes
■
■
Programming the RFID chips
The downloads are free of charge. Download under:
https://www.euchner.de/Service/Downloads
A commercially available USB 1.1 or USB 2.0 connection
line (up to max. 3 m) is required for connecting the EKS key
adapter via the USB interface. On the EKS side the line
requires a type B USB connector; for the USB interface a
type A connector.
The Euchner software "EKM Light Version" or "EKM single-user
version" is used to program the RFID chips.
This software has a specific input dialog box for TRUMPF
machines.
4‐30
Description of the controls and indicators
2017-11-17
B836en
"EKM" software input dialog box
Fig. 86051
Note
The software is only available from Euchner. First, a standard
version is installed for the user who must then establish contact
to receive the dialog specific to TRUMPF machines for writing
the RFID chips.
Please contact the following persons at Euchner.
Mario Deutsch
Phone: +49 711 7597-415, e-mail: mario.deutsch@euchner.de.
Thomas Raiser
Phone: +49 711 7597-319, e-mail: thomas.raiser@euchner.de.
Identification
The user logs on at the start of the shift using the chips and
logs off again when finished by removing the chip from the reading device. During login, the machine control saves the user
identification (user ID) in the message history (Diagnostics main
operation) as well as in the "user event logfile".
The personnel number programmed on the chip can be used by
the machine control and the operator to identify the different
users.
The machine control can evaluate the following user IDs: 1 to
65535.
B836en
2017-11-17
Description of the controls and indicators
4‐31
Note
Call up "User event logfile": see User event logfile
User groups
The machine control evaluates the following user groups:
■
■
■
"Production" user group (equivalent to Euchner authorization 8).
"Standard" user group (equivalent to Euchner authorization 7).
"Advanced" user group (equivalent to Euchner authorization 5).
Programming authorization "0" is not permitted.
When the operator logs off (removes chip), the "Production" user
group is always active.
If no chip is inserted in the reading device, there is no user-specific evaluation. In this case, the "Production" user group is
active.
Note
For user rights, see: User group.
4‐32
Description of the controls and indicators
2017-11-17
B836en
Reading device for RFID
chips
The reading device is mounted on the control panel. As soon as
the user inserts his chip into the reading device, he is automatically registered. The corresponding user rights take effect immediately.
1
Reading device
Access Control Key System on the control panel of the
machine
Fig. 84218
An LED on the reading device indicates the status:
Color
Description
Green
User management is ready for operation. No chip is
inserted. The "Production" user group is active.
Yellow
A chip is inserted in the reading device. User management is activated via the Access Control Key System. The
logged-on user group is active.
Tab. 4-10
Note
An error message is issued if login is incorrect.
In an error case: remove the chip and press the RESET button.
Then, a chip can be inserted again.
B836en
2017-11-17
Description of the controls and indicators
4‐33
1.5
Decentral control panel
A decentralized control panel for acknowledging the start and
loading is located on each light grid post.
1
EMERGENCY STOP push-button
2
MULTISWITCH
3
LOADING ACKNOWLEDGMENT
Decentral control panel
Fig. 62151
Notes
■
■
Machines with rotational
changer
Machines with rotary
indexing table
4‐34
The MULTISWITCH and LOADING ACKNOWLEDGEMENT
buttons are sensor buttons which react to touch.
Do not press the MULTISWITCH and the LOADING
ACKNOWLEDGMENT button, only tap them briefly!
The rotational changer has two decentralized control panels.
Both control panels are connected to each other. Operation can
be done either from the left or the right.
The rotary indexing table has two decentralized control panels.
Each control panel controls its assigned loading place.
Description of the controls and indicators
2017-11-17
B836en
Operating element
EMERGENCY
STOP push-button
MULTISWITCH
B836en
2017-11-17
Status
Explanation
-
Pressing the EMERGENCY STOP push-button triggers
the following functions:
■
All axes motions stop at maximum braking power.
■
The drives are switched off.
■
Gas supply is interrupted.
■
The power supply for the entire system (except the
24 V voltage of the control) is interrupted.
■
An active program is aborted and must be restarted,
if required.
■
The installed light path is interrupted. The absorber
(beam trap) closes.
Illuminated
In automatic operating mode: machining is active.
flashes
The control expects the button to be tapped.
flashes slowly
In automatic mode: Faulty part. Part acknowledgement
is required from the operator.
Description of the controls and indicators
4‐35
Operating element
LOADING
ACKNOWLEDGEMENT
Status
Explanation
Does not light
up
In automatic operating mode: the loading acknowledgment is active. If the safety circuit is closed and the
workpiece is correctly clamped, the workpiece changer
will turn as soon as the machining currently in progress
is completed.
Illuminated
Operator intervention permitted: It is possible to load
and unload the workpiece.
flashes
Safety circuit is interrupted.
In setup mode: Acknowledge the light grid. Then the
workpiece changer can be turned using a manual function.
In automatic mode with an active production plan, tapping the button has the effect of acknowledging the
loading. When the safety circuit is closed, the clamping
fixture closes. The workpiece changer will turn when
the machining is complete.
For machines with a Rotational changer:
The loading and interruption of the safety circuit are
acknowledged.
For machines with a Rotary indexing table:
The loading and interruption of the safety circuit for the
respective loading place are acknowledged. Only after
the loading of the second loading place (if two loading
places are active) has been acknowledged and the
machining has been completed does the rotary indexing table cycle.
In automatic mode in the Single job operating mode:
After the insertion of the part in the loading area,
acknowledge the light grid. If the safety circuit is
closed, the rotational changer can be turned and the
program is started with the START button.
Button continues
to flash after
loading acknowledgment.
Clamping error or reopen clamping device: If there
is a clamping error, then an error message is output. A FEED HOLD is triggered only after the end
of machining; the blue status display flashes.
■
In the event of a clamping error, tab on the button
again. The clamping devices open again.
■
As long as the clamping process has not yet been
completed, the clamping devices can be reopened
by tapping the button again.
Decentralized control panel control panel for the workpiece changer
4‐36
Description of the controls and indicators
Tab. 4-11
2017-11-17
B836en
1.6
Status indicators
The LED indicators are integrated into the front side of the
safety cabin, left and right. These LEDs indicate the machine
status.
■
■
1
For machines with a rotational changer: The left and right
indicators are coupled.
For machines with a rotary indexing table: The left indicator
shows the status for loading place 21 (left) and the right indicator for loading place 22 (right).
Status indicators
Fig. 74928
Signal color
Status
Description
Red, both status indicators
Illuminated
FEED HOLD is active, no program is active.
flashes
Fault, EMERGENCY STOP is active.
Blue
Illuminated
Machining is active.
flashes
The program is active but interrupted, FEED HOLD is active.
flashes slowly
Faulty part: Part acknowledgement is required from the operator.
Illuminated
Operator intervention permitted: It is possible to load and unload the workpiece.
flashes
The workpiece is due to be changed. Light barrier has been interrupted.
The control system is waiting for a loading acknowledgement.
Illuminated
Laser is ready for operation or laser processing is active.
not illuminated
Laser is not switched on.
Green
Orange
Status display
B836en
Tab. 4-12
2017-11-17
Description of the controls and indicators
4‐37
1.7
Scrap conveyor
1
EMERGENCY STOP push-button
2
Illuminated push-button FAULT
3
KEY-OPERATED SWITCH
Switchbox and controls for the scrap conveyor
Fig. 74475
In automatic mode, the conveyor belt will start as soon as a program is started. Once processing is complete, the conveyor belt
will stop in accordance with the lag time set.
The scrap conveyor is operated manually in setup mode.
If there is a fault or if the access door is opened while the belt is
running, then "feed hold" will be triggered.
Operating element
EMERGENCY
STOP push-button
MALFUNCTION
4‐38
Status
Explanation
-
The following happens when the EMERGENCY STOP
push-button is pressed:
■
All axes motions stop at maximum braking power.
■
Gas supply is interrupted.
■
The power supply for the entire system (except the
24 V voltage of the control) is interrupted.
■
An active processing program is aborted and needs
to be restarted, if required.
■
Scrap conveyor stops.
■
The installed light path is interrupted. The absorber
(beam trap) closes.
flashing
There is a fault. After fixing the fault, acknowledge.
Illuminated
Scrap conveyor is ready for operation.
Does not light
up
The drive motor is powered down.
Description of the controls and indicators
2017-11-17
B836en
Operating element
KEY-OPERATED
SWITCH
Status
Explanation
Left
Start the conveyor belt in reverse mode: The conveyor
belt will briefly run backwards, as long as the switch is
turned counter-clockwise.
Prerequisite:
■
The access door has been closed.
■
EMERGENCY STOP is not active.
Center
Switch the drive motor off.
Right
Start the scrap conveyor rotating clockwise. The key
can be removed in this setting.
Main operation Production: The conveyor belt will start
and stop automatically during the machining. If the sensors in the conveyor's ascending and drop area detect
a fault, the conveyor will stop immediately. The processing of the workpiece will be finished and only then
will a feed stop be triggered.
Main operation Set up: The conveyor belt can be
started and stopped with the manual function "Waste
conveyor belt".
Operating devices for scrap conveyor
B836en
2017-11-17
Tab. 4-13
Description of the controls and indicators
4‐39
1.8
Compact dust extractor
The compact dust extractor is supplied with power via the
machine's MAIN SWITCH. The compact dust extractor is controlled (MP12 filter control) via the machine's control system.
1
Extinguisher system control
panel
3
2
Manual fire alarm for the extinguisher system
Filter control display
Compact dust extractor with extinguisher
Extinguisher system
Fig. 74616
If the compact dust extractor is equipped with an extinguisher
system (option), a manual fire alarm and a control unit are part
of the equipment.
The extinguisher system is secured in front of the MAIN
SWITCH, and - provided the extinguisher system is switched
on - is always ready for use, even after switching the laser processing machine off.
NOTICE
Fire hazard in the compact dust extractor caused by
deactivated extinguisher system.
Ø
Ø
4‐40
Do not switch the extinguisher system off.
Switch the extinguisher system back on again, after completing the maintenance work.
Description of the controls and indicators
2017-11-17
B836en
1.9
1
Acknowledge the danger zone
ACKNOWLEDGE THE DANGER ZONE button
Fig. 73839
Risk of fatal injury from rapidly rotating rotational changer!
DANGER
Ø
Ø
Ø
Ø
Ø
Only press the ACKNOWLEDGE DANGER ZONE button
when leaving the danger zone.
Only press the ACKNOWLEDGE DANGER ZONE button
and close the door, if there is no one in the safety cabin.
Do not block the access doors from outside.
In an emergency, exit the safety cabin by the shortest possible route.
Before doing maintenance work in the work area or on the
rotational changer, press the EMERGENCY STOP push-button.
Risk of fatal injury from rapidly turning rotary indexing
table.
DANGER
Ø
Ø
Ø
Ø
Ø
Only press the ACKNOWLEDGE DANGER ZONE button
when leaving the danger zone.
Only press the ACKNOWLEDGE DANGER ZONE button
and close the door, if there is no one in the safety cabin.
Do not block the access and escape doors from outside.
In an emergency, exit the safety cabin by the shortest possible route.
Before doing maintenance work in the work area or on the
rotary indexing table, press the EMERGENCY STOP pushbutton.
The danger zone inside the safety cabin is monitored by the
control system. As soon as an access door is opened, the movement of the workpiece changer (i.e. rotational changer or rotary
indexing table) will be disabled in all operation modes.
B836en
2017-11-17
Description of the controls and indicators
4‐41
Movement of the workpiece changer and the starting of a program will not be enabled again until the ACKNOWLEDGE DANGER ZONE button inside the safety cabin has been pressed and
the associated access door is closed within 3 seconds.
1.10 Mechanically lock the door
The mechanical locking bar for the access door is an option.
With the help of the locking bar, the door can be secured
against unintended closing.
The locking bar is pushed forwards when the door is open so
that the door cannot be closed and it is secured in this position
with a padlock.
Fig. 76787
Mechanical door stop (option)
4‐42
Description of the controls and indicators
2017-11-17
B836en
2.
Operating modes of the machine
There are the following operation modes:
■
■
■
AUTOMATIC operating mode
MDA operating mode
JOG mode
Note
The machine's operating modes are not exactly the same as the
main operations of the control system.
Automatic mode
In AUTOMATIC operating mode, the machining programs are
executed fully automatically. Programs are selected and
executed in the main operation called PRODUCTION.
The machining programs can be executed in different ways:
■
■
B836en
In a single job: only a single job is started and executed. To
execute the next job, the program must be restarted.
In the production plan:
For different production locations, several jobs can be created in the production plan. After starting the production plan,
these jobs will be alternately processed in the defined
sequence. The production plan is started once and terminates when the specified number of parts has been
produced for all of the production locations. The set up of the
parts in the loading place must be acknowledged in each
case by the operator.
MDA operating mode
In MDA (Manual Data Automatic) operating mode, single or multiple NC records blocks can be created and immediately executed. MDA operating mode can only be selected in the SETUP
main operation.
JOG operating mode
In JOG operating mode, the NC axes can be moved manually,
either continuously or step-by-step. JOG operating mode is
active in all of the control system's main operations.
2017-11-17
Operating modes of the machine
4‐43
3.
Safety
Operating the machine
The access door is used to enter and leave the machine's work
area. As soon as the door is opened, a FEED HOLD will occur.
The danger zone should only be acknowledged when leaving the
working range. FEED HOLD will only be removed if the door is
closed within the time window of 4 seconds.
While in the work area (apart from set up and maintenance
work) do not step on the scrap conveyor.
DANGER
Risk of fatal injury from rapidly turning rotary indexing
table.
Ø
Ø
Ø
Ø
Ø
DANGER
Risk of fatal injury from rapidly rotating rotational changer!
Ø
Ø
Ø
Ø
Ø
Risk of collision in the 3D
working range
Only press the ACKNOWLEDGE DANGER ZONE button
when leaving the danger zone.
Only press the ACKNOWLEDGE DANGER ZONE button
and close the door, if there is no one in the safety cabin.
Do not block the access and escape doors from outside.
In an emergency, exit the safety cabin by the shortest possible route.
Before doing maintenance work in the work area or on the
rotary indexing table, press the EMERGENCY STOP pushbutton.
Only press the ACKNOWLEDGE DANGER ZONE button
when leaving the danger zone.
Only press the ACKNOWLEDGE DANGER ZONE button
and close the door, if there is no one in the safety cabin.
Do not block the access doors from outside.
In an emergency, exit the safety cabin by the shortest possible route.
Before doing maintenance work in the work area or on the
rotational changer, press the EMERGENCY STOP push-button.
There is always a risk of collisions between the Z barrel and fixtures, table sets, or workpieces in the 3D working range of the
machine.
There is a particular risk of collision:
■
■
■
4‐44
Operating the machine
When starting the axes.
When starting a machining program.
When resuming work with an interrupted machining program.
2017-11-17
B836en
Risk of collision between Z barrel and fixture or workpieces
in the working range of the machine!
NOTICE
Considerable property damage to the barrel can result.
Ø
Each time before the axes or the NC program is started, the
operator must make sure that the barrel cannot collide with
objects in the workspace.
3.1
Entering the work area
Note:The following section is valid for machines with a
rotary indexing table (option).
The air sucked in from above the scrap conveyor is fed via a
system of pipes to the compact dust extractor. Air can only be
effectively extracted if the air pressure in the safety cabin is low
and if the air can circulate sufficiently around the machining position.
To maintain these conditions, the scrap conveyor is in an enclosure. To the left and right of the scrap conveyor as well as on
the body of the machine, there are deflector plates which ensure
the effectiveness of the air extraction.
For maintenance and setting work as well as during teaching, it
is necessary to enter the machine's work area. For this reason,
the deflector plate on the side of the machine's body is hinged.
This deflector plate can be manually moved out or can be set at
an angle. The platform which you may step on when in the work
area is beneath this deflector plate.
For air to be effectively extracted, the deflector plate must be set
at an angle during the processing or parts and the side panel
must be closed.
The control system monitors the setting of the deflector plate.
Production may thus only be started if the plate is hinged out.
B836en
2017-11-17
Operating the machine
4‐45
1
Side air deflector plate
3
Handles (2x)
2
Hinged deflector plate
4
Area where you may walk
5
Locking bar
Machine with rotary indexing table
Stepping onto the platform
Exiting the safety cabin
Fig. 74483
1. Open the service door and leave it open, you may wish to
lock it to prevent it from closing accidentally.
2. Open the side panel fully.
3. Hinge up the deflector plate.
4. Set the deflector plate at an angle.
5. Close the side panel and lock it.
6. Go out of the safety cabin, acknowledge the danger zone
and close the door.
3.2
Switching the machine on and off
Switching on the machine
The laser machine is switched on via the MAIN SWITCH of the
machine.
When the MAIN SWITCH is switched on, all machine components which do not have their own mains disconnectors are supplied with voltage.
4‐46
Operating the machine
2017-11-17
B836en
Components which have their own optional mains disconnector,
such as laser devices, process coolers, scrap conveyors or compact dust extractors, must be additionally switched on at the
main switch of the component.
Condition
■
Laser light cable (LLC) is plugged in.
Note
The laser device has its own main switch. When the laser device
is switched on, the process cooler of the laser (chiller) is also
supplied with voltage.
When the machine is switched on, the operating status of
the axis drives is not monitored!
WARNING
Uncontrolled movements of the NC axes can be the result
in the even of an error.
Ø
Switching on the laser
device
No persons are allowed to remain the danger zone while the
machine is being switched on.
1. On the laser device: Set the key switch to the "I" position.
2. Switch on the MAIN SWITCH on the laser device.
3. If the ON/OFF button on the laser device is lit up in white,
the laser control can be switched on: Press the EIN/AUS button for longer than 1 second.
If the ON/OFF button is lit up in blue, the laser control is
switched on. The laser device is now ready for operation and
can be requested by the machine.
Switching on the machine
4. Switch on the gas and air supply.
5. Switch on the machine's MAIN SWITCH.
6. If the EMERGENCY STOP push-button is locked: Unlock
pressed EMERGENCY STOP push-button.
7. Acknowledge the danger zone and close the access door.
8. Switching on drives: Press the MACHINE ON/OFF button.
The drives for the NC axes are switched on and initialized.
The safety test (the safety shutdown of the NC axes) is carried out.
Requesting the laser device
B836en
2017-11-17
9. Press the ACKNOWLEDGE FEED HOLD button.
10. If the ON/OFF button on the laser device is lit up in blue, the
fieldbus connection to the laser device can be started on the
machine.
Ø On the machine's control panel: Briefly press the
LASER ON/OFF button.
Operating the machine
4‐47
or
Ø
−
−
−
−
Press Setupand select "Manual functions".
Select the Solid-state laser group.
Press "Active optical laser cable" and select LLK.
Press "Laser control 1" or "Laser control 2".
Press "Request laser".
The LASER ON/OFF button flashes. As soon as the laser of
the machine is allocated, the button lights up, and the laser
status display on the enclosed protective housing is lit up in
orange.
The machine and laser device are now ready for operation.
Switching off the machine
Condition
■
The machining program is completed.
Notes
■
■
■
Shutting down the laser
control
If the laser device is operated in a laser network, it usually
remains switched on. In this case, the laser device must be
enabled for the laser network before switching off the
machine (see "Enabling the laser in the laser network",
pg. 4‐131).
If the ON/OFF button on the laser device is lit up in white,
the laser control is shut down. In this case, the laser can
only be switched on again on the laser device.
In the case of outdoor installation of the process cooler: If
the ambient temperature is below 0°, the MAIN SWITCH of
the process cooler may not be switched off.
1. On the control panel: press the LASER ON/OFF button for
approx. 2 seconds.
While the laser control is shutting down, the LASER ON/OFF
button will flash quickly.
As soon as the laser control is switched off, the
LASER ON/OFF button will stop flashing. The orange-colored
laser status lamp on the enclosed protective housing is off.
Only after this may the machine control be shut down.
Switching off the machine
4‐48
2. Recommendation: Set the B and C axes to 0° in MDA mode.
3. Close the user interface:
− On the user interface, press on the TRUMPF Logo.
− Select "System" tab.
Operating the machine
2017-11-17
B836en
− Press Exit.
− Press Shut down.
4. If the user interface and the control system has been shut
down: Switch off the MAIN SWITCH.
5. Switch off the air and gas supply.
Switching off the laser
device
6. Only set the main switch on the laser device to OFF once
the ON/OFF button on the laser device is lit up in white.
7. Turn the key switch on the laser device counterclockwise and
remove.
The machine and laser device are switched off.
B836en
2017-11-17
Operating the machine
4‐49
3.3
Shutting down the machine in the
event of a malfunction/emergency
Tripping the EMERGENCY STOP
1. Press the EMERGENCY STOP push-button.
The power supply to the machine is interrupted (24 V control
voltage is maintained).
The installed light path is interrupted. The absorber closes.
All axes motions stop at maximum braking power.
The drives are switched off.
The gas supply is interrupted.
2. If the malfunction cannot be remedied: Switch off machine.
Cancelling the EMERGENCY STOP
Condition
■
Malfunction is eliminated.
1. Unlock pressed EMERGENCY STOP push-button.
2. Switching on drives: Press the MACHINE ON/OFF button.
3. An active program or an active production plan must be
restarted.
Trip the extinguisher with a manual alarm
The extinguisher is usually triggered automatically in the event of
a fire in the compact dust extractor. The interior of the compact
dust extractor is flooded with gas. The extinguishing device can
also be triggered manually in the event of an error.
4‐50
Operating the machine
2017-11-17
B836en
Condition
■
The extinguisher system is switched on.
Flames and hot components!
WARNING
Burns are the consequence.
Ø
Ø
Ø
1
Be careful and do not stand directly in front of the door of
the compact dust extractor when opening them.
Have a hand-held fire extinguisher ready for use
Only touch hot components with protective gloves.
Button
Manual fire alarm
Fig. 42365
1. Break glass.
2. Press the button hard.
The clean gas space is flooded with gas.
3. Switch off the MAIN SWITCH Machine.
Note
Keep a fire extinguisher to hand at all times. A fire can reignite if oxygen is added.
4. Open the door to the clean gas space with someone else
standing by to cover you.
5. Inform the manufacturer.
B836en
2017-11-17
Operating the machine
4‐51
3.4
Check safety functionality
The machine is equipped with the Safety Integrated control software by Siemens. The functions of this safety concept work
when the safety device (safety cabin, light barrier, etc.) is open
or closed as well as during the teach process. Safety Integrated
is effective in all control operating modes.
To ensure that the Safety Integrated safety function works reliably and correctly, a safety test is required every eight operating
hours. The safety test checks whether the drives of all the NC
axes are switched off electrically if there is a malfunction.
A cyclic safety test is requested every 8 operating hours. If this
requirement is active, the safety test is carried out:
■
■
■
■
■
The safety test is carried out each time the machine is
switched on.
With "Establish home position", the safety test is carried out
immediately.
At the end of the program (M30), the safety test is carried
out after confirmation by the operator (dialog).
If TC_SAFETY_TEST is activated in the NC program, the
safety test is carried out immediately. With endless loops, the
safety test must be requested at a suitable point in the
machining program by programming TC_SAFETY_TEST.
The safety test can be started manually at all times.
Note
If the safety test request is active and the safety test is not carried out within 15 minutes, an error message is displayed.
4‐52
Operating the machine
2017-11-17
B836en
Safety test for Z-axis
The safety test checks the Z-axis brake. If the brake slips 2 mm
or more during the test, an error message is output. In this case,
the Z-axis drive must be exchanged immediately.
Danger due to defective brake on the Z-axis drive! The
holding function of the brake is not ensured. The Z-axis can
drop down.
WARNING
Considerable material damage can result.
Ø
Exchange the Z-axis drive immediately if there is an error
message; request a service call.
Note
While the safety test is active, the NC axes cannot be moved
using the teach panel for safety reasons.
Manually start the safety test
The machine is equipped with the Safety Integrated control software by Siemens. The functions of this safety concept work
when the safety device is open or closed as well as during the
teach process. Safety Integrated is effective in all control operating modes.
To ensure that the Safety Integrated safety function works reliably and correctly, a safety test is required every eight operating
hours. The safety test checks whether the drives of all the NC
axes are switched off electrically if there is a malfunction.
A cyclic safety test is requested every 8 operating hours. If this
requirement is active, the safety test is carried out:
■
■
■
■
■
B836en
2017-11-17
The safety test is carried out each time the machine is
switched on.
With "Establish home position", the safety test is carried out
immediately.
At the end of the program (M30), the safety test is carried
out after confirmation by the operator (dialog).
If TC_SAFETY_TEST is activated in the NC program, the
safety test is carried out immediately. With endless loops, the
safety test must be requested at a suitable point in the
machining program by programming TC_SAFETY_TEST.
The safety test can be started manually at all times.
Operating the machine
4‐53
Conditions
■
■
■
■
■
At least "Standard" authorization is active.
The home position has been reached.
The safety doors are closed.
The program is not active.
FEED POTENTIOMETER larger than 0 %.
Note
While the safety test is being carried out, the NC axes may
move slightly.
1. Press Setupand select "Manual functions".
2. Select the General group.
3. Press "Safety test".
The dialog box starts.
The safety test is carried out.
Issue user consent
The NC axes must be reliably referenced. In case of a fault, the
referencing of an axis can be lost, e.g.
■
■
If a force takes effect on the Z tail spindle or on the motion
unit when without electrical power.
When switching the machine on or afterwards.
In case of a fault, the control system will generate an error message. The operator must then check the correct position of the
NC axis and grant "user permission".
When this user permission is granted, the operator confirms that
the actual position of an NC axis displayed matches the actual
position on the machine.
Condition
■
At least the "Advanced" user group is active.
1. When the Axis is no longer referenced safely error message
appears: Press Setupand select "Manual functions".
2. Select the Setting work group.
3. Press "User consent".
The dialog box starts.
4. Select axis.
4‐54
Operating the machine
2017-11-17
B836en
5. Press the Apply permission softkey.
The NC axis has been referenced safely. The correct axis position has thus been confirmed.
3.5
Eliminate malfunction
Triggering FEED HOLD
If a malfunction occurs while machining, a FEED HOLD can be
triggered manually at all times. The control system will switch to
safe operation stop. The following functions will then automatically be interrupted:
■
■
■
The installed light path is interrupted.
The axes stop.
The gas supply is interrupted.
Ø Press FEED STOP button.
Acknowledging FEED HOLD after opening
the door
Every time the access door is opened, the safety device will
switch to safe operating stop (SOS) and the software will trigger
FEED HOLD.
1. Inside the safety cabin: Press the ACKNOWLEDGE DANGER ZONE button.
2. Close the door.
3. Press the ACKNOWLEDGE FEED HOLD button.
An active program will immediately be resumed.
Acknowledging FEED HOLD after a
collision involving the nozzle
FEED STOP will be triggered if the cutting nozzle collides with
the sheet surface.
1. Press the ACKNOWLEDGE FEED HOLD button.
2. Move the Z axis away from the surface of workpiece using
the JOG buttons.
B836en
2017-11-17
Operating the machine
4‐55
3. If the processing is to be continued: Press the START button.
Machining is resumed at the point of interruption.
Restarting processing after knocking off
the processing optics
If there is a collision between the processing optics and an
object in the work area, the processing optics will be separated
from the magnetic coupling. The processing optics will be held
by a catch strap. The software will trigger a FEED HOLD.
Notes
■
■
If the processing optics moves in the Z direction to a collision, the connection plate which breaks the plastic screws
automatically folds away (predetermined breaking point).
If safety elements are damaged when the optics are
detached, they must be replaced immediately.
1. Press main operation Setup.
2. Select the NC axis and release it using the JOG button.
3. Connect the processing optics to the magnetic coupling.
The machine is ready for operation again.
4‐56
Operating the machine
2017-11-17
B836en
3.6
Operating the workpiece changer
Notes
■
■
■
Loading place and
production place
Configure the workpiece change: (see "Configuration",
pg. 4‐139)
Display and change loading status and workpiece status:
(see "Loading and workpiece status", pg. 4‐94).
Work with the production plan: (see "Creating and editing a
production plan", pg. 4‐81)
In the machine control, a distinction is made between production
place, fixture place and loading place.
■
■
Production place: Those segments on the workpiece
changer at which the workpiece is loaded and processed are
referred to as "production place". A maximum of two fixture
places are assigned to every production place.
Loading place: The area in front of the workpiece changer
where the workpiece is set up (loaded or unloaded) is referred to as "loading place". Every loading place is assigned to
a safety area.
A number is assigned to every production place and every loading place in the machine control:
Fig. 72867
Loading and production places
workpiece changer
Production
place
Loading
place
Safety range
rotary indexing
table(RST)
P1
P2
P3
21
A
22
B
Rotational
changer(RW)
P1
P2
20
A
Loading and production places
B836en
2017-11-17
Tab. 4-14
Operating the machine
4‐57
Notes
The production place on the workpiece changer is labelled
with a sign: P1 and P2 as well as P3 for a rotary indexing
table.
The numbers of the loading places (20, 21 and 22) as well
as their assignment to the safety area (A or B) are hardwired in the control and cannot be changed by the user.
The safety area is only relevant for machines with an automation interface (Automation interface option).
Fixture place: see Configurable control interface (KSS).
■
■
■
■
Rotary indexing table
loading places
For a machine with rotary indexing table there are two loading and unloading areas (loading place 21 and loading place 22).
The operator can optionally configure the loading and unloading
place. The following configurations are possible:
The workpiece is manually loaded on both loading places.
The workpiece is automatically loaded on both loading places.
The one loading place is manually loaded and the other one
is automatically loaded.
It is loaded and unloaded, either manually or automatically,
onto the same loading place.
■
■
■
■
Rotational direction of the
rotational changer
The rotational changer moves 180° back and forth between the
loading position and the working position.
Rotational direction of the
rotary indexing table
The rotary indexing table moves by 120° into the next position.
In setup mode, the rotary indexing table rotates the selected production place (P1, P2 or P3) directly into the working position.
In automatic mode, the rotary indexing table moves n*120° to
either the left or right, depending on the selected configuration.
It will turn clockwise: If items are loaded on loading space
21.
It will turn counterclockwise: If items are loaded on loading
space 22.
■
■
Safety position for station
change
Before the workpiece changer rotates, the NC axes automatically
move to the safety position:
Axis
Safety position
X, Y and C
Remain on the current axis position.
Z
Move to the top axis position.
B
Rotates to +90°.
Safety position
4‐58
Operating the machine
Tab. 4-15
2017-11-17
B836en
Tip
The tool-change height can be programmed for the X, Y and C
axes with the TC_PREPARE_STARTPOS cycle.
Manual functions
Group
Manual Function
Description
workpiece
changer
"Production
place 1"
Production place 1 rotates directly to the working area.
"Production
place 2"
Production place 2 rotates directly to the working area.
"Production
place 3"
Production place 3 rotates directly to the working area.
Setup main operation, Manual functions, "Workpiece changer" group
Tab. 4-16
Rotating workpiece changer in setup mode
The workpiece changer can be rotated in setup mode using the
manual function.
Conditions
■
■
The danger zone has been acknowledged and the access
door has been closed.
At least "Standard" user group.
Notes
■
■
■
Outside of the safety cabin, the workpiece changer can
rotate with open clamps.
If the production place should rotate into the working area,
all clamps of the fixture must be closed beforehand.
A fixture's clamps are controlled by the KSS and can be
manually opened or closed via the fixture group.
1. If required: Set up the component at production place P1, P2
or P3 and press the LOADING ACKNOWLEDGEMENT button.
2. Press Setupand select "Manual functions".
3. Select the clamping fixture group in the selection field and
close the clamp.
4. In the group selection field, choose Workpiece changer.
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Operating the machine
4‐59
5. Press "Production place 1" or "Production place 2" or "Production place 3".
Once the safety circuit is closed, the selected production place
will rotate into the working position.
RSTAcknowledge the loading operation in
automatic mode
The respective loading and unloading of the workpiece is
acknowledged in automatic mode. The rotary indexing table
(RST) only moves once the loading operation has been acknowledged and the current processing has finished.
If a production place has been deactivated in the production
plan, this production place is cycled empty with the clamps
closed.
Condition
■
The production plan is active.
1. When the LOADING ACKNOWLEDGEMENT button is illuminated in the unloading area: Remove the workpiece. Leave
the unloading area and press the LOADING ACKNOWLEDGEMENT button.
2. In parallel to that, set up a new workpiece in the loading
area. Leave the loading area and press the LOADING
ACKNOWLEDGEMENT button.
If both safety areas have been acknowledged and the current
processing has finished, the rotary indexing table continues to
cycle. Processing begins again in the working range.
RW: Acknowledge the loading operation in
automatic mode
The respective loading operation is acknowledged in automatic
mode.
The rotational changer will turn as soon as the loading operation
has been acknowledged and the current processing has finished.
Condition
■
The production plan is active.
1. If the LOADING ACKNOWLEDGEMENT button is illuminated:
Remove the workpiece and insert a new component.
4‐60
Operating the machine
2017-11-17
B836en
2. Leave the loading area and press the LOADING ACKNOWLEDGEMENT button.
After the end of the current processing, the rotational changer
rotates. Processing begins again in the working range.
Acknowledging malfunction
If there is a program interruption or a FEED HOLD during the
rotational movement of the workpiece changer, the workpiece
changer stops immediately in an undefined position.
Ø Acknowledge malfunction:
Ø In the event of a program interruption, press the RESET
button.
− Restart the production plan.
− PRESS THE MULTISWITCH.
− Press the LOADING ACKNOWLEDGMENT button.
or
Ø In the event of a FEED HOLD Press the LOADING
ACKNOWLEDGMENT button.
The workpiece changer will continue with the original rotational
movement.
Acknowledging clamping error
If the LOADING ACKNOWLEDGEMENT button continues to
flash after acknowledging loading, there is a clamping error.
In this case, an error message is output. After the end of the
current processing, FEED HOLD is triggered; the blue indicator
lamp will flash.
Condition
■
The production plan is active.
1. Acknowledge clamping error: Press the LOADING
ACKNOWLEDGMENT button.
Reopen the fixture's clamps.
2. Lift the workpiece and then put it back in.
3. Acknowledge loading again: Press the LOADING ACKNOWLEDGMENT button.
The changer will rotate and processing will be continued.
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Operating the machine
4‐61
3.7
Production
In the main operation Production, the waste conveyor belt will
automatically start when the program starts. The conveyor belt
will stop with some lag at the end of the program or when all of
the jobs in the production plan have been worked through.
■
■
Setup
Reverse mode
The following conditions must be met for reverse mode:
■
■
"Lubrication"
If the sensor in the ascending area or in the discharge hopper detects a malfunction during part processing, the waste
conveyor belt will stop immediately. Part processing will not
be interrupted. Only once the current part has been completely processed will FEED HOLD be triggered.
If the sensor reports a missing scrap container, then a FEED
STOP will be triggered. If a program is active, the FEED
STOP will only be triggered once the processing of the part
is finished.
In the main operation Set up, the conveyor belt can only be
started and stopped with the manual function "Waste conveyor
belt".
■
Manual Function
Operate scrap conveyor
The danger zone has been acknowledged and the access
door has been closed.
No fault on the scrap conveyor.
EMERGENCY STOP is not active.
Description
Status display.
■
inactive: Lubrication cycle is not active.
■
inactive: Lubrication cycle is active.
Note: The lubrication cycle will be started automatically. The lubrication interval and
lubrication time are applied. The lubrication valve is only opened if the conveyor belt
is running and the lubrication cycle is active.
"Waste conveyor belt"
Starting or stopping the conveyor belt.
■
off: stops the conveyor belt.
■
on: starts the conveyor belt in direction of run.
■
Lag: Lag is active. The conveyor belt can only be restarted again after the lag
time has expired.
■
Fault: The scrap conveyor has a fault. Fix the fault and then acknowledge it.
Prerequisites:
4‐62
■
The danger zone has been acknowledged and the access door has been closed.
■
EMERGENCY STOP is not active.
Operating the machine
2017-11-17
B836en
Manual Function
Description
"Maximum idle time"
The maximum permissible idle time for the conveyor belt, while at the same time
the processing of parts is still active. Only when the selected time has elapsed will a
FEED HOLD be triggered.
The time is selected using the JOG buttons PLUS and MINUS. The permissible
duration is 0 to 120 seconds.
Condition: The "Extended" user group is active.
Setup main operation, Manual functions, "Scrap conveyor" group
Tab. 4-17
Starting the conveyor belt
Conditions
■
■
■
■
EMERGENCY STOP is not active.
Teach mode is not active.
Scrap conveyor is ready for operation.
The danger zone has been acknowledged and the access
door has been closed.
1. Press Setupand select "Manual functions".
2. Select the Scrap conveyors group.
3. Set the manual function "Waste conveyor belt" to on.
The conveyor belt will start immediately.
Stopping the conveyor belt
Condition
■
Machining is not active.
1. If not yet selected, Press Setupand select "Manual functions".
2. Select the Scrap conveyors group.
3. Set the manual function "Waste conveyor belt" to off.
The conveyor belt will stop after the configured lag time has
elapsed.
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Operating the machine
4‐63
Starting the conveyor belt in reverse mode
Conditions
■
■
EMERGENCY STOP is not active.
The danger zone has been acknowledged and the access
door has been closed.
Ø Turn the key-operated switch on the switchbox counterclockwise and hold in this position.
Eliminate malfunction
If scrap skeleton or waste parts get stuck on the conveyor belt,
or if the sensors detect oversized waste parts, there will be a
malfunction and the belt will stop.
If there is a fault with the conveyor belt, the blue button on its
switchbox will flash.
NOTICE
Property damage caused by a scrap skeleton or waste parts
which are too large or too small.
Scrap skeleton and waste parts block the conveyor belt.
Ø
Ø
Ø
Scrap skeleton or waste parts may not exceed the minimum
and maximum dimensions.
Set parting cuts.
Before entering reverse mode, remove the waste parts from
the conveyor belt.
1. If necessary, briefly start the conveyor belt in reverse mode
(running backwards). Fix the fault.
2. When the fault has been fixed, press the ACKNOWLEDGE
FAULT button on the scrap conveyor's switchbox.
If the button is illuminated, then the scrap conveyor is ready
again for operation.
4‐64
Operating the machine
2017-11-17
B836en
4.
Description of the user interface
1
Status line
3
Sub-operations (Tab)
5
Login status
2
Message line
4
Context buttons
6
Main activity
User interface
Fig. 74946
Message line
Information (gray), warnings (yellow) and alarm (red) are shown
in the message line:
■
■
■
■
Log-in status
By pressing the "login status" field, the following functions can
be executed:
■
■
■
■
■
B836en
2017-11-17
Time when the message was issued.
Message number.
Description of the alarm or the fault.
Source of the error, element of the control system or of the
machine that caused the message.
Set language, measuring system, date and time.
Log on and off of user group.
Change the password.
Activate the on-screen keyboard.
Close the user interface (HMI).
Description of the user interface
4‐65
Main activities
Main activity
functions
Activating Production plan main operation.
The following functions can be executed:
■
Create, modify and delete production packages and
jobs.
■
Starting and editing the production plan.
■
Start the utility programs.
Activating Production main operation.
The following functions can be executed in automatic
mode:
■
Load programs.
■
Prepare programs.
■
Executing programs.
■
Modify technology parameters.
■
View and, depending on authorization, activate
manual functions.
Activating Setup main operation.
The following functions can be executed in setup
mode:
■
Move axes in jog mode.
■
Activate manual functions depending on authorization.
■
Working in MDA mode.
Activating Programming main operation.
The following functions can be executed:
■
Creating, editing and managing programs.
■
Defining zero point coordinates in the transformation accumulator.
■
Opening and operating graphic editor/
TruTops Cell Basic.
Activating Technology main operation.
The operator's manual, the supplement to the operator's manual as well as the programming manual can
be referred to for help (Main Help):
■
Show Main Help.
■
Start search.
■
Creating bookmarks.
Note:
Not all chapters of the machine's operator's manual
will be displayed. The "Main Help operator's manual"
is an excerpt from the operator's manual.
Tab. 4-18
4‐66
Description of the user interface
2017-11-17
B836en
Main activity
functions
Activating Maintenance/Commissioning main activity.
The following functions can be executed:
■
Displaying an overview of maintenance tasks and
their status.
■
Activate manual functions.
■
Calling up logbook functions.
Activating Diagnostics main activity.
The following functions can be executed:
■
Displaying and managing warnings, alarms and
messages.
■
Activate manual functions.
■
Display software versions.
■
Display digital inputs and outputs.
■
Starting Teleservice.
Note:
The Diagnostics button flashes when a new warning
or alarm is present.
Displaying online Help.
The online help for the operating and programming
instructions can be called up:
■
Show Main Help.
■
Creating bookmarks.
Tab. 4-19
Sub-operations
List selection
Display area
Path
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2017-11-17
Several sub-operations (special machine functions) are assigned
to each main operation, which are selected at the user interface
using what are called "tabs".
When pressing the
button, a selection field opens.
The display area of the user interface can be made larger or
smaller:
■
If you press the
button, the display area will be increased.
■
If you press the
decreased.
button, the display area will be
■
If you press the
button, the "Path" will be opened.
■
If you press the
button, the "Path" will be closed.
■
If you press the
button, the higher level will be opened.
Description of the user interface
4‐67
Status bar
Symbol
Description
Home position missing.
Approach home position
Home position has been established.
Status: production plan stopped.
Status: production plan running.
Program is active.
Program status: Stop.
Program status: Pause.
Program status: Active.
Laser device is switched off.
Laser device is switched off. The laser test is active.
The laser beam is switched off. The lasershutter is
closed.
Laser device is switched off. The laser test mode is
active.
The laser beam is switched off. Lasershutter is open.
The laser beam is switched off. The laser test is
active.
The laser beam is ignited. The lasershutter is closed.
The laser beam is ignited. The laser test is active.
The laser beam is ignited. Lasershutter is open.
4‐68
Description of the user interface
2017-11-17
B836en
Status bar
Symbol
Description
The laser beam is ignited. The laser test is active.
The laser beam is switched off. The central shutter is
closed.
The touchscreen is disabled.
Alarm messages have been received (the number of
messages is displayed next to the symbol).
Warnings have been received (the number of messages is displayed next to the symbol).
Maintenance symbol (maintenance work is pending).
Error has occurred.
Tab. 4-20
Program status
The program bar shows the status of the program:
Symbol
Program status
A program has been selected.
The program is checked and complete. The program can
be run.
Program is incomplete or faulty.
Program is active, but incomplete.
Program is valid and loaded in the production plan.
Program is loaded in the production plan. Program is
incomplete.
Program status of activated program
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Description of the user interface
Tab. 4-21
4‐69
User event logfile
The machine control creates a current "user event logfile" for the
user with the following information:
Event
Additional information
Description
LaserTechnologyTableChanged
LTT name
Technology table with modified parameter values
LaserTechnologyTableDeleted
LTT name
Deleted technology table
LaserTechnologyTableInserted
LTT name
Newly added technology table
ProgramDeleted
Program name
Deleted NC program
ProgramInserted
Program name
Added NC program
ProgramOverwridden
Program name
NC program was overwritten
and replaced
ProgramUpdated
Program name
NC program was edited
(changed)
UserLogOn
User
User login (Access Control Key System option only)
UserLogOff
User
User log off (Access Control Key System option only)
UserIdChanged
Serial number
User identification
(Access Control Key System
option only)
MmcStarted
-
HMI was started
MmcEnded
HMI was ended
Structure of the logfile
Tab. 4-22
The logfile is stored under the following path: 'C:\dh\topsmanu.dir
\systrans\out\UserInteractions<number>.log'.
A logfile can have a maximum size of 1 MB. If this size is
exceeded, a new logfile is created. A maximum of two logfiles
are displayed and saved.
The logfile has the following structure: "yyyy-mm-dd
HH:MM:SS.FFF;UserId;UserLevel;User;Event;(additional information)".
Example: "2016-12-24 11:35:12.157;1542;0;STANDARD;ProgramDeleted;TEST_PROGRAM".
4‐70
Description of the user interface
2017-11-17
B836en
5.
System settings
5.1
Setting data and time
1. On the user interface, press on the TRUMPF Logo.
The dialog "Settings" is displayed.
2. Select "System" tab.
3. Press the
button and modify the setting.
4. Press Apply.
The selected setting will be saved.
5.2
Selecting language and measuring
system
Note
If the Inch measuring system is selected, only the display on the
HMI will change from from metric to imperial. The control will
continue its internal calculations using the metric system.
1
"Language" selection field
2
"Unit system" selection field
Selecting language and measuring system
Fig. 66861
1. On the user interface, press on the TRUMPF Logo.
The dialog "Settings" is displayed.
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System settings
4‐71
2. Select "Language" and/or "Measuring system".
3. Press Apply.
The selected setting is active right away.
5.3
Activate the on-screen keyboard
The on-screen keyboard is activated by tapping on a text entry
field. This setting can be modified.
1
"On-screen keyboard" selection field
Activating the on-screen keyboard
Fig. 66857
Selection
Description
Off
Deactivate the on-screen keyboard.
Activate by tapping
Activate the on-screen keyboard by tapping. (default setting)
Activate by double-tapping
Activate the on-screen keyboard by double-tapping.
Tab. 4-23
1. On the user interface, press on the TRUMPF Logo.
The dialog "Settings" is displayed.
2. Open the "On-screen keyboard" selection field.
3. Select Off or Activate by tapping or Activate by double-tapping.
4. Press Apply.
The selected setting is active.
4‐72
System settings
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B836en
5.4
Open TRUMPF Operating System
(TOS)
1. Press the CHANGE APPLICATION
button.
2. Select TRUMPF Operating System (TOS).
TOS is displayed.
5.5
Close user interface
The user interface for the machine control system is called HMI
(Human Machine Interface).
Fig. 75037
1. On the user interface, press on the TRUMPF Logo.
The dialog "Settings" is displayed.
2. Select "System" tab.
3. Press Exit.
4. Either
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System settings
4‐73
Ø If only the HMI is to be closed, press Exit HMI.
or
Ø If the machine is to be switched off, press Shut down.
5.6
Switching to the TruControl interface
TruControl 1000 is a program for the operation of beam sources
from TRUMPF. For operation, see "TruControl 1000 software
manual".
Condition
■
Laser device is ready for operation.
1. Press Change of application
.
2. Select TRUMPF Operating System (TOS).
The user interface is not closed. The "TRUMPF Operating
System" (TOS) dialog is displayed.
3. Press Laser Application.
The user interface TruControl will open.
4‐74
System settings
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B836en
6.
User administration
Note
If the machine has the Access Control Key System option, then
the management of users by issuing passwords does not work.
User group
User groups with different rights can be logged in to the
machine's control system.
Depending on which user group is currently logged on, functions
and parameters are blocked for access or are not shown on the
user interface.
The following user groups are shown in the control as default
and can be logged into.
User group
Description
"Production"
Authorization for production mode without the option
of influence.
"Standard"
Authorization for processing of NC programs as well
as for influencing of the production mode.
"Advanced"
Complete access to the scope of functions of the
operator: authorization for setting, set up and programming work.
"TRUMPF Service"
Complete access to all of the machine's functions.
User groups (standard configuration)
Password
Tab. 4-24
Generally, each user group has its own password. A user group
with a higher authorization than the one currently logged in is
protected by the password insofar as a password has be issued.
It is possible to issue an identical password for all user groups
(except "TRUMPF Service").
When the machine is delivered, only the "TRUMPF Service" user
group is password protected.
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User administration
4‐75
6.1
Log on user group
Conditions
■
■
Password is known.
Machining is not active.
1. On the user interface, press on the TRUMPF Logo.
2. Press the Log off button.
1
User group
Selecting the user group
Fig. 66856
3. Select the user group:
Ø If a lower user group is to be logged in:
− Select the user group.
− Press the Log in button.
or
Ø
−
−
−
If a higher user group is to be logged in:
Select the user group.
Enter the password.
Press the Log in button.
The user interface is restarted. It is only shown for the enabled
functions and parameters for the logged-on user group.
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6.2
Change password
Conditions
■
Machining is not active.
Password is known.
1.
2.
3.
4.
5.
6.
On the user interface, press on the TRUMPF Logo.
Press the Change password button.
Enter the old password.
Enter New password.
Confirm new password: Repeat entry.
Press OK.
■
6.3
Deleting the password
Conditions
■
Machining is not active.
Password is known.
1.
2.
3.
4.
On the user interface, press on the TRUMPF Logo.
Press the Change password button.
Enter the old password.
Press OK.
■
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User administration
4‐77
7.
Production plan
1
Context buttons
4
Production plan button
6
Cell status button
2
Job
5
Job button
7
Program details button
3
Production place xx
Production plan
Fig. 89143
Button
4‐78
Description
Orders
Display, edit or delete jobs. Create new jobs.
Production plan
Display, start, disable or delete available production plans. Create new production plans.
Program details
Display information about the active NC program with or without preview
image.
Production plan
2017-11-17
B836en
Button
Description
Cell status
The status of all installed components at the machine will be displayed.
Component is active.
Pause
Component is stationary.
Production plan buttons
Tab. 4-25
Context buttons
Depending on the context, the following buttons will be shown:
Button
Description
Starting
Start the production plan. All released jobs are processed in the selected order.
Stop
To end the production plan:
■
"Stop after cycle end" ends the production plan as soon as the current operation
is finished at all production places and the workpiece changer has clocked once
again.
■
"Run empty" ends the production plan as soon as all workpieces loaded have
been processed and unloaded.
Technology correction
Edit the laser technology table for the selected NC program. The modification will
take effect after the production plan has been restarted.
Modifying
Process the marked job.
Note: an active job can be processed. The modification will take effect the next time
the production plan has been started.
Disabling
Disable job or production plan.
Note: an active job or production plan cannot be disabled.
Delete
Delete job or production plan.
Note: an active job or production plan cannot be deleted.
Delete Orders
Delete marked jobs.
Delete programs and
orders
Delete marked jobs and the corresponding NC programs in the NCK.
Creating
Create new production plan or new job.
For preparation
Note: the jobs will be deleted. An NC program will only be deleted if it is not used
in any other job. If the NC program is currently active, it will not be deleted.
Changes the status of the job to "Preparation". The tooling status is being checked;
the telegram (information) will be transferred to the PLC.
Example: "The job is processed in tightened empty form (without clamping) although
there is a clamping fixture available."
Release
Release job for processing.
Finish
Transfer released jobs to the NC control.
Continue
Resume interrupted production plan.
Production plan context buttons
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Tab. 4-26
Production plan
4‐79
Order status
Symbol
Description
Job is released for production.
Job is disabled.
Job is checked.
Job is currently being produced.
The last workpiece of this job is currently being producted.
Job is finished.
An error occurred.
NC program is missing.
Order status
Program sequence
Tab. 4-27
Within a production plan, the order of the jobs for processing
can be changed using the following buttons:
Button
Description
Set the job at the start of the list.
Set the job at the end of the list.
Set the job one place upwards on the list.
Set the job one place downwards on the list.
Program sequence buttons
4‐80
Production plan
Tab. 4-28
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7.1
Production plan
Creating and editing a production
plan
A production plan includes jobs (NC programs for part processing) that are processed in the order selected by the operator.
When doing this, only the released jobs will be produced.
The operator starts the production plan. Then; the individual jobs
are automatically called up one after the other and processed.
Parts are produced until the production plan has been gone
through or until the operator ends the production plan.
Production place
Production place refers to the area on the machine where the
workpiece is produced. A number is assigned to every production place in the machine control:
Configuration
Production place
Machine with rotary indexing table
1, 2 and 3
Machine with rotational changer
1 and 2
Production place
Tab. 4-29
For machines with the Automation interface option:
■
■
Job
A job consists of an NC program for part processing and the
corresponding job data. Every job is is assigned to a production
place (a synonym for a station). There is the following job data:
■
■
■
■
■
■
B836en
2017-11-17
A KSS module must be configured for every production
place.
The Synchronization automation element must be configured
in the KSS module.
The actual number of program runs. The number can be
changed by the operator, if desired.
The required number of program runs. Alternatively, a continuous machining can be selected. To stop continuous processing, the production plan must be stopped.
The number of the production place where the job is to be
produced.
If the machine has a configurable control interface (KSS): the
number of the KSS module.
The number of the KSS module.
All released jobs are always processed at the current production place. Only then are the jobs of the next production
place processed.
Production plan
4‐81
Creating a new production plan
When a new production plan is created, at least one job must be
created, released and assigned to a production place.
A production plan is created for every production place.
For each production place, several different jobs can be created
whose loading is acknowledged at the same time.
Conditions
■
■
■
Select NC program
The tooling status is valid and has been activated.
The configuration of the workpiece change has been created.
The program is stored in the internal management system.
1. Press the Production plan main operation.
2. Press Create.
3. Select Internal management as the "storage location"
).
(
1
NC program
Create new production plan
Fig. 73649
4. Select an NC program: select the checkbox next to the program name.
5. Press Continue.
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B836en
The "Job details" dialog opens.
1
Job
2
Job data
Modifying job data
Creating a new job
Enable job
Fig. 89275
6. Enter the following job data:
− "Required qty": Enter the number of program runs or,
alternatively, select "Continuous machining".
− "Production place": Enter the number of the production
place.
− "KSS module": On machines with KSS, enter the module
number.
7. Press Finish.
8. Press For preparation.
9. Create the next job:
− Press Create.
− Select the NC program.
− Press Continue.
− Enter the job data.
− Press Finish.
− Press For preparation.
10. Once all jobs have been created: Press Enable.
The production plan has been created. Jobs are released.
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Production plan
4‐83
Editing job data
The job data of an existing job is to be modified. The modification will take effect the next time the production plan has been
started.
1. Press the Production plan main operation.
2. Either
Ø Select a job from the job list.
or
Ø
3.
4.
5.
6.
7.
Press the Job button (
) and select a job.
Press Modify.
Modify job data.
Change the program sequence, if required.
Press Finish.
Release the job.
Disable job
A disabled job is skipped during production.
Condition
■
The job is not active.
1. Press the Production plan main operation.
2.
Press the Job button (
) and select a job.
3. Press Disable.
Delete the order in the production plan
All marked jobs are deleted from the production plan.
Condition
■
The job is not active.
Notes
■
4‐84
Production plan
The programs are still on the machine control's hard drive
after the job is deleted.
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■
By pressing the Delete programs and orders button, all
marked programs on the machine control hard drive will be
deleted.
1. Press the Production plan main operation.
2. Either
Ø Select a job from the job list.
or
Ø
Press the Job button (
) and select a job.
3. Press Delete.
4. Either
Ø If only the marked job is to be deleted: press Delete
orders.
or
Ø If all orders are to be deleted: press Select all.
All the orders or the marked ones will be deleted.
Delete programs and orders
Attention: All marked programs and jobs are deleted irrevocably from the machine control's hard drive!
Condition
■
The job is not active.
1. Press the Production plan main operation.
2. Either
Ø Select a job from the job list.
or
Ø
Press the Job button (
) and select a job.
3. Press Delete.
4. Press Delete programs and jobs.
All marked NC programs and jobs are immediately deleted.
Deleting a production plan
1. Press Production plan.
2. Press the Production plan button.
3. Select "Production place".
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Production plan
4‐85
4. Press Delete.
The production plan for the selected production place is deleted
with all jobs created.
7.2
NOTICE
Risk of collision on 3D work area by transfer movements of
the NC axes.
Ø
Ø
Loading place
Production with the production plan
There is a risk of collision during the transfer movement of
the NC axes when changing the job as well as at the start
and end of the program.
If the program sequence is changed, note that there is a risk
of collision during the transfer movement of the NC axes.
Loading place refers to the area on the machine where the new
workpiece is loaded and the finished part is removed.
Before the production plan can be started, the loading place
must be configured and activated.
Notes
■
If there is no valid configuration for a workpiece change, the
production plan is not started.
To configure and activate the loading place, see "Configuration" section: (see "Configuration", pg. 4‐139).
■
Loading acknowledgment
If different jobs are to be processed at a production place
(e.g. 2 different workpieces on 2 different fixtures), the operator acknowledges loading simultaneously for all workpieces
set up at this loading place.
By pressing the LOADING ACKNOWLEDGMENT button, the
operator acknowledges the loading of the new workpiece and at
the same time the safety device for this loading place.
After the loading acknowledgment, the following sequence starts:
the fixture clamps, the workpiece changer turns to the
processing position and processing starts.
Notes
■
■
4‐86
Production plan
For manual loading: whenever the LOADING ACKNOWLEDGMENT button flashes, the control is expecting a workpiece change. Then, the operator acknowledges the loading
operation by pressing the button.
For automatic loading acknowledgment: the loading acknowledgment is carried out by the external automation component.
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Clamping fixtures
On machines with fixtures that are controlled using the configurable control interface (KSS), opening and closing the actuators
depends on whether a "safe movement" is configured for the
corresponding KSS module.
■
■
If a safe movement is configured, the actuators of the
fixture can only be moved if the guard is closed for this loading place.
If no safe movement is configured, the actuators of the fixture are also moved if the guard is not closed for this loading
place.
With manual loading: after starting the production plan, the KSS
"unloading" sequence always starts first. The clamping elements
open in order that the workpiece can be inserted into the fixture.
Automation
On machines with activated automation interface (Automation
interface option), the external control specifies the loading and
unloading sequence.
Starting a production plan (manual loading)
Note: This section is valid for manual loading.
When the production plan is started, all released jobs of a production place are produced in succession in the selected order.
The automatic run and processing start as soon as the operator
has loaded the first workpiece and pressed the LOADING
ACKNOWLEDGMENT button.
If a workpiece is already loaded when the production plan starts,
the following conditions apply:
■
■
■
■
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2017-11-17
The status for a workpiece already loaded must first be
acknowledged. Then, the production plan must be restarted.
An error message is issued if the control detects an unexpected workpiece status. In such a case, the workpiece status must be changed for the loading place and then acknowledged. The workpiece must be removed for the relevant
loading place and a new workpiece must be loaded.
There is an unexpected workpiece status if the workpiece
status for the relevant loading place does not match the data
management in the machine control. Reasons for this could
be an abortion of the production plan or manual intervention.
A workpiece loaded in the working area must have the Raw
part in order that the NC program can start.
A workpiece loaded at the Unload loading place with the finished part status can be removed after starting the production plan (without acknowledgement) (the fixture opens automatically).
Production plan
4‐87
Conditions
■
■
■
■
At least one order is released in the production plan.
At least one loading place is activated.
The configuration of the workpiece change has been created.
Fixtures are closed.
Notes
■
■
■
■
■
■
If no safe KSS movement is configured for the clamping fixture, the fixtures also open at the start of the production plan
if the guard is open.
If a safe KSS movement is configured for the clamping fixture, the guard must be closed first before the actuators of
the fixture can be moved.
Recommendation: When the production plan is started, no
workpiece has been loaded yet.
If the LOADING ACKNOWLEDGMENT button flashes, the
workpiece can be loaded.
The production plan is aborted by pressing the RESET button.
The workpiece status displayed must correspond to the workpiece loaded.
Loading and workpiece status: (see "Loading and workpiece
status", pg. 4‐94).
1. Press the Production plan main operation.
2. Press Continue.
The production plan is started.
If no workpiece has been loaded yet, the clamping fixture
opens in the loading area. Then, the LOADING ACKNOWLEDGEMENT button flashes.
3. Load the first workpiece and press the LOADING
ACKNOWLEDGMENT button.
or
Ø If a workpiece is already loaded:
− Select the "Status" tab.
− If required (unexpected workpiece status), change the
workpiece status for the relevant loading place.
− Acknowledge the workpiece status for the loading place.
− Restart the production plan.
− Remove the workpiece and insert it again or load a new
workpiece.
− Press the LOADING ACKNOWLEDGMENT button.
The clamping fixture is closed and the workpiece changer
rotates. Processing and the automatic run start.
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B836en
After the end of processing, the workpiece changer clocks
and the finished part can be unloaded.
4. While processing is active, the next workpiece can be loaded
in the loading area.
5. Load the workpieces in succession and acknowledge each
loading operation.
All released jobs are processed in succession in the selected
program sequence.
Starting a production plan (automatic
loading)
Note: This section is valid for automatic loading.
When the production plan is started, all released jobs of a production place are produced in succession in the selected order.
If the operator starts the production plan, the automatic run is
also started if the required conditions are met.
If a workpiece is already loaded when the production plan starts,
the following conditions apply:
■
■
The status for a workpiece already loaded must be acknowledged.
After the acknowledgement, the loaded workpieces are
clocked up to the loading and unloading place, regardless of
the workpiece status.
If a workpiece is already clamped at the Load loading place,
this fixture must be closed.
An error message is issued if the control detects an unexpected workpiece status. In such a case, the workpiece status must also be acknowledged manually.
There is an unexpected workpiece status if the workpiece
status for the relevant loading place does not match the data
management in the machine control. Reasons for this could
be an abortion of the production plan or manual intervention.
Conditions
■
■
■
■
■
At least one order is released in the production plan.
At least one loading place is activated.
The configuration of the workpiece change has been created.
Fixtures are closed.
The external automation component is ready for operation.
Notes
■
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2017-11-17
Recommendation: When the production plan is started, no
workpiece has been loaded yet.
Production plan
4‐89
■
■
The production plan is aborted by pressing the RESET button.
The loaded workpiece must correspond to the workpiece status displayed.
Loading and workpiece status: (see "Loading and workpiece
status", pg. 4‐94).
1. Press the Production plan main operation.
2. Press Continue.
If no workpiece is loaded: the production plan and the automatic run are started.
If a workpiece is already loaded, the operator must acknowledge the workpiece status once after being requested to do
so (message).
3. If the workpiece status needs to be acknowledged:
− Select the "Status" tab.
− Acknowledge the workpiece status for the corresponding
loading place.
The automatic run is started, regardless of the status of the
workpieces already loaded.
All released jobs are processed in succession in the selected
program sequence.
Changing the program sequence
The order of the job processing is to be modified.
1. Press the Production plan button.
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1
Job
2
Program sequence buttons
Change sequence
Fig. 63878
2. Select "Production place". Open directory structure.
3. Select a job and insert it at the desired position in the production plan.
Modifying the number of program runs
Regardless of the job status, the number of program runs can
be modified for all jobs created.
1. Press the Production plan main operation.
2.
Press the Job button (
).
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Production plan
4‐91
1
Job
Changing the number of program runs
Fig. 68768
3. Select a job and changed the required quantity and/or the
actual quantity.
4. Change the program sequence, if required.
Stopping the production plan with "Stop
after cycle end"
After requesting "Stop after cycle end", the current operation
(loading, processing or unloading) is still carried out at all production places. The changer is clocked again after the loading
acknowledgment.
Then, the production plan is ended. No further workpiece change
takes place any more.
If production is then to be continued, the production plan must
be restarted, either manually at the control panel or - if available
- via the automation interface (Automation interface option).
1. Press the Stop button.
2. Select "Stop after cycle end".
After the loading acknowledgment, the workpiece changer is
clocked one more time. Then the production plan ends.
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Starting to run empty, ending the
production plan
After requesting "run empty", all raw parts still loaded are processed. No new workpieces are loaded any more.
If all parts have been removed and the LOADING ACKNOWLEDGMENT button is pressed, the production plan is ended.
Note
If the machine is equipped with the Automation interface option
and the automation system is active, "running empty" can also
be requested by the external automation system.
1. Press the Stop button.
2. "Select Idle stroke".
One after the other, each production place turns to the
unloading area. The fixture opens.
3. Remove every part and do not insert a new workpiece any
more.
After removing the part, press the LOADING ACKNOWLEDGMENT button.
Once all production places have been "run empty", the production plan is ended.
7.3
Exporting order
All or portions of the order data should be exported.
Condition
■
The job is not active.
Note
When a job is exported, the NC programs and the XML files of
the KSS module are also exported.
1. Press the Production plan main operation.
2. Select the "Export orders" tab.
3. Either
Ø Select the order to be exported.
or
Ø If all displayed orders are to be exported: press Select
all.
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Production plan
4‐93
4. Press Export.
5. Select and confirm the directory.
7.4
Starting step-by-step cycle
Step-by-step mode means that the workpiece changer continues
to rotate after the loading acknowledgment by one cycle only.
The mode is self-holding.
Condition
■
The production plan is active.
1. Press the Production plan main operation and select "Status".
2. Press the Step-by-step button.
Step-by-step mode remains active until it is deactivated again.
7.5
Loading and workpiece status
The machine control manages workpiece statuses and status
data for production places and loading places.
There is a relationship between the workpiece status and the
configured loading place.
Workpiece status
4‐94
Production plan
The machine control manages the following workpiece statuses:
Workpiece status
Symbol
Description
"Raw part"
Green
The workpiece is unprocessed.
"Partially processed"
Green
The workpiece is only partially
processed.
"Finished part"
Green
The workpiece is completely processed.
"No component"
Gray
There is no workpiece in the fixture.
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Workpiece status
Symbol
Description
"Contains errors"
Red
The workpiece is faulty.
Loading and workpiece status
Tab. 4-30
In the following conditions, the machine control marks the workpiece as faulty:
■
■
The part was not processed completely ("partially processed"
status).
− In the event of a program abortion.
− By pressing the LASER TEST button during processing.
After an ObserveLine error.
Notes
■
■
■
Error handling
After starting the production plan, the operator must acknowledge the workpiece status once. Only then can the automatic
run be started.
The processing program can only start if the workpiece at
the processing location has the "Raw part" status.
A workpiece status can only be changed and acknowledged
for the workpiece at the loading and unloading place. The
set status changes with the workpiece. The status can only
be checked for the processing location.
If the machine control identifies a faulty part, an error message
is output according to the selected strategy:
■
■
■
No reaction: No error message is to be output in the event of
a faulty part.
Acknowledge after every error: An error message is to be
output for every faulty part. The workpiece status must be
acknowledged.
Acknowledge after several errors: An error message is only
to be output when the defined number of faulty parts is
reached. The workpiece status must be acknowledged.
The troubleshooting strategy is defined in the configuration dialog
at "Missing part handling" (see "Configuration", pg. 4‐139).
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Production plan
4‐95
Displaying the loading and workpiece
status
While the production plan is active, the loading and workpiece
statuses can be shown and also acknowledged, if required.
For machines with automation interface (Automation interface
option), the status of the automation components is also shown.
Condition
■
The production plan is active.
Note
The Acknowledge toolpiece status button (position 7) is only displayed if the acknowledgement request is active.
Fig. 85676
Loading status and workpiece status for machines with rotational changer
4‐96
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Loading status and workpiece status for machines with rotary indexing table
Fig. 85675
Position
Legend
Description
1
Loading and unloading status
The status is displayed for every loading place.
2
Processing status
The status is displayed for the processing location.
3
Components status
The statuses of the automation components is displayed.
4
Step-by-step button
Activate step-by-step mode.
"Run empty"
"Run empty" status display.
"Stop after cycle end"
"Stop after cycle end" status display.
5
Workpiece status
The workpiece status of each production place is shown.
6
Automation status
The status of the automation interface is displayed.
7
Acknowledge workpiece status button
The current workpiece status is acknowledged after an
interruption.
Legend
Tab. 4-31
Ø Press the Production plan main operation and select "Status".
The "Status" dialog is opened.
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Production plan
4‐97
Changing the loading and workpiece status
When the production plan is started, when a fixture or a workpiece is run in, it may be necessary to change the workpiece
status. Then, the selected workpiece status must be acknowledged.
Conditions
■
■
Production plan is not active.
At least the "Advanced" user group is active.
1. Press the Production plan main operation and select "Status".
2. Press the Change workpiece status button.
The workpiece status is displayed for the loading and unloading places and for the working position.
Fig. 86043
Changing the workpiece status
3. Select the loading place and select the workpiece status.
4. Press OK.
The workpiece status changes.
5. Press the Acknowledge workpiece status button.
6. If the production plan is to be started:
− select "Production plan".
− Press Continue.
4‐98
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Acknowledging workpiece status with
manual loading
If the workpiece status needs to be acknowledged, a message is
displayed with an acknowledgement request. The workpiece status must be acknowledged in the following situations:
■
■
■
After starting the production plan if a workpiece is already
loaded.
After manual intervention by the operator.
After aborting the production plan.
Conditions
■
■
The production plan is active.
At least "Standard" authorization is active.
Notes
■
■
In the event of an error, the blue status indicator flashes
slowly.
The workpiece at the loading place must have the Raw part
status.
1. If the control issues an error message:
Press the Production plan main operation and select "Status".
2. Press the Acknowledge workpiece status button.
3. Restart the production plan.
The workpiece changer rotates the workpiece into the
unloading position.
4. If a workpiece is already inserted in the fixture in the loading
area, it must be lifted and re-inserted.
5. Press the LOADING ACKNOWLEDGMENT button.
The production plan continues.
Acknowledging the workpiece status with
automatic loading
Before the automatic run is started, that the workpiece status
and the tooling status of the workpieces at the machine must
match must be ensured.
During automatic operation, clocking of the workpieces continues
after acknowledging the workpiece status, regardless of the status (Raw part, Partially processed, Finished part, Faulty part)
unloading station.
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Production plan
4‐99
Workpiece transport only takes place if a workpiece loaded at
the loading station is clamped. If the fixture is not closed, an
error message is issued. In such a case, the workpiece status
must be clamped manually.
Conditions
■
■
■
The production plan is active.
At least "Standard" authorization is active.
Clamping fixtures must be closed.
1. If the control issues an error message:
Press the Production plan main operation and select "Status".
2. Press the Acknowledge workpiece status button.
3. If the production plan is to be started:
− select "Production plan".
− Press Continue.
The automatic run starts as soon as the external automation
component has loaded the first workpiece.
4‐100
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7.6
Remaining time display
The remaining time display is an option for the laser processing
machine. It shows the operator the time left ("remaining time")
on a screen.
The helps the operator see, for example, how much time there is
before the setting up of the next workpiece.
The "Remaining time display" option is available in two variants:
Basic and Comfort.
Screen
The screen for the remaining time display is on the outside at
the safety cabin. The screen is optional and is not part of the
standard scope of delivery of the "Remaining time display"
option.
During the processing, the remaining duration is visualized on
the screen.
The differences in the display for variants Basic and Comfort are
described below.
1
Monitor
Fig. 76782
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Production plan
4‐101
Remaining time
The remaining time for the tool change is the time from the start
of the part processing until the next loading acknowledgment by
the operator.
The basis for the calculation of the remaining time is the piece
rate, which is the result of the processing time plus non-productive time for the set up of the workpiece.
Resetting the remaining time
display
The remaining time saved in the control is reset under the following conditions and recalculated:
■
■
■
■
■
If the production plan is changed.
If the production plan is restarted within the shift.
If the processing sequence changes.
For a workpiece change on one station.
For a change of the feed at the potentiometer or in the program.
Notes
■
■
4‐102
Production plan
The remaining time display only changes when the change in
the production plan becomes effective.
While feed hold is present, the remaining time display
pauses.
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Basic remaining time display
The still remaining time until the setting up of the next workpiece
is shown.
Once the processing of a workpiece starts, the remaining time
display counts backwards parallel to processing. Simultaneously,
the green progress bar visualizes the duration.
1
Progress bar
2
Remaining time
3
Current time
Remaining time display Basic
Fig. 86048
After the first processing run-through of all stations (synonymous
to production place), the machine control is familiar with the
processing sequence as well as the processing times for each
workpiece and calculates the remaining time from this.
With each further processing cycle, the controller calculates an
average value of the piece rate and, in this way, optimizes the
remaining time.
Note
The remaining time display Basic is a standard function and cannot be configured.
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Production plan
4‐103
Comfort remaining time
display
The following functions are included in the scope of delivery of
the variant Comfort:
■
■
■
■
Configuration of shift and day shift plans.
Calculation of the required quantities per workpiece and shift.
Visualization of the remaining time for setting up of the next
workpiece.
Visualization of the shift goals per station and workpiece.
1
Remaining time progress bar
4
Remaining shift time
2
Remaining time
5
Current time
3
Shift goal progress display
Remaining time display Comfort
Fig. 86049
Remaining time display: While the production plan is active,
the screen shows and visualizes the remaining time.
Once the processing of a workpiece starts, the remaining time
display counts backwards parallel to processing. Simultaneously,
the green progress bar visualizes the duration.
Shift goal: The current shift plan is the basis for calculating the
required quantities per workpiece and shift. When calculating the
shift goal, breaks in the shift plan as well as earlier running out
of workpieces are considered.
The shift goal is reset and recalculated under the following conditions:
■
■
■
When a shift is manually started or extended.
If the piece rate for a workpiece is recalculated or changed.
When a shift plan is changed.
The progress display visualizes the shift goal with the following
information for each station:
■
■
■
■
■
4‐104
Production plan
Designation of the job.
Actual quantity per shift.
Required quantity per shift.
Shift goal progress bar.
Remaining shift time.
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Different colors signal the status.
Signal color
Description
Blue
The required quantity per shift has been reached.
Yellow warning
triangle
The actual quantity per shift is within the tolerance
range of -5% of th planned required quantity.
Red warning triangle
The planned required quantity per shift has not
been reached.
Shift goal progress bar
Tab. 4-32
Configuring the remaining time display
Note
The configuration of the remaining time display for the variant
Comfort is described below.
Production plan
In the "Production plan" main operation, the operator can enter
the piece rates for all released orders as well as creating and
editing shift and day shift plans.
1
Released orders
3
Piece rate per workpiece
2
Program name
4
Remaining time per order
Production plan: piece rates and remaining time
Piece rate
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Fig. 77362
The control calculates the remaining time per order and shift
from the entered piece rate per workpiece, multiplied by the
required quantity per shift.
Production plan
4‐105
Operation mode
The operation mode for the shift change can be switched over:
■
■
Shift plan
Day shift plan
"AUTO" operation mode (default setting): The shift change is
automatically done in accordance with the current shift plan.
"MANUAL" operation mode: The shift change is performed
manually. The operator starts and stops the shift.
The shift plan is a week plan. It is valid for all shifts of the current week insofar there is no day shift plan for the current day.
The operator can create a day shift plan that is only valid for the
current day.
Creating a new shift plan
A new week shift plan is to be created. For this, the following criteria must be defined:
■
■
■
■
4‐106
Production plan
Working days.
Shifts per working day: for example, early shift, late shift,
night shift, special shift, etc.
Begin and end of shift.
Definition of pause times.
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Condition
■
At least the "Advanced" user group is active.
1
Active operation mode
3
Shift begin
2
Weekdays
4
Shift end
Shift plan
Button
Description
Start shift
Manually begin shift.
Fig. 77364
Note:
This will cause the shift goal to be recalculated.
Stop shift
Manually stop shift.
Note:
This will cause the shift goal to be recalculated.
Extend shift
Manually extend the current shift in "AUTO" operation mode.
Changing the operating mode
Activate the "AUTO" or "MANUAL" operation mode.
Create new shift
Create a new week shift.
Edit shift
Edit the week shift.
Delete shift
Delete one shift in the week shift plan.
Create day shift plan
Create and edit the day shift plan for the current working day.
The shift plan for the current day is copied and can then be further edited
as a day shift plan.
Context button
Tab. 4-33
1. Press the Production plan main operation and select "Shift
plan".
2. Press Create new shift.
The "Edit shift" dialog is opened.
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1
Define shift
2
Add pause
Editing the shift
Fig. 77365
A new goal is added with the Plus button.
The Minus button is used to delete the goals.
3. Create a new shift, for example, early shift:
− Activate working days.
− Enter the begin and the end of the shift.
− Add pauses and enter the pause times.
− Press OK.
4. Create the next shift:
− Press Create new shift and enter Late shift.
− Define the late shift.
− Press OK.
5. Create the next shift:
− Press Create new shift and enter Night shift.
− Define the night shift.
− Press OK.
The week shift plan for the current week has been created and
is effective right away.
Editing shift plan
The shift plan can be changed at any time. The production plan
must not be stopped or interrupted for this.
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Condition
■
At least the "Advanced" user group is active.
1. Press the Production plan main operation and select "Shift
plan".
2. Select the shift that is to be edited.
3. Press Edit shift.
4. Edit the shift plan:
− Activate or deactivate the working days.
− Change the begin and end of the shift.
− Add or delete pauses.
− Edit pause times.
5. Press OK.
The changed shift plan is effective right away. The shift goal will
be recalculated.
Recreate the day shift plan
A day shift plan is to be created that deviates from the shift plan.
Condition
■
At least the "Advanced" user group is active.
1. Press the Production plan main operation and select "Shift
plan".
2. Press Create day shift plan.
The shift plan for the current day is copied and can then be
further edited as a day shift plan.
3. Select shift and press Edit shift.
− Edit the shift plan.
− Press OK.
The newly created day shift plan is effective right away. The
remaining time display is reset.
Editing the day shift plan
This current day shift plan is to be edited.
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Production plan
4‐109
Condition
■
At least the "Advanced" user group is active.
Note
The "Day shift plan" tab is only visible if a day shift plan has
already been created.
1
Active operation mode
3
Shift begin
2
Current day shift plan
4
Shift end
Day shift plan
Button
Description
Shift begin
Manually begin shift.
Fig. 77366
Note:
This will cause the shift goal to be recalculated.
Stop shift
Manually stop shift.
Note:
This will cause the shift goal to be recalculated.
Extend shift
Manually extend the current shift in "AUTO" operation mode.
Create new shift
Create a new day shift plan.
Edit shift
Edit the day shift plan.
Delete shift
Delete early shift, late shift or night shift in the week shift plan.
Delete day shift plan
Delete the day shift plan for the current day.
Context button
Tab. 4-34
1. Press the Production plan main operation and select "Day
shift plan".
2. Select shift and press Edit shift.
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−
−
Edit the shift plan.
Press OK.
The change of the day shift plan is effective right away. The
remaining time display is reset.
Deleting day shift plan
The week shift plan becomes effective again as soon as the day
shift plan is deleted.
Condition
■
At least the "Advanced" user group is active.
1. Press the Production plan main operation and select "Day
shift plan".
2. Press the Delete day shift plan button.
The day shift plan is deleted.
Editing piece rates
The "Piece rate" is the processing time plus the non-productive
time for a workpiece.
Condition
■
At least the "Advanced" user group is active.
1. Press the Production plan main operation and select "Piece
times".
The programs in all the released manufacturing orders in the
production plan are displayed.
2. Press the Edit piece rates button.
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Production plan
4‐111
The "Edit piece times for programs/parts" dialog opens.
Fig. 77363
3. Enter the "Piece rate" in seconds for the respective workpiece.
4. Press OK.
The piece rate is saved. The value is effective until the new
value has been entered. The shift goal will be recalculated.
Changing the operation mode
The "AUTO" operation mode corresponds to the default setting.
The shift change is performed automatically in this operation
mode in accordance with the created shift plan. Shift begin and
end are defined when the shift plan is created.
The operation mode can be changed in "MANUAL". The
operator must manually begin and stop the shift again in "MANUAL" operation mode.
Condition
■
At least the "Advanced" user group is active.
Notes
■
■
4‐112
Production plan
The shift goal is calculated at the beginning of the shift in
"MANUAL" operation mode on the basis of the current shift
plan.
If the operator forgets to begin the shift in "MANUAL" operation mode, the shift will be automatically begun as soon as
the first workpiece is processed.
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1. Press the Production plan main operation and select "Shift
plan".
2. Press the Change operation mode button.
The other operation mode becomes effective right away until the
mode is changed again.
Extending the shift
Operators can extend their own shift before it ends in the
"AUTO" operation mode if, for example, the required quantity
has not yet be reached.
Condition
■
The "Production" or "Standard" authorization is active.
Notes
■
■
If a shift is manually extended, the shift time and therefore
also the required quantity of the subsequent shift is automatically reduced.
The shift can be extended at a maximum of 30 minutes
before the end of the shift.
1. Press the Production plan main operation and select "Shift
plan".
2. Maximum 30 minutes before the end of the shift: press the
Extend shift button.
The automatic shift change is immediately invalid for the current
shift.
The shift will be ended only when the Stop shift button is
pressed or when the next shift end has been reached.
Manually beginning and ending the shift
Conditions
■
■
The "Production" or "Standard" authorization is active.
The "MANUAL" operation mode is active.
1. Press the Production plan main operation and select "Shift
plan".
or
Ø Press the Production plan main operation and select
"Day shift plan".
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Production plan
4‐113
2. To start the shift: press the Start shift button.
The shift remains active until the Stop shift button is pressed.
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8.
Production
8.1
Current program
NC programs can be loaded via network drives or USB-MemoryStick.
A filter can be set for the program selection. Press the
to reset the filter.
button
Start program
A program will be started in single job mode. A single job always
means that only one workpiece is processed. To process the
next workpiece, the program must be restarted with the START
button.
Conditions
■
■
■
■
The machine is ready for operation.
Laser device is ready for operation.
The tooling status is valid and has been activated.
The safety door is closed.
1. Press Production and select "Current program".
2. Press Program selection.
3. For the "Storage location", select Internal management.
All programs created in the Internal management system will
be displayed.
4. Select the program.
5. If the laser technology table is to be changed: Press Technology correction.
6. Press Continue.
The NC program will be loaded to the machine control system.
7. Press the START button.
The program starts.
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Pause program
If required, the active program can be halted during machining.
Condition
■
Program is active.
1. Press FEED STOP button.
2. To continue the machining: Press the ACKNOWLEDGE
FEED HOLD button.
Aborting a program
An active program should only be aborted if absolutely necessary.
Condition
■
Program is active.
Ø Press the RESET button.
The program is aborted and must, if necessary, be restarted.
Switch screen view
1. Press Production and select "Current program".
2. Select the program.
3. Open the "View" field with
.
4. To display the NC simulation and the process data, select
NC simulation + process data.
or
Ø To display the NC simulation, select NC simulation + NC
blocks.
or
Ø To display the current position of the NC axes, select Display axes + NC blocks. Select MKS or WKS.
or
Ø To display the sequence of the NC blocks or the NC programs, select Call sequence of NC programs and NC
blocks.
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Display Switching over the axis positions
In the Production main operation, the display of the actual axis
position for each station can be switched between MKS
(machine coordinate system) and WKS (workpiece coordinate
system).
1
Selection field axis display
Fig. 68891
1. Open the selection field with the
button.
2. Either
Ø To display the axis positions in MKS: select Main axes.
or
Ø To display the axis positions in WKS: select Main axes
(workpiece coordinate system).
The actual position of the NC axes is shown.
Display NC simulation
TruTops Cell Basic is an option of the laser processing machine.
In the NC simulation + process data view, the tool path of the
workpiece for the selected program is shown as a simulation.
Condition
■
A program has been selected.
1. Press Production and select "Current program".
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4‐117
2. Open the "View" selection field and select NC simulation +
NC blocks.
Fig. 74947
8.2
Preparing programs
Import master file
To be able to edit a program on the machine it must be saved to
the disc of the industrial PC and it must be divided into its component parts (main program, subprograms and tables).
The editing program will be imported as a master file into the
"Internal management" . During the import, the master file will be
separated into its parts.
The file can be imported from a USB-Memory-Stick or from a
network drive.
Note
If all of the files in a folder are to be imported, press Select all.
1. Press Production and select "Prepare program".
or
Ø Press Program and select "Manage programs".
2. For the "Storage location", select Drives.
3. Select drives via "Path" or via the folder structure.
4. Select the program.
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5. Press Import.
6. Press Import.
The master file will be imported into the Internal management.
Prepare program
In parallel to the main time, the operator can prepare another
NC program for editing.
Load program
1. Press Production and select "Prepare program".
2. Load a program from the Internal management.
or
Ø Import a program via Drive.
3. Select the program.
Editing a program
Checking the NC program
4. If the technology parameters are to be changed:
− Press Technology correction.
− Select the page of the table.
− Modify parameters.
− Press Save and close.
5. If the NC program is to be edited using the NC Editor:
− Press Program and select "Manage programs".
− Select the program.
− Press Edit.
− Select "Text editor" or "TruTops Cell Basic".
− Press Open.
− Edit the program and save. Close the editor.
Note
If programs are changed or split up, a syntax check will be
carried out automatically in the background. When this is
done, only the TRUMPF-specific components of the control
system are checked, such as the laser technology tables.
The syntax can be manually checked at any time.
6. To check the program, press Check.
The syntax check is carried out. Any syntax errors are displayed.
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8.3
Manual functions
Machine functions are called "Manual functions" if their status
(switch state) can either be displayed or altered in automatic
mode.
The manual functions are collected in groups.
Group
Manual Function
Description
Workpiece counter
"Production
place" (number)
Status display: The number of parts made at the production place is
shown.
Note:
With the "Advanced" user group, the workpiece counter can be changed.
Laser machining
"STOP single
contour"
"Analyser"
"Test marking"
"Real time test
mode"
Cutting process
gas
"Gas pressure
override"
Requests a program stop after each single contour.
■
Active: program stop is requested.
■
off: default setting, function is deactivated.
Recording for service purposes.
■
On: default setting.
■
Off: recording ended.
Switches marking test mode on or off.
■
off: default setting.
■
On: switches on marking test mode (see the "Activating marking test
mode" section).
The NC program is executed in test mode with 1 % laser power. The gas
supply is then active.
■
off: default setting.
■
On: real time test mode active.
Increasing or reducing the gas pressure by 10 % in each case:
■
To increase the gas pressure, press the JOG PLUS button.
■
To reduce the gas pressure, press the JOG MINUS button.
"Gas pressure"
Status display: Shows the current cutting gas pressure in bar.
"Post flushing
time"
Enter the post flushing time in seconds.
"Post flushing
pressure"
Set the post flushing pressure in bar:
■
To increase the gas pressure, press the JOG PLUS button.
■
To reduce the gas pressure, press the JOG MINUS button.
Process parameters
"Contour checking"
Status display: The current contour offset in the beam direction is shown.
Transformation
"Transformation"
The status of the transformation is shown.
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Group
Manual Function
Description
Laser
"Laser Test"
Activating or deactivating LASER TEST operating mode:
■
on: LASER TEST is activated.
■
off: LASER TEST is deactivated.
"Laser reset"
Acknowledging errors in the laser control system:
■
On: error will be acknowledged.
■
off: default setting.
"Alignment laser"
Distance control
system
Solid-state laser
Switches the alignment laser (pilot laser) on or off:
■
on: switch alignment laser on.
■
off: switch alignment laser off.
"Recording the
characteristic
curve"
Record characteristic curve for distance control.
"Distance control
system"
Switches the distance regulation ControlLine on or off.
"Collision detection"
Sets the reaction time of the distance regulation after detecting a collision
until FEED HOLD is triggered. The reaction time is self-holding (see the
Set-up section, Setting the reaction time for the distance regulation).
"Active laser
light cable"
Condition:
The distance regulation must be switched on.
■
Slow 2 D: slow reaction time for the machining of flat sheets.
■
Medium 3 D: medium reaction time for 3 D machining.
■
sensitive: fast reaction time for special applications.
Read in the number of the active laser light cable (LLK).
■
LLK1: Laser light cable number 1.
■
LLK2: Laser light cable number 2.
"Active laser
control system"
Status display: Device number of the active laser.
"Active light
path"
Status display: Number of the active laser light path.
"Laser control
system 1"
"Laser control
system 2"
Read in number of the active laser.
■
Connect: The machine control system will connect to the laser control
system.
■
Ready for operation: Laser control 1 (2) is ready for operation.
■
off: Laser control 1 (2) is not active.
"Request laser"
B836en
The laser is assigned via the laser network interface of the machine or is
enabled in the laser network again.
■
Enabled: Laser is not assigned to the machine.
■
Request: Laser is assigned to the machine and is ready for operation.
The assignment is active until the laser is enabled again by the manual
function.
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Group
Manual Function
Description
Solid-state laser
"Number of
active lasers"
Status display: Device number of the active laser.
"Status active
lasers"
Indicates the operating status of the active laser.
■
Ready for operation: Laser is ready for operation.
■
Undefined: No communication between the machine and the laser control system.
■
off: Laser device is switched off.
■
Start-up: Laser control system starts up.
■
Malfunction: A malfunction is registered. An alarm is output.
Note:
The cause of the error is displayed via the "Alarm" dialog, Cause softkey.
The user interface display changes from the machine control to the user
interface of the TruControl 1000 laser control system to the "Diagnostics"
dialog.
Dynamic cutting
optics
workpiece
changer
"Operating mode
status"
Status display: current operating mode of the additional axis
■
On: Additional axis is enabled and active.
■
Off: Additional axis is deactivated.
"Position"
Status display: the current position of the additional axis (up, center, down)
"Axis position"
Status display: the current position of the additional axis in mm
-
Manual functions: (see "Manual functions", pg. 4‐59)
Follow groups and manual functions configured with the KSS (project-specific).
Producing manual functions
Tab. 4-35
Call manual functions
1. Press Production and select "Manual functions".
2. Open the field with
and select group.
3. Press "Manual function".
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Activating marking test mode
With the "Marking test mode" function a contour is engraved on
the workpiece. This can be used, for example, to compare the
actual contour with the nominal contour. The control system uses
the "Marking" laser technology table internally instead of the LTT
"Cutting large/medium/small contours".
For laser technology tables that the user creates, the "marking"
laser technology table also needs to be created. The parameters
for marking are automatically available for all TRUMPF laser
technology tables.
Conditions
■
■
■
The machine is ready for operation.
LASER TEST mode is deactivated.
The machining program has been created.
Note
The LASER TEST operating mode (LASER TEST button illuminates) has a higher priority than the "Marking test mode" function.
1.
2.
3.
4.
Press
In the
Press
Press
Production and select "Manual functions".
group field, select the Laser machining.
"Test marking".
the ENTER button.
The LASER TEST button flashes.
5. Select the program.
6. Press the START button.
The program starts. The first time TC_LASER_ON is activated, the "Marking test mode" dialog opens.
7. Press Continue.
The test run is started. The contour is engraved on the workpiece.
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Activating STOP after single contour
To check the laser cut, with the "STOP single contour" manual
function, a targeted stop can be requested in the program. The
machining will stop after each single contour.
Condition
■
Program is active.
1.
2.
3.
4.
Press Production and select "Manual functions".
In the group field, select the Laser machining.
Press "STOP single contour" and set to active.
To start machining: press the START button.
The machining will start and stop after the first
TC_LASER_OFF.
5. To restart machining, press the ACKNOWLEDGE FEED
HOLD button.
Display the workpiece counter
Condition
■
Displaying the counter
reading
At least the "Advanced" user group is active.
1. Press Production and select "Manual functions".
2. In the group field, select the Workpiece counter.
3. Press "Production place 0".
The number of workpieces made will be displayed.
Changing the counter
reading
4. To reduce the counter level: press the MINUS button.
or
Ø To increase the counter level: press the PLUS button.
Resetting the workpiece counter
Condition
■
At least the "Advanced" user group is active.
1. Press Production and select "Manual functions".
2. In the group field, select the Workpiece counter.
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3. Press "Production place 0".
The number of workpieces made will be displayed.
4. Press the MINUS button and the PLUS button
simultaneously for about 2 seconds.
The counter reading is reset to 0.
8.4
Utility tools
Utility programs can be activated and started in the "Utility tools"
sub-operation.
The following dialog-driven utility programs can be started:
■
■
CP_HEAD_SETUP: utility program for setting up the processing optics as well as the machine.
CP_FIXTURE_SETUP.LST: utility program for setting up the
clamping fixture.
Note
Performing setting work: see "Setting work" chapter.
Starting utility programs
1. Press Production, select "Utility tools".
2. Select utility program.
3. Press Execute.
The utility program is started.
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9.
Setup
9.1
Moving the axes manually
In jog mode, the axes can be moved manually either with the
JOG PLUS and JOG MINUS buttons or with the teach panel.
If the teach panel is installed, the JOG buttons have no effect.
Moving the axis continuously
Conditions
■
FEED HOLD must not be active.
The home position has been reached.
FEED POTENTIOMETER larger than 0 %.
1.
2.
3.
4.
5.
Press Setup and select "Move axes".
Select "Travel mode", "Continuous".
If there are several groups of axes, select a group.
Select axis.
Press JOG PLUS or JOG MINUS.
■
■
The axis moves as long as the button is pressed.
Moving the axis incrementally
Position the axis according to the increment selected. The increment indicates by how many mm the selected axis is positioned
each time the button is pressed.
Conditions
■
■
■
FEED HOLD must not be active.
The home position has been reached.
FEED POTENTIOMETER larger than 0 %.
Note
It is not possible to move the axes incrementally using the teach
panel.
1. Press Setup and select "Move axes".
2. Select "Incremental" for "Travel mode".
3. Enter increment in mm.
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4.
5.
6.
7.
Press ENTER.
If there are several groups of axes, select a group.
Select axis.
Press JOG PLUS or JOG MINUS.
The axis is positioned.
9.2
Manual functions
Special machine functions are called "Manual functions" if their
status (switch state) can be altered in setup mode.
The manual functions are collected in groups.
Group
Manual Function
Description
General
"Safety test"
The dialog starts. Start the safety test (see "Manually start the safety test",
pg. 4‐53).
"Machine home
position"
Move the axes to their home position:
■
on: axes immediately move to their home position.
■
off: default setting.
■
not available: basic setting missing.
Note:
After the machine is switched on, the "Approach home position" dialog box
automatically starts.
Distance control
system
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"Optics replacement"
Release the magnetic coupling.
"Recording the
characteristic
curve"
Record characteristic curve for distance control ControlLine.
"Distance control
system"
Switches the distance regulation ControlLine on or off.
"Collision detection"
Set the reaction time of the distance regulation after detecting a collision
until FEED HOLD is triggered. The reaction time is self-holding.
Prerequisite:
The distance regulation is switched on.
■
2D series production: Fast reaction time for processing flat sheets.
■
2D prototype: Slow reaction time for machining flat sheets.
■
3D series production: Average reaction time for 3D processing.
■
3D prototype: Fast reaction time for 3D processing.
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4‐127
Group
Manual Function
Description
Solid-state laser
"Active laser
light cable"
Read in the number of the active laser light cable (LLK).
Note:
A maximum of
2 LLK can be
connected.
If 2 laser devices are connected, the
machine control
makes a distinction between
laser control 1
and laser control
2.
■
LLK1: Laser light cable number 1.
■
LLK2: Laser light cable number 2.
Prerequisite:
■
The machine and laser device are ready for operation.
■
LLK is fully installed.
"Active laser
control system"
Status display, number of the active laser is displayed.
"Active light
path"
Status display, number of the active laser light path is displayed.
"Laser control
system 1"
Read in number of the active laser.
"Laser control
system 2"
"Request laser"
■
Connect: The machine control system will connect to the laser control
system.
■
Ready for operation: Laser control system 1 is ready for operation.
■
off: Laser control system 1 is not active.
Read in number of the active laser.
■
Connect: The machine control system will connect to the laser control
system.
■
Ready for operation: Laser control system 2 is ready for operation.
■
off: Laser control system 2 is not active.
The laser is assigned via the laser network interface of the machine or is
enabled in the laser network again.
■
Enabled: Laser is not assigned to the machine.
■
Request: Laser is assigned to the machine and is ready for operation.
The assignment is active until the laser is enabled again by the manual
function.
"Number of
active lasers"
Status display, device number of the active laser is displayed.
"Status active
lasers"
Indicates the operating status of the active laser.
■
Ready for operation: Laser is ready for operation.
■
Undefined: No communication between the machine and the laser control system.
■
off: Laser device is switched off.
■
Start-up: Laser control system starts up.
■
Malfunction: A malfunction is registered. An alarm is output.
Note:
The cause of the error is displayed via the "Alarm" dialog, Cause softkey.
The user interface display changes from the machine control to the user
interface of the TruControl laser control system to the "Diagnostics" dialog.
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Group
Manual Function
Description
Laser
"Laser Test"
Activating or deactivating LASER TEST operating mode:
■
on: LASER TEST is activated.
■
off: LASER TEST is deactivated.
"Laser beam"
Laser beam status display:
■
on: The laser beam is switched on.
■
off: The laser beam is switched off.
"Laser reset"
Acknowledging errors in the laser control system:
■
On: error will be acknowledged.
■
off: default setting.
"Alignment laser"
Switches the alignment laser (pilot laser) on or off:
■
on: switch alignment laser on.
■
off: switch alignment laser off.
Cutting process
gas
"Cutting gas"
Select the cutting gas and adjust its pressure.
"Gas pressure"
Status display: The current cutting gas pressure in bar is shown.
Control Interface
"Data channel"
Switch the data channel for the configurable control interface (KSS) on or
off.
Suction system
"Suction system"
Switches the suction system on or off. After the configured delay, the
extraction system will switch off. The applied lag time is 10 minutes.
Note:
The exhaust system cannot be switched on if an EMERGENCY SHUTDOWN is active.
Setting work
"Purging"
Manually start the purging cycle.
"Park axes"
The dialog starts. Deactivate one or more axes (see "Park axes",
pg. 4‐135).
"Set position"
■
Reference the B and/or the C axis to an absolute position of 0°.
■
Carry out a controlled warm start.
"Lubrication
cycle"
Triggers the lubrication cycle manually. The lubricating pinions are lubricated for 20 seconds.
With each movement, all NC axes are lubricated permanently via a lubricating pinion that is supplied by the central lubrication unit. A lubrication
cycle is triggered every 96 operating hours automatically by default. The
lubrication cycle can be carried out manually at all times.
■
On: lubrication pulse is triggered.
■
off: default setting.
Note: the control system monitors the movement of the axes. If there is
no movement within 60 minutes in the defined monitoring window, then an
operation message will be displayed.
B836en
"No. of lubrications"
The number of lubrication cycles performed is displayed.
"Reset lubrication counter"
The counter for the lubrication cycles will be reset.
"Focal position"
Setting value for the focal position on machines withoutFocusLine.
The required focal position is entered manually.
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4‐129
Group
Manual Function
Description
Dynamic cutting
optics
"release"
Enable additional axis for dynamic cutting optics.
"Operation
mode"
"Position"
■
Yes: additional axis is activated and enabled.
■
No: Additional axis is not enabled. The axis is in the neutral position
(nominal value).
Status display: The status of the additional axis is controlled from the NC
program.
■
On: Additional axis is active (corresponds to TC_ADC_ON).
■
Off: Additional axis is not active (corresponds to TC_ADC_OFF).
Status display. Actual position of the additional axis:
■
+9 mm: top position.
■
+/ 0 mm: Additional axis in neutral position at "nominal value".
■
-9 mm: bottom position.
"Top axis position"
Move the additional axis to the upper end position.
"Center axis
position"
Move additional axis to the neutral position. This position corresponds to
the nominal value.
"Lower axis
position"
Move the additional axis to the lower end position.
workpiece
changer
-
Manual functions: (see "Manual functions", pg. 4‐59)
Scrap conveyor
-
Manual functions: (see "Tab. 4-36", pg. 4‐130)
Transformation
"Transformation"
Switches the transformation on or off.
■
Off: Transformation is deactivated.
■
BC: The transformation for the TCP is active, this corresponds to the
TC_TRAFO_ON command.
Setup main operation, Manual functions
Tab. 4-36
Call manual functions
1. Press Setupand select "Manual functions".
2. Open the field with
and select group.
3. Press "Manual function".
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Requesting the laser in the laser network
The machine can be connected to a laser network with a maximum of 2 solid-state lasers.
The machine is supplied with a laser light cable (LLK) as standard. It is optionally possible to connect 2 laser light cables (LLK1
or LLK2).
Conditions
■
The machine is ready for operation.
Laser device is ready for operation.
Laser light cable (LLC) is plugged in.
1.
2.
3.
4.
Press Setupand select "Manual functions".
Select the Solid-state laser group.
Press "Active optical laser cable" and select LLK.
Press "Laser control system 1".
■
■
or
Ø Press "Laser control system 2".
5. Press "Request laser" and set to Request.
The laser device is assigned to the machine.
Enabling the laser in the laser network
The machine can be connected to a laser network with a maximum of 2 solid-state lasers.
1. Press Setupand select "Manual functions".
2. Select the Solid-state laser group.
3. Press "Request laser" and set to Enable.
The laser device is enabled in the laser network.
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Setup
4‐131
Enabling the dynamic distance control
system
"Dynamic cutting optics" are equipped with an additional axis for
dynamic distance regulation (ADC). If work is done with dynamic
distance regulation, the additional axis must be enabled.
Condition
■
The dynamic cutting optics are ready for operation.
Notes
■
■
■
At the beginning of every NC program, the dynamic distance
regulation must be activated with the TC_ADC_ON cycle.
The drive of the additional axis references automatically
after switching on the machine unless the doors are closed
or when the doors are closed for the first time. The upper
position of the additional axis defines the reference position.
During the reference point run, the additional axis moves to
the upper end position or remains in this position.
In teach mode, the additional axis moves to the neutral position as soon as an enable key is pressed on the teach panel.
1. Press Setupand select "Manual functions".
2. Select the Dynamic cutting optics group.
3. Press "Enable" and set to On.
Dynamic distance regulation is enabled.
Deactivating the dynamic distance control
system
In case of, for example, an error, the additional axis for dynamic
distance regulation (ADC) can be deactivated. The cutting optics
can also be used without additional axis.
Note
If the optics without additional axis, the TC_ADC_ON cycle is
omitted in the NC program or is commented out (;TC_ADC_ON)
1. Press Setupand select "Manual functions".
2. Select the Dynamic cutting optics group.
3. Press "Enable" and set to No.
The distance regulation is deactivated. The additional axis moves
to the neutral position.
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Positioning the additional axis
The additional axis can be manually positioned.
Condition
■
The dynamic cutting optics are ready for operation.
1. Press Setupand select "Manual functions".
2. Select the Dynamic cutting optics group.
3. Position the additional axis:
Ø To move the axis to the upper position: press "Axis position, top".
or
Ø To move the axis to the neutral position: "Axis position,
center"
or
Ø To move the axis to the lower position: press "Axis position, bottom".
The additional axis moves in position.
Activating distance regulation
The distance control must be re-activated:
■
■
■
after the machine has been switched on.
after replacement of optics or nozzles.
after replacement of the sensor body.
Condition
■
At least 30 seconds have passed after the mounting of the
focusing optics.
1. Press Setupand select "Manual functions".
2. Select Distance regulation group.
3. Press "Distance control" and set to on.
The distance control has been activated.
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Setup
4‐133
ControlLineRecord characteristic curve
The distance control system of the processing optics works using
a characteristic curve. This characteristic curve has to be
recorded again:
■
■
■
After switching on the machine.
After replacing the optics or nozzle.
After replacing the sensor body.
Conditions
■
■
■
■
At least 30 seconds have elapsed since installing the
machining optics.
The active transformation type matches the configuration at
the machine.
New nozzle.
The distance regulation is switched on.
Note
The characteristic curve may also be recorded using the NC
cycle DIAS_3D.
1. Position the processing optics approx. 1 mm above the workpiece surface.
2. Press Setupand select "Manual functions".
3. Select Distance regulation group.
4. To switch the distance control on: Press "Distance control"
and set to on.
5. Press "Record characteristic curve".
6. Set the speed potentiometer to 100%.
7. Press the START button.
The characteristic curve is recorded. The distance control system
is ready for operation.
Switching the kinematic transformation on
or off
Note
When the kinematic transformation is turned on, the last stored
transformation type remains active until another transformation
type is programmed.
1. Press Setupand select "Manual functions".
2. Select the "Transformation" group.
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3. Press "Transformation" and set to BC.
Park axes
Condition
■
The axes to be parked are active and applied as parking
axes at the system.
Note
Each NC axis must be parked individually.
1.
2.
3.
4.
Press the EMERGENCY STOP push-button.
Press Setupand select "Manual functions".
Select the Setting work group.
Press "Park axes".
The dialog box starts.
5. Select axis.
6. Press Apply.
The selected axis is deactivated.
7. Switch off the MAIN SWITCH.
8. Disconnect the axes from the electrical power supply.
Displaying and resetting workpiece counter
The workpiece counter is an option of the laser processing
machine. The workpiece counter displays the number of produced tools per production place.
Condition
■
Workpiece counter option is applied.
1. Press Setupand select "Manual functions".
2. Select the Workpiece counter group.
The applied production places and the workpiece quantity is
shown.
3. If the workpiece counter is to be reset:
− Press "Production place x".
− Use the JOG MINUS button to set the value for the
quantity to 0.
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Setup
4‐135
Running a warm start
A warm start can be necessary for various reasons. A controlled
warm start can be carried out using the manual "Warm start"
function.
The drives are switched off, and the NC axes remain in their current actual position. The laser remains switched on.
Condition
■
At least "Standard" user group.
1. Press Setupand select "Manual functions".
2. Select the Additional functions group.
3. Press "Warm start"
The control system shuts down in a controlled manner and
carries out a warm start.
4. After a restart of the control system:
− Acknowledge any error messages with the RESET button.
− Switch on the drives, press the MACHINE ON/OFF button.
The drives are switched on. The machine is ready for operation
again.
Focal position without FocusLine setting
Only valid for machines without FocusLine.
For machines without FocusLine, the precise focal position is
determined by cutting trials. The focal position depends on the
material type and on the sheet thickness.
The focal position is manually set to a fixed value before the
machining.
Condition
■
The focal position for the workpiece to be machined is
known.
Notes
■
■
4‐136
Setup
The parameter "FocusLine setting value" in the laser technology table has no effect in this case.
It is not possible to adjust the focal position during the
machining.
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The permitted focal position adjustment range depends on the
focal length of the dynamic cutting optics.
Focal length
Permissible focal position adjustment range
f = 200 mm
-12.5 mm to +8.0 mm
f = 150 mm
-5.25 to + 5.25
Tab. 4-37
1.
2.
3.
4.
Press Setupand select "Manual functions".
Select the Setting work group.
Press "Focal position".
Set the value for the focal position with the MINUS or the
PLUS button.
The setting is valid immediately.
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Setup
4‐137
9.3
MDA
In MDA (Manual Data Automatic) mode, single or multiple NC
blocks can be created and executed immediately in single block
or block-by-block mode.
Note
The control system saves the programmed NC blocks permanently.
NOTICE
Risk of collision between Z barrel and fixture or workpieces
in the working range of the machine!
Considerable property damage to the barrel can result.
Ø
Each time before the axes or the NC program is started, the
operator must make sure that the barrel cannot collide with
objects in the workspace.
Execute the NC blocks in the following
block
Conditions
■
■
EMERGENCY STOP is not active.
Teach mode is deactivated.
Note
"Block-by-block" mode is preset.
1. Press Setup and select "MDA".
2. Enter the NC text using the keyboard.
3. Press Start.
MDA operation starts. NC blocks will be executed up to the programmed stop.
Execute the NC blocks in a single block
Conditions
■
■
EMERGENCY STOP is not active.
Teach mode is deactivated.
1. Press Setup and select "MDA".
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2. Enter the NC text using the keyboard.
3. Select "Single block".
4. Press Start.
MDA operation will start. The first NC block will be executed.
5. To run each of the other NC blocks, press Start.
9.4
Configuration
In the configuration dialog, the user defines how to change the
workpiece at the machine.
The workpiece change can be carried out manually or automatically:
■
■
■
Configuration of workpiece
change
Manual workpiece change: With a manual workpiece
change, the operator loads the workpiece. After processing,
the operator removes the finished part.
Automatic workpiece change: The workpieces are loaded
and unloaded by an external automation component that is
controlled via the machine's automation interface (Automation
interface option).
If there are several loading places at the machine, mixed
mode consisting of manual and automatic loading and
unloading is also possible.
The area in front of the workpiece changer where the workpiece
is set up (loaded or unloaded) is referred to as "loading place".
A number is assigned to every loading place.
The configuration of the workpiece change depends on the configuration of the machine. A valid configuration means at least
one loading place must be activated.
The following parameters can be defined for every loading place:
■
■
■
■
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2017-11-17
Load: The new workpiece is loaded at this loading place
(before processing).
Unload: The completed workpiece is unloaded at this loading
place.
Load and unload: The new workpiece is loaded at this loading place and the completed workpiece is unloaded.
No action: This loading place is deactivated.
Setup
4‐139
A
With rotary indexing table
B
With rotational changer
Loading place
Fig. 89267
Configuration of automation
interface
On machines with automation interface, the following parameters
are also configured:
Parameter
Description
Valid for
"Beam threshold value on"
Defines the threshold for the evaluation of
whether the laser bean is switched on or off. If
the laser power drops below the entered
threshold, the LASER_BEAM_IS_ON signal
(laser beam on) is reset.
Automation interface
Basic
Comfort
Professional
"Handling defective part"
Defines the strategy of the automation system
when defective parts are recognized.
Automation interface
Comfort
Professional
■
"Number of defective parts"
4‐140
Setup
No reaction
■
Acknowledge after every error
■
Acknowledge after several errors
Only relevant for the Acknowledge after several errors strategy:Number of permissible
defective parts. If this number is exceeded, the
automation reacts in accordance with the
selected strategy.
Automation interface
Comfort
Professional
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Parameter
"Activate automation"
"External safety device"
Description
Valid for
Activate or deactivate external automation.
Automation interface
Comfort
Professional
■
Activate: The workpieces are put in the fixture by the external automation component
and also taken out again. The external
safety device is effective.
■
Deactivate: The workpieces are manually
loaded. The machine's safety device is
effective.
The checkbox is status information. The checkbox is activated if the external safety device is
active.
Automation interface configuration parameters
Tab. 4-38
Note
These parameters are only displayed if the Automation interface
option is applied.
Configure loading and unloading place
This section is valid for machines without automation interface.
Condition
■
At least the "Advanced" user group is active.
1. Press Setup main operation and select "Configuration".
The configuration dialog starts. The user interface shows the
respective machine configuration and the corresponding loading places.
2. In the "Workpiece change configuration" selection field, select
the parameters for the "loading place".
The configuration is completed and is effective immediately in all
the machine's operating modes.
Configure loading and unloading place
This section is valid for machines with automation interface
(automation interface option).
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Setup
4‐141
Condition
■
At least the "Advanced" user group is active.
Note
The "External safety control system" parameter is a status display.
For machines with a rotary indexing table:
Activate automation
Fig. 77308
For machines with rotational changer:
Fig. 79717
Activate automation
1. Press Setup main operation and select "Configuration".
The configuration dialog starts. The user interface shows the
respective machine configuration and the corresponding loading places.
2. If the automation interface is to be activated: select "Activate
automation".
3. In the "Workpiece change configuration" selection field, select
the parameters for the "loading place".
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4. Optional: Enter the threshold for the laser power at the
"Beam threshold value on" parameter.
5. Define the parameters for handling of defective parts:
− Select the "Defective part handling" strategy in the selection list.
− If the Acknowledge after several errors strategy is
selected: Enter the "Number of defective parts" after
which there should be a reaction.
The configuration is completed and is effective immediately in all
the machine's operating modes.
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Setup
4‐143
10.
Programming
10.1 Program management
The "Internal management" is the program management on the
machine's operating PC.
Programs can be managed and edited at the "Manage programs" sub-operation:
■
■
■
■
■
■
■
■
■
4‐144
Programming
Load master files into the "internal management" (operating
PC hard disc).
Export master files to a network directory.
Create and process main programs.
Create a subroutine and sub program macros.
Change to TruTops Cell Basic programming system.
Fill the transformation accumulator.
Show setup schedule as PDF file.
Show any PDF file.
Teaching.
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1
Internal management
4
PDF file
6
Folder structure
2
Hard drive/USB
5
Path
7
Program selection
3
Filters
Manage programs
Fig. 71606
Notes
■
■
■
Network directory
For the program selection, a filter can be set with the
button.
Only empty folders can be deleted.
Programs that are saved in a production plan as orders cannot be deleted.
The machine's operating PC can be integrated into a network.
Files can be imported and exported via the network.
Due to the active firewall, files can no longer be imported via the
network directory '\topsmanu.dir' into the "Internal management".
The import is only possible with a USB-Memory-Stick or via an
external network directory.
The export of files via the network directory '\topsmanu.dir' continues to be possible.
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Programming
4‐145
KSS modules
During import of the NC program, the associated KSS modules
associated with the program will also be imported.
If an error occurs during import of the KSS modules, the module
must be separately imported.
Importing KSS module; see: "Supplement to operator's manual",
TruLaser Cell, document number M265.
Setup plan
When importing programs from the TruTops programming systems, the setup plan can be called up and displayed as a PDF
file.
Selecting program
Condition
■
The program is stored in the internal management system.
1. Press Program and select "Manage programs".
2. For the "Storage location", select Internal management.
All NC programs that are stored in the "internal management
system" are displayed in the list.
3. Select the program.
Creating a new program
New programs can be created, for example by copying an existing program.
Newly created programs contain a standard program header
which can be edited in the text editor.
Notes
■
■
Only main programs can be created at the machine control.
Main programs with subprograms can be imported. Subprograms can be edited at the user interface.
1. Press Program and select "Manage programs".
2. For the "Storage location", select Internal management.
3. Press New.
or
Ø Select the program which should be copied.
Press Copy.
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4. Enter the program name.
5. Press OK.
The program has been created and can be edited now.
Copying a program
Conditions
■
The program is stored in the internal management system.
■
Program status "OK"
.
1. Select the program.
2. Select Copy.
3. Press Rename.
Note
The file type *.tpp or *.lst must be retained.
4. Enter the new file name. Press OK.
Editing a program in the text editor
Programs created in the internal management system can be
edited in a text editor.
Programs that are saved in a production plan as order can also
be processed.
Conditions
■
Program status "OK"
■
At least "Standard" user group.
.
Notes
■
■
NC cycles and commands which change the path of a tool
and which are not supported by TruTops Cell Basic cannot
be interpreted by the graphic editor. The program will abort.
Context-dependent, online help for the NC cycles can be displayed in the selection field.
1. Press Programming main operation.
2. Select the program.
3. Press Edit.
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Programming
4‐147
4. Select "Text editor".
The Editor opens.
5. Press Open.
6. Editing NC text.
A yellow bar on the left border marks the changed NC block.
7. To save the changes, Press Save.
or
Ø To close the table, Press Save and close.
Create subroutine
Note: The following description is valid for one local subroutine (UP).
"Subroutine macro" (see "Creating and managing subroutine
macros", pg. 4‐153).
In the program editor, a sub program can be created after selection of a main program. The sub program is firmly assigned in
this main program and is only effective in this main program.
There are three possibilities to create a new sub program:
■
■
■
A block sequence marked in the main program can be
stored as a sub program. The marked NC blocks are deleted
in the main program; in place of them, an NC block with the
sub program name is added as activation in the main program.
If no NC blocks are marked, an empty sub program will be
created. In this case, the NC block must be manually added
into the main program.
An existing sub program can be copied. The copied sub program is also only effective in this main program. The NC
block with the sub program activation must be manually
inserted into the main program.
If a new subroutine is created, the control automatically gives it
a temporary program name: SP1, SP2 etc.
Recommended sub program name: SP_NAME, "SP" for Subprogramm.
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Conditions
■
The main program has been created and stored in the internal management.
■
Program status "OK"
.
Notes
■
■
1.
2.
3.
4.
The program name can be renamed, if need be. If the program name is changed, the NC block with the program activation (program name) in the main program must be manually changed.
During deletion, the sub program is permanently deleted from
the hard drive. The NC block with the program names must
be manually removed from the main program.
Press Program and select "Manage programs".
For the "Storage location", select Internal management.
Select the program.
Press Edit.
The program editor opens.
5. Either
Ø Mark NC blocks which are to be saved as a new sub
program.
or
Ø If an empty sub program is to be created: do not make
any NC blocks in the program.
6. Press New sub program.
The control creates a subroutine with, for example, the program name SP1. The marked NC blocks are deleted in the
main program. An NC block with the activation SP1 is added
in its place.
7. If the program name is supposed to be modified:
− Select the subroutine.
− Press the Rename subroutine button.
− Enter the new program name and confirm.
− Change the NC block with the program name in the main
program.
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Programming
4‐149
Number program
Condition
■
The program has been selected and the text editor has been
opened.
1. Open "Selection field" and choose Numbering.
2. Enter the "Start number" and "Increment size" for the numbering.
3. Press Number.
The NC blocks will be renumbered.
4. To save the changes, Press Save.
or
Ø To close the table, Press Save and close.
Exporting program
Programs created or changed on the machine can be exported
to a network drive or to a USB-Memory-Stick. A master file will
be produced during the export.
For the export file, a file type of *LST or *TPP can be selected.
Condition
■
The program is not active.
Notes
■
■
The LTT valid for the program will only be exported if the
associated tooling status is been selected.
If all of the programs in the folder are to be exported: press
Select all.
1. Press Program and select "Manage programs".
2. If not yet selected, For the "Storage location", select Internal
management.
3. Select the program.
4. Press Export.
5. Select "file type".
6. Select export folder.
7. If a new folder is to be created for the export:
− Press New folder.
− Enter folder name.
− Press OK.
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8. Press Apply.
The program will be saved as a master file to the selected
export folder.
Importing program
Programs that are externally created or changed can be
imported into the program manager by a USB-Memory-Stick or
another external network directory.
Note
If all of the programs in the folder are to be imported: press
Select all.
1. Press Program and select "Manage programs".
2. Select "Path" or "Folder".
The "Program selection" dialog opens. All programs in the
selected folder will be displayed.
3. Select the program.
4. Press Import.
5. Press Apply.
The selected programs are saved in the "internal management".
Delete program
Conditions
■
■
The program is not active.
At least "Standard" user group.
Note
Programs that are saved in a production plan as orders cannot
be deleted.
1.
2.
3.
4.
5.
Press Program and select "Manage programs".
For the "Storage location", select Internal management.
Select the program.
Press Delete.
Press Delete.
The program will be deleted from the "internal management"
(from the industrial PC's disc).
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Programming
4‐151
Show setup plan
Conditions
■
■
1.
2.
3.
4.
The setup plan is stored as a PDF file in the same folder as
the *.LST master file.
The PDF file has the same file name as the master file: e.g.,
"MyProgram.LST" and "MyProgram.PDF".
Press Program and select "Manage programs".
Select the external management.
Select the program.
Press the Set-up plan button.
The setup plan is shown.
Show PDF file
Any PDF file can be shown.
Note
PDF files are only shown in the folder structure if the "Show
PDF" function has been activated.
1.
2.
3.
4.
5.
Press Program and select "Manage programs".
Select the external management.
Activate the "Show PDF" box.
Mark "PDF file" in the folder structure.
Press the Display button.
The PDF file will be shown.
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10.2 Creating and managing subroutine
macros
Subroutine macros are globally effective subroutines which, once
created, can be called up in more than one main program. In
comparison: local subroutines (UP) are only effective in the one
main program where they have been assigned.
Users can create and manage their own subroutine macros.
1
Subroutine macros selection list 2
Macro included in the program
Managing the subroutine macro
Fig. 77358
Button
Description
Editing
Processing and existing or new subroutine macro.
New
Create a new subroutine macro.
Copy
Copy the selected subroutine macro.
Delete
Delete the selected subroutine macro.
Tab. 4-39
Importing the subroutine
macro
Only one subroutine macro can be saved with the same name in
each case in the program management on the operating PC.
Therefore, the following should be noted when importing main
programs:
■
■
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2017-11-17
When importing a main program with a subroutine macro
that already exists in the program management, the macro
will not be imported with the main program.
If a subroutine macro was changed outside the program
management, the macro must either be imported under a
Programming
4‐153
new name or the macro that exists in the program management must be deleted before the import.
Note
If main programs with subroutine macros are imported to another
machine, for example, to a TruLaser Cell 8030 (L45), then the
subroutine macro will become a local subprogram (UP).
Exporting the subroutine
macro
Deleting the subroutine
macro
When exporting a main program with a subroutine macro, the
macro is exported with the main program.
Note the following when deleting subroutine macros:
■
■
Subroutine macro
programming
If a subroutine macro is deleted which is not linked to any
main program, the macro and the NC code will immediately
and permanently be deleted from the hard drive without
warning.
If a subroutine macro is to be deleted which is linked to at
least one main program, a query appears. If the subroutine
macro is deleted in this case, only the macro is deleted,
while the program and NC code are kept as a local subroutine (UP).
Subroutine macros are called up in the NC program by inserting
the program name to the desired position in the NC program as
an NC block.
Subroutine macros can be programmed with or without transfer
parameters.
Note
Programming subroutine macros: see the machine programming
manual.
Creating a subroutine macro
A new subroutine macro can be created by copying an existing
macro or by creating and editing a new macro.
When a new subroutine macro is created, the editor places the
prefix "SPM_" in front of the macro name. This prefix should not
be changed by the user.
"SPM" stands for SubProgrammMakro.
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Condition
■
At least "Standard" user group.
Creating a new subroutine macro
Fig. 77357
1. Press the Programming main operation; select "Manage macros".
2. Creating a new macro:
Ø Select an existing macro in the selection list.
− Press Copy.
or
Ø Press New.
3. Enter new macro name. Keep the SPM_ prefix.
4. Press OK.
A new subroutine macro is created.
Processing a subroutine macro
The subroutine macro can only be edited in the macro editor.
Condition
■
At least "Standard" user group.
Note
The subroutine macro is write-protected in the program editor.
1. Press the Programming main operation; select "Manage macros".
2. Select the macro in the "Programm macro" selection list.
3. Press Edit.
Opens the macro editor.
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4. Editing NC text.
5. Press Save and close.
The subroutine macro can now be inserted in the main program.
Deleting the subroutine macro
If a subroutine macro is deleted, it is retained as a local subprogram (UP) under the same name with the prefix SPM in the program management: only the macro is deleted; the program code
is retained. The local subroutine continues to be effective in the
main program with which it is linked.
Condition
■
At least "Standard" user group.
1. Press the Programming main operation; select "Manage macros".
2. Select the macro in the "Programm macro" selection list.
3. Press Delete.
The subroutine macro is either deleted or converted into a local
subroutine.
Inserting the Subroutine macro
With the program editor, subroutine macros can be inserted into
the main program.
Conditions
4‐156
Programming
■
The macro has been created; macro status "OK"
■
At least "Standard" user group.
1.
2.
3.
4.
Press Programming main operation.
Select the main program.
Press Edit.
Select "Text editor".
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A list is displayed of subroutine macros which are assigned to
the main program.
1
Available subroutine macros
Using the subroutine macro
Fig. 77360
5. Press Use macro.
A list is displayed of subroutine macros that are available in the
control.
Fig. 77359
Inserting a subroutine macro
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6. Select subroutine macro.
7. Press OK.
The subroutine macro is now assigned to the main program.
8. Insert an NC block in the main program at the desired position with the name of the subroutine macro.
For example: N200 SPM_Example_1.
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10.3 Transformation
Note
The values displayed for the actual position of the NC axes are
dependent on which coordinate transformation (Frame) is active:
the machine coordinate system (MKS), the workpiece coordinate
system (WKS) or an active zero point offset.
1
Zero point offset status
5
Applied axes
9
2
Transformation status
6
Actual value, display, axes
10 Frame Scale
3
Transformation accumulator
selection list
7
Marked axes
11 Frame Rotation
8
Frame Translation
4
Frame Flip
Transformation accumulator
Transformation
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Column
Symbol
Description
"Axis current value"
-
The entered values corresponds to the actual position of the NC axes.
By pressing the Apply current value button, the actual positions of all
marked axes in the selected transformation accumulator are applied as
zero point coordinates.
"Translation"
Zero point offset for the respective axis by translation, based on the currently set translation accumulator.
The saved Frame is activated during the start of the program as zero
point offset for the selected transformation accumulator.
"Revolve"
Zero point offset for the respective axis by rotation, based on the currently
set transformation accumulator.
The saved Frame is activated during the start of the program as zero
point offset for the selected transformation accumulator.
"Mirror"
Flip the marked axis, based on the currently set transformation accumulator.
The saved Frame is activated during the start of the program as zero
point offset for the selected transformation accumulator.
"Scale"
Scaling factor for the respective axis by rotation, based on the currently
set transformation accumulator.
The saved Frame is activated during the start of the program as zero
point offset for the selected transformation accumulator.
Tab. 4-40
Transformation accumulator
There are four transformation accumulator: G54, G55, G56 and
G57.
In each transformation accumulator, a zero point or a new Frame
can be saved. The saved zero point or Frame is activated in the
NC program by programming of, for example, SET_G54.
There are the following possibilities to fill the transformation
accumulator:
■
■
■
■
By applying the actual positions of all marked axes.
By manually entering the zero point coordinates in the text
input fields for translation and/or rotation.
By flipping of individual axis coordinates.
By scaling of individual axis coordinates.
If the "Offer all accumulators for selection" checkbox is activated,
the following will be shown in the "Transformation accumulator"
selection list:
■
■
■
4‐160
Programming
The transformation accumulator G54, G55, G56 or G57.
Current Gxx: Status display for the last activated zero point
offset.
TRANS/ROT/ATRANS: Status display for translation and rotation, based on the selected transformation accumulator.
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Note
If the "Offer all accumulators for selection" checkbox is not activated, the four transformation accumulators will be shown in the
selection list:
Kinematic transformation
The kinematic transformation defines the way in which the NC
axes move to the programmed position.
Symbol
Description
Kinematic transformation is switched on: if the orientation
axes (B and C1) are rotated, the geometrical axes (X, Y
and Z) perform balancing movements.
Kinematic transformation is switched off: if the orientation
axes are rotated, the geometrical axes do not perform balancing movements.
Tab. 4-41
Applying the actual position as the zero
point
Kinematic transformation is generally switched on if the actual
positions of the NC axes are to be applied as zero point coordinates in the transformation accumulator.
■
■
The axis values correspond to the WKS coordinates when
transformation is switched on.
The axis values correspond to the MKS coordinates when
transformation is switched off.
Conditions
■
■
At least the "Advanced" user group is active.
No zero point offset may be active: the display in the
"Actively adjustable zero point offset" field is empty.
1. Switch on kinematic transformation.
2. Move the NC axes to the position that is to be saved as zero
point.
3. Press Programing, select "Transformation".
4. Open the "Transformation accumulator" selection field.
5. Select a transformation accumulator e.g. G54.
6. Mark the NC axes whose positions are to be saved.
7. Press the Apply actual values button.
The actual positions of the marked axes are saved in the transformation accumulators.
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Moving zero point incrementally
The Frame values saved in the transformation accumulator for
translation or rotation can be changed step by step (incrementally).
Condition
■
At least the "Advanced" user group is active.
1.
2.
3.
4.
5.
Press Programing, select "Transformation".
Open the "Transformation accumulator" selection field.
Select a transformation accumulator e.g. G54.
Select the text input field whose value is to be incremented.
Either
Ø If the software keyboard opens: press OK.
or
Ø Press the Increment value button.
6. Enter the increment in the "Increment (+/-)" field. Note the
operational sign.
7. Press OK.
The entered value is added to or subtracted from the value of
the selected text input field.
The calculated Frame value is immediately saved in the transformation accumulator.
Select Frame and fill transformation
accumulator
A new Frame can be created by translation, rotation, flipping or
scaling. The Frame is saved in the selected transformation accumulator and later activated in the NC program by a zero point
offset.
Condition
4‐162
Programming
■
At least the "Advanced" user group is active.
1.
2.
3.
4.
Press Programing, select "Transformation".
Open the "Transformation accumulator" selection field.
Select a transformation accumulator e.g. G54.
If a new Frame is to be created by "Mirror": Select NC axis
whose coordinates are to be mirrored.
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or
Ø If a new Frame is to be created by "Scaling": enter a
scaling factor for the respective axis.
or
Ø If a new Frame is to be created by translation or rotation:
activate the NC axes and Frame values in the respective
input field.
The selected Frame is saved in the selected transformation
accumulator.
Deleting transformation accumulator
Condition
■
At least the "Advanced" user group is active.
1.
2.
3.
4.
Press Programing, select "Transformation".
Open the "Transformation accumulator" selection field.
Select a transformation accumulator e.g. G54.
Press the Delete all values button.
All axis coordinates are set to 0 in the selected transformation
accumulator. The values for scaling are set to 1. The value
"OFF" is set for the Frame mirroring.
10.4 Operate KSS
Note
Module configuration, Interface description as well as automation
interface: see supplement for TruLaser Cell Operator's manual,
document number M265.
Start KSS configuration
Ø Press Programming; select "CCI configuration".
The KSS configuration start page opens.
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Activate module and load module data
If a program is to be started with KSS activation, the module
data must be previously transferred to the control (the PLC). The
module data is active in the control until the module is removed
from the control.
Several modules can be active at the same time in the control.
Conditions
■
■
■
■
Module is created, elements and sequences are configured.
Production plan is not active.
Machining is not active.
User group "Standard" or "Advanced" is active.
1. Press Programming; select "CCI configuration".
2. Select the module in the left column.
3. Press Activate/deactivate.
The module has been activated but not yet loaded in the
PLC.
4. Press Apply data.
The module data is transferred to the PLC. Manual functions,
diagnostics functions as well as error texts are generated.
Deactivating the module
The module is deactivated in the PLC. The module data remain
loaded in the PLC.
Condition
■
At least "Standard" user group.
1. Press Programming; select "CCI configuration".
2. Select the module in the "Active module" column.
3. Press Activate/deactivate.
The module is deactivated. The module status changes to gray.
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10.5 Programming system
Starting TruTops Cell Basic
TruTops Cell Basic is an option for the laser processing machine.
Conditions
■
■
■
1.
2.
3.
4.
5.
TruTops Cell Basic is applied.
The NC program was created using TruTops Cell.
The machine configuration agrees with the configuration in
the simulation program.
Press Programming main operation.
Select the program.
Press Edit.
Select "TruTops Cell Basic".
Press Open.
TruTops Cell Basic opens; NC program and machine configuration are shown.
Call up advanced shop floor programming
The "Advanced shop floor programming" (option) can be called
up from the control panel of the machine.
To do this, the operator connects to a TruTops computer/server
outside the machine network.
1.
2.
3.
4.
Press Programming and choose "Programming system".
Select "Unit system".
Enter "Server name", "Domain", "User" and "Password".
Either
Ø Press Connect.
or
Ø To change the configuration, press Configuration.
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11.
Laser technology tables
Technology
All technology parameters for laser processing are transferred to
the control in the form of a laser technology table. The laser
technology table is called up in the processing program by programming NC cycles.
A distinction is made between the following technology tables:
■
Technology tables for laser cutting (LTT).
Notes
■
■
■
Technology parameters and
programming
The user can create his own tables, e.g. by copying existing
tables and editing the processing parameters.
Technology tables from TRUMPF are write-protected.
Technology tables are global tables. Modifications in a
technology table are active in all programs where this
table is programmed.
For technology parameters and programming, see the "TruLaser Cell programming manual" in the chapter "Laser processing", section "Laser cutting".
For laser technology tables for cutting (LTT),. see "TruLaser Cell
data collection".
Embedded Help
For every parameter in the table, context-sensitive help can be
displayed.
■
Embedded Help is opened using the
■
Embedded Help is closed using the
button.
button.
If the button for the Embedded Help is opened, pressing the
input field for the parameter concerned will result in a description
of the parameters being displayed.
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11.1 Laser cutting
The processing parameters are programmed in so-called laser
technology tables for cutting (LTT).
Cutting parameters
1
"Tables" selection field
3
"Technology" selection field
2
Selection
4
Cutting parameters
Laser cutting technology table
Fig. 67415
The table name consists of 2 characters:
Naming convention
Description
First part: Viewer name
The Viewer name is manually entered by the user. It may not have more
than 12 characters. The naming should adhere to the following TRUMPF
conventions:
■
Material: "Material", "Thickness", "System of dimensions", "Material
standard".
■
Process: "Gas type", "Processing type", Index". The user can use the
digits 5 to 9 for the "Index". The digits 0 to 4 are reserved for TRUMPF
tables.
Second part: Key extension
The Key extension automatically generates the control for the active tooling status. The extension contains the following information in the following
sequence:
■
Laser: "Nominal laser power", "Laser type".
■
Beam formation: "LLK diameter", "Collimation focal length", "Focusing
focal length", "Type of optics".
■
Machine: "Machine group", "Machine length" for the main axis.
■
Workpiece: "Type of workpiece", "Material".
Cutting table naming convention
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Tab. 4-42
Technology
4‐167
Selecting the setting for the "Table"
selection field
For displaying the technology tables, a presetting can be
selected in the "Tables" selection field.
Setting
Selection
"Should the table for the selected
program be selected?"
"Yes": The current program table will be loaded and marked in the focus in
the "Tables" selection field.
"No": The last selected table will be loaded and marked in the focus in the
"Tables" selection field.
"Tables for the current tooling status"
Only the tables that belong to the current tooling status are displayed.
"All tables"
All tables are shown.
"Tables" selection field
Tab. 4-43
1. Press Technology, select "Laser cutting".
2. Press the Settings button.
3. Either
Ø If the table of the current program is to be selected:
select "Yes".
or
Ø Select "No".
4. Choose setting:
Ø Select "Tables for the current tooling status."
or
Ø Select "All tables."
5. Press Apply.
The selected setting is active until a different setting is selected.
Creating a cutting table
A new cutting table can always only be created for the current
state of tooling.
Generally, a new table is created by copying an available table.
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Condition
■
The tooling status for which table should be created has
been activated.
Note
The current tooling status is taken into account when copying a
technology table. Tooling-relevant parameters of the table are
replaced by parameters of the tooling status.
1. Press Technology, select "Laser cutting".
2. Select the table to be copied.
3. Press Copy table.
− Enter table name.
− Press Copy.
4. Select technologies:
Ø In the "Technologies" field, choose the table page.
or
Ø Select the table page with the Previous technology or
Next technology buttons.
5. Modify parameters.
Edit the cutting table
Process parameters are changed by changing the entries in the
table of the programmed cutting table.
Parameters can only be changed in the tables that the users
have created themselves. Tables from TRUMPF are write-protected.
Notes
■
■
Modifications in a cutting table are effective in all programs in
which this table is programmed.
If the parameters of a cutting table are to be reset to default
values, press the Default values button.
1. Press Technology, select "Laser cutting".
2. In the "Tables" field: Select a table.
3. Select the technology (machining process):
Ø In the "Technologies" field, choose the table page.
or
Ø Select the technology with the Previous technology or
Next technology buttons.
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4. Modify parameters.
The modifications take immediate effect.
11.2 Ramp cycles
Programming ramp cycles
A ramp cycle for piercing is defined via calibration points. A maximum of six calibration points can be programmed per ramp
cycle.
The "Ramp cycle number"parameter is programmed in the LTT,
"Piercing".
Note
The user can program the cycle numbers 81 to 99. The cycle
numbers 1 to 80 are reserved for TRUMPF applications.
1
Cycle number
3
Calibration point
2
Graphic representation of ramp
cycle
4
Cycle parameter
Ramp cycles
Fig. 67416
1. Press Technology and select "Ramp cycles".
2. Enter the "cycle number".
3. For each calibration point, enter "Laser power", "Time",
"Pulse frequency" and "Pulse power".
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4. Press Accept cycle.
5. Enter the cycle number in the LTT.
11.3 Managing the tooling status
The laser processing machine can be operated with differing
configurations. For each configuration, a tooling setup must be
created.
The machine's tooling statuses are created, managed and activated in the "Tooling status administration" sub-operation
(Laser Tooling Management).
Notes
■
■
■
Tooling setup
The following components belong to a tooling setup:
■
■
■
■
Commissioning the
components
The machine will be commissioned with at least one tooling
status by a service engineer.
Only those parts of the machine can be commissioned for
which there is an application.
The display of the components and their tooling parameters
as well as the activation of the input fields depends upon
which user group is currently set.
"Component" laser device.
"Component" beam formation/LLK.
"Component" Processing optics for laser cutting.
As well as additional components according to the machine
configuration.
Default parameters are stored for all of the machine's variable
components in the control system. The parameter blocks are collected together as a tooling setup. When creating the tooling
setup, the user can change the approved parameters.
The individual components, e.g. the processing optics, will generally be commissioned using service programs.
Note
Service programs: see chapter "setting work".
Component serial numbers
When the machine is commissioned, the parameters for all components are set under their serial number.
If components with identical serial numbers are configured for
different setup states, the parameter values will also be transmitted.
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Setup status display
Symbol
Description
Active setup state.
■
The tooling status has been activated.
■
The components have been commissioned.
Active setup state.
■
The setup state has been activated in the PLC.
■
The components have not (yet) been commissioned.
Invalid setup state:
■
The setup state does not match the machine's
state.
■
Invalid or missing parameters.
Setup state activated, waiting for response from PLC.
Without Icon
No tooling status selected.
Setup status
Tab. 4-44
Activate setup state
An activated tooling setup will remain active until a different tooling setup is activated.
If the machine's configuration is changed, for example if processing optics with a different focal length are to be used, then
before starting the laser processing, the newly selected tooling
setup must be activated.
The machine control system will not check whether the
active setup state matches the machine's actual state for all
components.
Conditions
■
■
NOTICE
The setup state has been created, the components have
been commissioned.
The setup state corresponds to the machine's configuration.
The activated setup state or the component parameters do
not correspond to the machine's configuration.
Destruction of the beam guidance components.
Ø
Check that the activated setup state matches the machine's
actual state.
1. Press Technology, select "Tooling status management".
All of the created setup states will be displayed.
2. Select tooling status.
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1
Selected tooling status
Fig. 75035
3. Press Activate.
The selected tooling status is being loaded. The setup state is
valid and active as soon as the green icon appears.
Creating a new setup state
If a new setup state is created, the components which belong to
that state must then be commissioned.
For the commissioning, the parameters for all components are
preset with the default values. When the service programs are
run, the actual parameter values will be determined and saved to
the current setup state.
The selectable components (laser, beam shape and process
adapter) are arranged in a hierarchical tree structure on the user
interface.
■
■
■
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First, the components will be collected to make up a "setup
state".
Then the components will be commissioned using service
programs.
Depending on the combination of the components, certain
sets of parameters can then be manually changed.
Technology
4‐173
Conditions
■
■
1.
2.
3.
4.
5.
At least the "Advanced" user group is active.
There are applications for the components on the machine.
Press Technology, select "Tooling status management".
Press New.
Enter a "Name" for the tooling setup.
Press Continue.
One after another, select the components and enter their
serial number or device number.
For the laser device, enter the "Laser light path number".
6. Press Continue.
or
Ø If the setup state is complete: Press Finish.
The setup state will be created. The setup state is valid as soon
as all of the necessary service programs have been run and all
of the relevant parameters have been set.
Editing the tooling level
A tooling setup can be edited, by changing the parameters enabled for the components involved.
All parameters are either preset to default values or have been
determined during commissioning.
The default value and the permissible upper and lower limits for
a parameter will be shown on the user interface.
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Conditions
■
■
The setup state has been created.
At least the "Advanced" user group is active.
Fig. 75036
1.
2.
3.
4.
5.
Press Technology, select "Tooling status management".
Select tooling status.
Press Edit.
Select component: e.g. laser device.
Check the parameters and change if necessary. In the
"Description" field, a comment may be added.
6. Press Apply.
Deleting a setup state
The setup state and with it the commissioning of the components will be irrevocably deleted in the control system.
Conditions
■
■
At least the "Advanced" user group is active.
The tooling setup has been activated.
1. Press Technology, select "Tooling status management".
2. Select tooling status.
3. Press Delete.
Query: Should the selected tooling setup be permanently
removed from the management system?
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4‐175
4. Press Delete.
The setup state will be deleted.
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12.
Maintenance
The following functions can be called in the Maintenance main
operation:
■
■
■
Manual functions: Display status.
Partial backup: Performing data backup.
Data manager: Managing files.
12.1 Manual functions
Group
Manual Function
Description
Welding gases
"Helium"
Gas valve
"Monitoring"
No effect
Manual maintenance functions (status display)
Tab. 4-45
12.2 Partial backup
Backing up data
The user data stored on the hard disks in drives "C" and "D" can
be backed up daily, weekly or monthly, either on the internal
hard disk drive of the control system or on an external network
drive.
Notes
■
■
If the data is saved to the internal hard disk drive, only the
TRUMPF Service engineer can access the data backup in
the C:\tcommc\ directory.
To back up the data in such a way that the user can access
the data backup, the data should be saved on a network
drive.
1. Press Maintenance, select "Partial backup".
2. Press "Perform partial backup when starting up the user
interface".
3. Select backup location:
Ø To back up the data to a network drive, select Network
drive in the "Backup path" selection field.
− Select folder and storage medium.
− Press Apply.
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4‐177
or
Ø To save the data to the internal hard disk, select Internal
hard disk in the "Backup path" selection field.
4. Enter the maximum number of backups (7 backups are
standard). The respectively oldest backup will be deleted
when the maximum number of backups in the backup path is
reached.
5. In the "Maximum of one backup" selection field, select either
Daily, Weekly or Monthly.
At the next start-up, the data will be saved according to the
selected interval and in the selected backup path.
12.3 File manager
In the data manager, files can be stored and edited on the hard
disk drive of the machine control and on external drives. Access
depends on the currently set authorization.
1
2
Source directory
Target directory
Data manager
4‐178
Maintenance
Fig. 68773
Button
functions
Update
Update list display
Copy file
Select copy file.
Edit file
Edit selected file.
New folder
Create new folder in target directory or in
source directory.
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Button
functions
Rename
Rename file.
Note: Only files on external drives can be
renamed.
Delete
Delete file or folder.
Note: Only empty folders can be deleted.
Buttons
Tab. 4-46
Edit and save file
Condition
■
At least "Standard" authorization is active.
1. Press Maintenance, select "Data manager".
2. If the file is to be saved to a different drive:
− Select a folder in the "Source" selection field.
− Select a folder in the "Target" selection field.
− Select file.
− If the file is to be edited before copying it: press Edit file
and edit the file.
− Press Copy File.
The file is saved to the target folder.
3. If the file is (only) to be edited:
− Select a folder in the "Source" selection field.
− Select file.
− Press Edit file.
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13.
Diagnostics
13.1 Displaying all messages
All current messages are displayed. All messages can be filtered
by the type of message (alarms, warnings, messages).
1. Press Diagnostics and select "Pending messages".
2. To display the details of a message:
− Select message and press Message details.
− Select "Cause", "Effect", "Measure" or "Error location".
3. To end the display, Press Close.
13.2 Displaying all messages
All messages are displayed. Messages can be filtered out from
these messages according to message types and the period of
the message.
1. Press Diagnostics and select "Message history".
2. To filter out certain types of message, select "Alarms", "Warnings", "Infos" or "Acknowledgeable messages".
3. To display the details of a message:
− Select message and press Message details.
− Select "Cause", "Effect", "Measure" or "Error location".
4. To update a message:
− Select message.
− Press Update message.
5. To end the display, Press Close.
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13.3 Displaying the software version
1. Press Diagnostics and select "Display version".
2. In the "Machine" field, select the machine type.
A table with all software versions will be displayed.
13.4 Display I/O monitor
The I/O monitor displays all of the machine's digital inputs and
outputs and the configured automation components.
1. Press Diagnostics and select "I/O monitor".
2. In the "Configuration" field, select Machine components.
The states of the inputs and outputs will be displayed.
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4‐181
13.5 Logging the process data for service
purposes
To diagnose the ControlLine distance control, for service purposes, a recording can be started.
1. Press Diagnostics and select "Manual functions".
2. Select Distance regulation group.
3. Press "Record".
Recording starts.
4. After the end of the recording:
− Press the MACHINE ON/OFF button.
− Press the RESET button.
The machine is ready for operation.
13.6 Starting Teleservice
Teleservice are used to establish a connection between the
machine control and TRUMPF Technical Service. The customer
service employee can use Teleservice to localize problems and,
in some cases, to eliminate them directly.
The Teleservice for the machine and laser device is started via
the user interface of the machine control system.
Condition
■
For Teleservice via Internet: UDP Port 500 and
UDP Port 4500 permitted to access Internet over LAN.
Note
The teleservice session must be previously coordinated with
Technical Service.
Establishing the connection
1. Start the Teleservice via the machine's user interface:
− Press Diagnostics, select "Remote diagnostics".
− Press Execute.
or
Ø Start Teleservice via TOS:
− Press the CHANGE APPLICATION button.
− Press Trumpf Operating System.
− Press Start, Teleservice.
2. Press Connect.
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pcANYWHERE starts and establishes the connection
between the machine control and the TRUMPF Telepresence Portal.
Teleservice is active if, under "Telediagnostics status", the
state Program not in RAM changes to Wait for call.
When all status symbols are green, the connection has been
established.
One or more status symbols are red.
Ø In the case of "Default Gateway reachable", local network
settings at TRUMPF are faulty.
Ø In the case of "mGuard configured", Telepresence-Box
(mGuard) at TRUMPF defective.
Ø In the case of "VPN Tunnel established", check the firewall configuration.
Ø In the case of "TRUMPF Telepresence Portal", the Telepresence Portal status at TRUMPF is faulty.
Ending the connection
3. Press Disconnect.
The connection is terminated.
4. To close the Telepresence portal:
− Press the CHANGE APPLICATION button.
− Press HMI.
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13.7 Visual Online Support (VOS)
Visual Online Support
The Visual Online Support (VOS) is a teleservice function. In
real time (instant messaging) image, audio and video can be
transmitted wirelessly in both directions between the customer
and TRUMPF Technical Service.
Images and audio are transmitted between the Technical Service
Telepresence Portal and the customer's tablet PC or smartphone
via the machine's local WLAN, the TRUMPF Wireless Operating Point.
After transmission, the image and audio material can be edited
and information can be added. This thus makes targeted instructions possible via image processing and audio analysis of
machines and automation components.
Note
In connection with a Basic service contract or within the warranty period, Visual Online Support is free of charge.
Costs will arise for the user if there is no maintenance contract
and if support is required outside of the warranty.
Wireless Operating Point
The Wireless Operating Point (WOP) is the machine's local
WLAN.
The tablet PC or smartphone are connected to the WOP via the
WLAN router in the machine's switch cabinet.
Note
The Wireless Operating Point has no connection to the
machine's network drives or to the customer's network.
VOS App
The Visual Online Support function uses a tablet PC or a smartphone and the VOS app supplied by TRUMPF.
The VOS app can only access the machine's local WLAN
(WOP).
The VOS app is free of charge from Google Play and
Apple App-Store.
Tab. 4-47
4‐184
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Prerequisites
Visual Online Support requires that the machine is equipped with
a TRUMPF Wireless Operating Point.
The user needs a tablet PC with a camera or a smartphone.
The following devices are supported:
■
■
An iPad Tablet with a camera or an iPhone iPhone (minimum
requirement: iOS version 7.0).
An Android Tablet PC with a camera or a smartphone (minimum requirement: Android version 4.0).
Starting Visual Online Support
To start Visual Online Support, a teleservice date & time must
first be agreed with Technical Service.
For Visual Online Support, the following steps are required:
■
■
■
■
■
First, start the TRUMPF Telepresenc Portal on the machine.
When the connection has been established, start the
VOS app on the tablet PC or smartphone.
Then set up the connection between the VOS app and the
machine's WLAN (WOP).
As soon as the connection has been established, the user
can take & edit photos or videos or can speak to or chat
with the TRUMPF Technical Service employee. Images and
sound are transmitted synchronously. Images can be edited
both by the user as well as by technical service staff.
When the teleservice session is finished, end the connection
to the Telepresence Portal.
Conditions
■
At the machine:
−
−
■
The Visual Online Support option has been installed.
The machine is equipped with a WLAN router from
TRUMPF (Wireless Operating Point).
The VOS app has been installed on a tablet PC or smartphone.
Notes
■
■
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2017-11-17
The connection between the VOS app and the machine's
local WLAN (WOP) will be disconnected no later than one
hour after the telepresence connection has been closed and
each time that the machine is restarted.
The VOS app can be disconnected from the machine's
WLAN at any time.
Diagnostics
4‐185
Starting Teleservice
1. On the machine's user interface:
− Press Diagnostics, select "Remote diagnostics".
− Press Execute.
A new QR code will be generated each time that the Telepresenc Portals is started or after the machine has been
switched on.
QR code for Visual Online Support
Fig. 78922
2. Press Connect.
If all of the symbols light up green, the connection between
the machine and the Telepresence Portal has been established.
Establish a connection
between the VOS app and
the WOP.
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Diagnostics
3. Once the Teleservice connection has been established, start
the VOS app:
Tap the TRUMPF icon in the tablet PC or smartphone.
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VOS app menu
Fig. 78923
4. Tap on Change Network.
5. If an Android tablet or Android smartphone is used: scan
the QR code on the machine.
By scanning the QR code, the connection between the
VOS app and the machine's WLAN (WOP) is started automatically.
6. If an iPad or iPhone is used: scan the QR code on the
machine.
− To copy the password to the clipboard, tap on "Copy
passwort to clipboard".
− Tap on the "Settings" icon (gearwheel).
− Select the network name (SSID) of the machine.
− To paste the password from the clipboard, tap "Password", "Insert" and "Connect".
The connection between the VOS app and the machine's
WLAN (WOP) is started.
Using online support
7. Tap on New Session on your tablet PC or smartphone.
Once the green checkmark appears next to the TRUMPF
logo, the connection to customer service has been established and data transmission is active.
8. While in contact with the customer service employee, photograph the problem, film and discuss it.
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VOS app menu "Image transmission"
Close the teleservice
connection
Fig. 78924
9. At the end, close the VOS app.
10. On the machine's user interface, close the Telepresence portal.
− Press Disconnect.
− Press the CHANGE APPLICATION button.
− Press HMI.
The teleservice connection will be closed.
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14.
Online help
Help
The documentation for the machine can be called up as Online
help.
Displaying help text:
■
The display is opened using the
button.
■
The display is reduced using the
button.
Button
Description
Search
Search for a specific term in the online help.
The pages found are displayed in a list.
Double-click to open the desired page on the list.
Index
Displaying index.
To jump to the desired page: double-click to open the
desired page.
Bookmark
Insert a bookmark on the page opened.
The bookmarks are saved in sequence.
To open a page with bookmarks: double-click to open
the desired page.
Start page
Open the start page of the online help.
Forward
Displays the next page that has already been viewed.
Back
Displays the previous page that has already been
viewed.
Functions in the online help
Programming instructions
for context-sensitive help
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Tab. 4-48
In the text editor, for all of the NC commands and cycles marked
in blue, context-sensitive help can be called up.
Help
4‐189
14.1 Starting online help
1. Press Help.
2. In the "Area" selection field, select the respective instructions.
3. Open the chapter with
and choose the section.
or
Ø Press Search.
− Enter search string.
− Press Apply.
or
Ø Press Index.
− Enter the index term.
− Press Apply.
The help text will be displayed.
14.2 Editing bookmarks
For quick access to select help subjects, the user can set and
then call "bookmarks".
Creating bookmarks
1. Start online help and open the subject or page.
2. Press Bookmark.
3. Press Add current page.
The bookmark will be created.
Calling up a bookmark
4. Press Bookmark.
5. Select bookmark.
6. Press Go to.
Jump to the selected page.
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14.3 Starting context-sensitive help
In the text editor, for all of the NC commands and cycles marked
in blue, context-sensitive help can be called up.
1.
2.
3.
4.
5.
6.
Select the NC program.
Press Edit.
Select "Text editor".
Press Open.
In the selection field, select Programming instructions.
Select NC block. Put the cursor in front of the command
marked in blue.
The help text will be displayed to the left of the editor.
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15.
WARNING
Risk of crushing and hitting during teaching!
Ø
Ø
Ø
Ø
Machining programs for 3D
laser processing
Teachen
During teaching, do not step on the rotational changer.
During teaching, do not move between barrel and body of
machine.
During teaching, do not touch area between surface of workpiece and nozzle tip.
While the program is running in test mode, keep sufficient
distance from the fixture.
Machining programs that were created using the TruTops Cell
programming software are imported into the machine's control
and are usually executable and process-sure immediately,
depending on the complexity of the workpiece and the experience of the programmer. The NC program generated with TruTops Cell must be tested on the machine and, if need be, be
corrected by teaching with TruTops Cell Basic (option).
The corrections taught in this way are not lost. A taught or corrected program can in turn be loaded into TruTops Cell and subsequently edited.
Manual 3D programming
If the user has no 3D programming software, the contour to be
machined must be programmed manually (taught).
Teaching means that the positioning information for the NC control is calculated for any contour by the step-by-step movement
and the saving of selected points (teaching points). During teaching, any geometric contours as well as standard inner contours
(circle, elongated hole, rectangle, square) can be programmed.
The contour that is drawn or scribed on the workpiece is run
over visually and the teach points are recorded. The control system uses the axis coordinates of the recorded teach points and
the interpolation mode to calculate the shape of the contour to
be machined. The control writes the positioning information in
the NC program and the operator supplements the required NC
cycles and technology parameters.
The respective processing optics that are later to be used for
machining are used for teaching. The teach points are applied in
the teach panel.
Workpiece and contour
4‐192
Teachen
The contour that is to be machined must be drawn or inscribed
on the surface of the workpiece so that it is clearly visible. It is a
good idea to use a template to do this. The accurate identification of contour transitions (e.g. the transition of an arc into a
straight line) makes it easier to establish teach points and
increases production accuracy.
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When recording a contour, it is important to observe the following:
■
■
■
■
■
■
■
■
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Always place the zero point at a distinctive position on the
workpiece or fixture which can be easily reached with the
TCP. The programs are then transferable.
Place the safety and loading positions outside of the workpiece/fixture area in order to avoid a potential collision
between the processing optics and the workpiece/fixture.
Teach and cut inner contours before outer contours.
The cutting optics may not move over an already cut-out
contour during machining. The distance regulation regulates
the Z axis in the beam direction, in which case a collision
would occur.
Clearly mark contour transitions.
Ensure a constant machining speed. In order to avoid
scorching, the speed must be kept as constant as possible
during machining. For this reason, required compensation
motions of the B and C axes should be executed over longer
sections of travel.
Align the TCP at right angles to the workpiece surface. To
obtain a clean, high-quality cut (with the exception of intentionally angled cuts), the processing optics must always be
aligned perpendicular to the workpiece surface during
machining.
To achieve a high level of machining accuracy and repeatability, the workpiece must be positioned on the fixture, on
which it will later be machined using a fixed index point. The
fixture must be installed axially parallel to the work table.
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4‐193
15.1 Teach panel
A holding magnet is on the rear of the teach panel.
1
Enable key left
4
Display
2
STOP button
5
Enable key right
3
Function key
6
6D mouse
Teach panel
Fig. 69855
The teach panel is used for teaching 3D parts. The following
functions can be executed with the teach panel:
■
■
■
4‐194
Teachen
Manually move the machine axes in the teaching operating
mode or in jog mode.
Record teach points.
Execute all the functions that are relevant for teaching.
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Operating elements
■
■
■
■
■
Display
STOP button: All axis movements are safely stopped by
pressing this button. After the axes are in the idle state, the
drives are de-energized. A machine stop is triggered.
Function key: By pressing a key, a function is requested or
a status is issued.
Display: Visualization of a pending or executed action.
Enable key on the left and the right of the housing: The
axes can only be moved if at least one of the enable keys is
kept pressed.
6D mouse: The axes are moved with the 6D mouse.
In the display, pending actions as well as prompts in the form of
symbols are shown in real time. If an action has ended, the current status will be shown two seconds per action.
The display always show the active interpolation type.
Function key
Each function key is assigned one function. If the control issues
the enable, the function requested by the operator will be carried
out immediately.
The buttons with the blue LEDs show a status. The status can
be changed with the button or on the user interface in the >Programming > Teaching menu.
Function
Button
F1
The user can assign his own selected function to this
button (see "Configure the function for F1 and F2 buttons", pg. 4‐208).
Note: Special functions can be assigned to the button
for specific projects.
F2
H WORD
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2017-11-17
Insert H word. The distance regulation moves the nozzle tip on the workpiece surface and measures the
nozzle distance when doing so. The measured nozzle
distance is added as H word in the current NC block.
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4‐195
Button
Function
ZERO POINT
Display screen
Sets the zero point. The current axis coordinates are
set in the program with SET_G54 as zero point. There
are two ways of doing this. Which variant is used is
selected beforehand at the user interface in the
>Teaching > Settings menu.
■
Either: the first SET_G54 NC block is to be overwritten in an available program.
■
Or: a current position in the program is to be set
with SET_G54 workpiece zero point.
Notes:
MODE
■
Before the overwriting of the workpiece zero point,
the kinematic transformation is automatically activated should it not already be active.
■
The taught zero point is immediately effective.
Select "Replace block" or "Add block".
-
LED on: the current NC block is replaced.
LED off: a new NC block is added after the current NC
block.
BLOCK
SEQUENCE
Select block sequence: single block of block-by-block.
-
LED on: single block is active. Only one NC block is
processed at a time. To continue the program, the
START button must be pressed again after each NC
block.
LED off: block-by-block is active. All the NC blocks of a
program will be processed one after the other.
DISTANCE
CONTROL SYSTEM
Distance regulation: switch on or off.
-
LED on: distance regulation is active.
LED off: distance regulation is not active.
KSS
LED flashes: the control waits for the confirmation by
the operator.
The fixture's clamping elements which are controlled by
the KSS only open or close after the operator presses
the button.
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Button
Function
STOP
Display screen
Pause RESET or program.
The active program is resumed by pressing the START
button at the interruption place or at the start of the
program.
■
If the STOP button is pressed once, the program
will be resumed at the interruption place.
■
If the STOP button is pressed twice, the program
will be resumed from the start of the program.
PLAY / START
Start the program or continue after an interruption.
TEACH IN
Add teach point with the current axis coordinates.
Note:
The interpolation type must be selected.
FLAG
Set Flag. An NC block is written with the comment ;TODO in the program at the current position.
If the button is pressed several times in succession in
the same NC block, the comment ;TODO is incremented, e.g.: press twice ;TODO1, press three
times ;TODO2 and so on.
Note:
For postprocessing of the program, the comment ;TODO can be replaced by "Search" and
"Replace" by another NC text, for example, by
TC_LASRER_ON.
AXIS GROUP
Select the axis group for the 6D mouse. Depending on
the setting selected here, single axes or several axes
will proceed with the 6D mouse.
The axis group Single, 3D or TOOL is previously
selected at the user interface.
-
Note:
The mode of operation of the 6D mouse depends on
the selected axis group: Operate 6D mouse.
Axis group 3D: Several axes are to be moved; for
example, select axis group XYZ.
Axis group Single: Only one axis is to be moved; for
example, select axis group X.
Axis group TOOL: The axes are to be moved in beam
direction or in the opposite direction.
The axes that have been moved are shown in color in
the display.
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4‐197
Button
INTERPOLATION
Function
Display screen
Select interpolation type.
-
G01: Insert a straight line (default setting).
CIP: Insert arc. One after the other, starting point, intermediate point, and end point are taught.
"Macro center". The R parameters R1 to R5 are
inserted into the current NC block.
"Macro help point". The R parameters R6 to R8 are
inserted into the current NC block.
Function keys
Tab. 4-49
Selecting the axis group
The axis group defines the mode in which the axes are to be
moved with the teach panel. An axis group can be one or more
axes.
The control differentiates between the following axis groups
whose mode is preset on the user interface:
■
■
■
4‐198
Teachen
Axis group Single: Only the axis moves that receives the
strongest deflection signal for the 6D mouse.
Axis group 3D: The selected axes move synchronically.
Axis group TOOL: Move the linear axes in beam direction or
in the opposite direction. The orientation of the B and C axes
remain unchanged during this.
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Operate 6D mouse
The 6D mouse uses an optical sensor to control the NC axes.
Individual axes or axis groups are moved by deflection of the
sensor.
The speed at which the axes move depends on whether one or
both enable keys are pressed.
■
■
If one enable key is pressed, the axes move slowly.
If both enable keys are pressed, the axes move faster.
The 6D mouse is manually pushed, pulled or turned in the direction in which the axis is to be moved.
In direction
Axis group
Axis group Single
Deflection
X+
Push the 6D mouse to the left.
X-
Push the 6D mouse to the right.
Note
Y+
Pull the 6D mouse forwards.
If the kinematic transformation is
active, the other axes make compensating movements around the
tool center point.
Y-
Push the 6D mouse backwards.
Z+
Pull the 6D mouse up.
Z-
Push the 6D mouse down.
B+
Tilt the 6D mouse to the left.
B-
Tilt the 6D mouse to the right.
C+
Turn the 6D mouse counterclockwise.
C-
Turn the 6D mouse clockwise.
in PLUS
Diagonally pull the 6D mouse forwards.
in MINUS
Diagonally push the 6D mouse backwards.
in direction of
the beam
Pull the 6D mouse up.
opposite to the
direction of the
beam
Push the 6D mouse down.
Axis group 3D
Axis group TOOL
Operating the axes with the 6D mouse
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Tab. 4-50
Teachen
4‐199
Fig. 69856
Note
If the 6D mouse is pushed diagonally, the axes move synchronously if "3D" is selected as the axis group.
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15.2 Description of the user interface
This dialog opens if Teachen operating mode is selected:
1
Active "axis group"
6
Active "interpolation"
10 Program status
2
"Single block" on/off
7
"Display" selection field
11 Context buttons
3
"Transformation" on/off
8
Axes actual position
12 "Geometry deviation display"
4
"Replace block" on/off
9
Active axes
13 NC editor
5
"ControlLine" on/off
Teaching user interface
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4‐201
Program status symbols
Symbol
Description
Marks an interruption place or a re-entry place:
■
Interruption place: the program stops at the marked NC
block.
■
Re-entry place: the program can be continued at the
marked NC block with START.
By tapping on any NC block, the position for the re-entry
in the program can be selected.
Note:
The NC blocks before the marked NC block are run
through in simulation when a program is started. Starting
from the marked NC block, all following NC blocks are
actually executed.
Marks the current NC block.
Program status symbols
Context button
Tab. 4-51
Depending on the context, the following buttons will be shown:
Button
Description
Stop
Stop the program.
Play / Start
Starts the program or continues the program after an interruption.
Note
The program does not need to be saved beforehand.
Inserting points
Inserts the teach point.
Action
Another button bar is opened in which the other buttons can be supplemented for
project-specific actions or user-defined MACROS.
Cycles
"Cycles editor" is opened. The following actions can be performed:
Settings
■
Selection of NC cycles, parameter input and transfer into the program.
■
Selection of laser technology table (LTT).
The "Settings" dialog box is opened. The following settings can be configured:
Save
■
Select editor functions.
■
Activate and rename axes. Define the number of digits after the decimal point.
■
Define the thresholds for the error indicator of the distance regulation ControlLine.
The current program is saved in "internal management".
Notice!
If "No" is pressed for saving, all changes made since the last saving will be lost.
ControlLine calibration
Record characteristic curve for distance control.
Setting the zero point
Set the zero point: the current actual coordinates are set with SET_G54 as zero
point in the program.
■
Either: overwrite the first SET_G54 block.
■
Or: set the zero point at the current position in the NC program.
H word
Insert the H word: the nozzle distance measured with the distance regulation is written as H word in the current NC block.
Automatic orientation
Align the TCP perpendicular to the workpiece surface (AUTO_ORI).
Technology
The "Technology selection" dialog box is opened. Select the laser technology table
and save in the current cycle or as variable in the program.
Context button
4‐202
Tab. 4-52
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Teach functions buttons
The function of the following buttons is identical with the functions of the corresponding button on the Teachpanel.
Button
Display
functions
"Axis group"
Single
3D
TOOL
Select the axis group.
"Single block"
Single block active.
Block-by-block active.
"Transformation"
Kinematic transformation activated
(WKS)
Kinematic transformation deactivated (MKS)
"Replace block"
Replace the marked NC block.
Insert new NC block.
ControlLine
Distance regulation switched on.
Distance regulation switched off.
Buttons for teach functions
Tab. 4-53
15.3 Activating TEACHIN operating mode
The axes can be moved with open protective devices using the
teach panel in jog mode in the TEACHIN operating mode.
The following functions are activated automatically in teach
mode:
■
■
■
■
The laser automatically switches to LASERTEST: The shutter
switch of the installed light path (LLK) is disabled.
The axes can only be moved with the teach panel if at least
one of the enable keys is pressed.
The axes move at a safely reduced speed.
Automatic movements of a device controlled via the KSS are
only executed after the KSS key on the teach panel has
been pressed Function key or the corresponding warning
message has been acknowledged on the user interface.
Conditions
■
■
At least "Standard" user group.
TEACHIN key is present.
1. Set the TEACHIN key-operated switch at the control panel to
"ON".
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4‐203
2. Press Programming; select "Teaching".
3. Press the enable key on the teach panel.
Only after the enable key has been pressed once is the
TEACHIN operating mode activated.
15.4 Starting online help
The machine's programming manual can be displayed as online
help.
Ø Select Programming manual in the "Display" selection field.
The complete programming manual is shown.
Tip
Besides this activation of the online help, there is a further context-sensitive access for the processing of NC cycles in the
"Cycles editor" (see "Insert and process cycles", pg. 4‐225).
15.5 Setting basic functions
The settings described below are valid for teach mode and are
selected on the user interface. They are active in all programs.
Automatically replacing the zero point
When setting the zero point, the first SET_G54 NC block should
be overwritten in the current axis coordinates in the NC program.
If the following conditions are present, then this setting should
not be selected:
■
■
For processing in two-station operation.
If there are several zero points in the program.
Note
If the automatic zero point search has not been activated, then
the zero point is inserted at the current place in the program
with the SET_G54 cycle.
1. Press Settings.
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2. At the "Editor" tab: activate "Automatic zero point search during replacement".
3. Press OK.
The selected setting is effective immediately.
Activate the imperial (inch) measuring
system
Axis coordinates can be recorded and displayed during teaching
as inch values.
Notes
■
■
The control (always) calculates internally in the control system measuring system.
The processing of the NC blocks depends on which measuring system has been programmed: G70 (inch programming)
or G71 (metric programming).
1. Press Settings.
2. At the "Editor" tab: activate "Record and display axis coordinates in the imperial (inch) measuring system".
3. Press OK.
The taught coordinates are recorded and displayed as inch values.
Activate and set the NC axes
At the "Axes" tab, the axes are activated whose coordinates are
to be recorded during teaching. The user can select the following
settings for the coordinate output in this menu:
■
■
■
■
Activate or deactivate the axes. For deactivated axes, no
axis coordinates are recorded and output in the program.
Issue project-based names. The entered name is output in
the program. The axis name that deviates from the standard
is marked in orange in the axis actual display.
Define interpolation parameters for individual axes.
Select the number of digits after decimal point for the coordinates output.
Note
An R parameter must be selected for the X, Y and Z axes.
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1
Active axes
3
R parameter "Main axes"
2
"Adapt axis names"
4
Number of "Digits after decimal
point"
Activating and managing NC axes
Fig. 71168
1. Press Settings.
2. Select the "Axis" tab:
− Activate or deactivate the axes.
− If need be, enter the axis names.
− Select the settings for "Main axes" and "Number of digits
after decimal point".
3. Press OK.
The selected setting is effective immediately.
Setting threshold values for determination
of the geometry deviation
A possible geometry deviation of the loaded workpiece compared
to the programmed contour can be recorded with the distance
regulation. While the contour is being moved along, the distance
regulation keeps the nozzle distance consistent and visualizes
the axis correction in beam direction.
At the "Threshold values" tab, the permitted threshold values can
be entered for the checking of geography deviation:
■
■
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The "Warning level geometry deviation" parameter defines at
which nozzle distance the lower tolerance limit has been
reached.
The "Error level geometry deviation" parameter defines at
which nozzle distance the permissible tolerance limit has
been reached.
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If the value 0 has been entered for both parameters, the signal
display is deactivated.
The geometry deviation should be checked in the following
cases:
To run in a new workpiece
For a batch change
For frequent nozzle collision
■
■
■
The measurement results are shown on the user interface by
signal colors as well as measured values.
1
Geometry deviation visualization 2
Measured deviation in beam
direction
Geometry deviation display
Fig. 71170
Signal color
Description
Green
The measured geometry deviation is within the permissible tolerance.
Yellow
The measured geometry deviation has reached the
threshold value (warning level).
Red
The measured geometry deviation is outside the permissible tolerance. Check what the cause for this is.
Geometry deviation signal colors
Tab. 4-54
The geometry deviation is also visualized in the display of the
teach panel. If the threshold value is exceeded, a vibrator that is
integrated in the teach panel will be activated for a few seconds.
Display screen
Description
Geometry deviation function is not active.
The measured geometry deviation is within the permissible tolerance.
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Display screen
Description
The measured geometry deviation has reached the
threshold value (warning level). The workpiece surface
is lower in the beam direction than the programmed
contour.
The measured geometry deviation has reached the
threshold value (warning level). The workpiece surface
is higher in the beam direction than the programmed
contour.
The measured geometry deviation is outside the permissible tolerance. The workpiece surface is lower in
the beam direction than the programmed contour.
The measured geometry deviation is outside the permissible tolerance. The workpiece surface is higher in
the beam direction than the programmed contour.
Teach panel display screen
Tab. 4-55
1. Press Settings.
2. Select "Threshold values".
3. Enter threshold values for the "Warning level" and "Error
level" parameters.
4. Press OK.
The selected setting is effective immediately.
Configure the function for F1 and F2
buttons
Users can configure the functions for the F1 and F2 keys themselves. No functions are assigned to these keys in the factory.
The following functions can be selected by the user:
■
■
■
■
NC cycles: The user can assign the F1 key with a selection
of NC cycles (see "Configure the cycle selection for the F1
key", pg. 4‐209).
Automatic orientation: align perpendicular to the workpiece
surface (AUTO_ORI).
ControlLine calibration: Record characteristic curve for distance regulation.
Transformation: Switching the Kinematic transformation on or
off.
The selected functions are visualized and immediately performed
by pressing the buttons in the teach panel display. The key
assignment is self-holding until a new selection has been made.
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Each key can only be assigned one function. Different functions,
except for the NC cycles, can be selected for keys F1 and F2,
for example: Transformation for the F1 key and ControlLine calibration for the F2 key.
Pre-assignment
Fig. 75651
1. Press Settings.
2. Select "F key" tab.
3. Either
Ø Open the "F1 key" selection list and select function.
or
Ø Open the "F2 key" selection list and select function.
4. Press OK.
The key assignment is immediately effective.
Configure the cycle selection for the F1 key
The user can select the enabled cycles in the cycle editor in
order to assign this function to the function key F1.
After selection of the cycle with the F1 key, the F2 key is used
to insert the cycle at the current position in the NC program.
Note
Before every NC cycle, only one parameter configuration can be
saved. If cycle parameters have to be changed, then the most
recently saved parameters are overwritten.
Adding cycle from the
selection list for the F1
button
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1. Press the Cycles button.
The cycles editor is opened.
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2. Select the cycle and press Add to F1.
3. Press Cancel.
Assigning cycle to button F1
4.
5.
6.
7.
Press Settings.
Select "F key" tab.
In the "F1 key" selection list, select NC cycles.
Select the desired NC cycle to be assigned to the button. If
necessary, edit the transfer parameters.
8. Press OK.
The selected cycle can be selected with the F1 button immediately and inserted in the program with the F2 button.
Delete the configuration for the F1 key
The configured NC cycles can be deleted again in the cycle
selection for the F1 key.
Fig. 75652
1.
2.
3.
4.
5.
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Press Settings.
Select "F key" tab.
Open the "F1 key" selection list and select NC cycles.
Mark the cycle that is to be deleted.
Press Remove cycle.
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15.6 Recording teach points
Note
The interpolation type can be selected on both the teach panel
as well as on the user interface.
Teach points
When teaching a path, individual path points are approached
with the machine axes. The paths between two path points are
interpolated by calculation. Here, different types of interpolation
can be selected.
The control calculates the contour path by recording individual
teach points (axis coordinates) in combination with the selected
interpolation type.
The start point for all interpolation types is the respectively current axis position.
The individual teach points must be recorded in a specified order
according to the contour and interpolation mode (movement
type). The following interpolation types are possible:
■
■
■
■
Straight line end point (G01).
Help point and end point of an arc (CIP)
Macro center as measuring point or as center of a standard
inner contour.
Macro help point as measurement point or as help point for
a standard inner contour.
Note
Usually, teaching is done with the active kinematic transformation (synonymous with 5-axis transformation). The kinematic transformation must be activated manually.
Teaching a straight line
A straight line is defined – starting at the start position – by a
point set in the direction of travel (straight line end point).
The current position of the axes marks the beginning of the
straight line. The end point of the straight line is taught as a
point and written into the program with the G01 motion block.
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Condition
■
Kinematic transformation is active.
Note
The interpolation type G01 is the default status. G01 are active
until another interpolation type is selected.
1. Move the TCP from the start point to the end point of the
straight line.
2. If G01 is not active: select G01 interpolation type.
3. Press TEACH IN button.
An NC block is inserted at the current position in the program
with the G01 command: G01 X = ... Y = ... Z = ... B = C = ...
Teaching the arc with CIP
An arc is defined by the start position, any help point and the
end point. The help point must be on the arc.
The arc is calculated with the CIP circular interpolation.
Condition
■
Kinematic transformation is active.
1. Approach help point on the arc.
2. Select the CIP help point interpolation type.
3. Press TEACH IN button.
An NC block is inserted with the CIP command and the interpolation parameters I1, J1 and K1:
CIP I1 = .. J1 = .. K1 = ..
4. Approach the arc end point.
5. Press TEACH IN button.
The current NC block with CIP is supplemented with the axis
coordinates of the end point:
CIP I1 = .. J1 = .. K1 = .. X = .. Y = .. Z = .. B = .. C = ..
Tip
The help or end point can be individually corrected by reteaching. (see "Correct path", pg. 4‐229)
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Teaching the macro center
The "macro center" interpolation type is used to teach a contour
center, for example, a circle or a rectangle center or a
measuring point.
Condition
Kinematic transformation is active.
■
R parameter
Coordinate
R1
X axis
R2
Y axis
R3
Z axis
R4
B axis
R5
C axis
Center coordinates
Tab. 4-56
1. Approach point.
2. Select the "Macro center" interpolation type.
3. Press TEACH IN button.
An NC block is inserted in the current position in the program
with the center coordinates R1 = .. R2 = .. R3 = .. R4 = .. R5
= ...
Tip
The center can be corrected by reteaching. (see "Correct path",
pg. 4‐229)
Teaching macro help point
The "Macro help point" interpolation type is used to insert a help
point which, for example, can be used for the following function:
For the calculation of the position and direction of standard
inner contours: square, oblong hole and rectangle.
For calculation of measurement functions.
■
■
Condition
Kinematic transformation is active.
■
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R parameter
Coordinate
R6
X axis
R7
Y axis
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R parameter
Coordinate
R8
Z axis
Help point coordinates
Tab. 4-57
1. Approach help point.
2. Select "Macro help point" interpolation type.
3. Press TEACH IN button.
An NC block is inserted at the current position in the program
with the help point coordinates R6 = .. R7 = .. R8 = ...
Tip
The help point can be corrected by reteaching. (see "Correct
path", pg. 4‐229)
Teaching circular contour
These circles are programmed using the TC_CIRC2 NC cycle.
The cycle switches the laser beam on and off.
A circle is defined by the coordinates of the center point as well
as the corresponding transfer parameters.
Condition
■
Kinematic transformation is active.
Note
Parameter definition; see online help.
Teaching the center
1. Approach the center of the contour.
2. Select the "Macro center" interpolation type.
3. Press TEACH IN button.
An NC block is inserted in the current position in the
program with the center coordinates R1 = .. R2 = .. R3 = ..
R4 = .. R5 = ...(see "Teaching the macro center", pg. 4‐213)
Inserting and editing the
TC_CIRC2 cycle
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4. Press Cycles.
5. In the cycle editor, select cycle TC_CIRC2 at path 'Laserschneiden'.
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Parameter input TC_CIRC2
Fig. 71602
6. Enter transfer parameter (mandatory parameter) and correction parameters (optional parameters).
7. Press OK.
Two NC blocks are inserted in the program at the current position with the command TC_CIRC2:
R11 = 0.000 R21 = 0.000 R22 = 0.000 R23 = 0.000 R24 = 0.000 R26 =
0.000 R27 = 0.000 R28 = 0.000
TC_CIRC2 (20.000, 2.000, 0.500, 1, 10, 100, TM_LTTNAME)
Tab. 4-58
Tip
The center coordinates can be corrected by reteaching. (see
"Correct path", pg. 4‐229)
Teaching a rectangle contour (square)
Rectangles or squares are programmed using the NC cycle
TC_RECT2. The cycle switches the laser beam on and off.
A rectangle or square is defined by the coordinates of the center
point, the help point and the corresponding transfer parameters.
Condition
■
Kinematic transformation is active.
Note
Parameter definition; see online help.
Teaching the center
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1. Approach the center of the contour.
2. Select the "Macro center" interpolation type.
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3. Press TEACH IN button.
An NC block is inserted in the current position in the
program with the center coordinates R1 = .. R2 = .. R3 = ..
R4 = .. R5 = ...(see "Teaching the macro center", pg. 4‐213)
Teaching help point
4. Approach contour's help point.
5. Select "Macro help point" interpolation type.
6. Press TEACH IN button.
An NC block is inserted at the current position in the program with the help point coordinates R6 = .. R7 = .. R8 = ...
(see "Teaching macro help point", pg. 4‐213)
Inserting and editing the
TC_RECT2 cycle
7. Press Cycles.
8. In the cycle editor, select cycle TC_RECT2 at path 'Laserschneiden'.
Fig. 71603
Parameter input TC_RECT2
9. Enter transfer parameter (mandatory parameter) and correction parameters (optional parameters).
10. Press OK.
Two NC blocks are inserted in the program at the current position with the command TC_RECT2:
R11 = 0.000 R21 = 0.000 R22 = 0.000 R23 = 0.000 R24 = 0.000 R26 =
0.000 R27 = 0.000 R28 = 0.000
TC_RECT2 (1.000, 2.000, 2.000, 0.500, 0.500, 1, 10, 100,
TM_LTTNAME)
Tab. 4-59
Tip
The center and help point coordinates can be corrected individually by reteaching. (see "Correct path", pg. 4‐229)
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Teaching oblong hole
An oblong hole is programmed using the TC_OBLONG2 NC
cycle. The cycle switches the laser beam on and off.
The oblong hole is defined by the coordinates of the center
point, the help point and the corresponding transfer parameters.
Condition
■
Kinematic transformation is active.
Note
Parameter definition; see online help.
Teaching the center
1. Approach the center of the contour.
2. Select the "Macro center" interpolation type.
3. Press TEACH IN button.
An NC block is inserted in the current position in the
program with the center coordinates R1 = .. R2 = .. R3 = ..
R4 = .. R5 = ...(see "Teaching the macro center", pg. 4‐213)
Teaching help point
4. Approach contour's help point.
5. Select "Macro help point" interpolation type.
6. Press TEACH IN button.
An NC block is inserted at the current position in the program with the help point coordinates R6 = .. R7 = .. R8 = ...
(see "Teaching macro help point", pg. 4‐213)
Inserting and editing the
TC_OBLONG2 cycle
7. Press Cycles.
8. In the cycle editor, select cycle TC_OBLONG2 at path 'Laserschneiden'.
Fig. 71604
Parameter input TC_OBLONG2
9. Enter transfer parameter (mandatory parameter) and correction parameters (optional parameters).
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10. Press OK.
Two NC blocks are inserted in the program at the current position with the command TC_OBLONG2:
R11 = 0.000 R21 = 0.000 R22 = 0.000 R23 = 0.000 R24 = 0.000 R26 =
0.000 R27 = 0.000 R28 = 0.000
TC_OBLONG2 (1.000, 2.000, 2.000, 0.500, 0.500, 1, 10, 100,
TM_LTTNAME)
Tab. 4-60
Tip
The center and help point coordinates can be corrected individually by reteaching. (see "Correct path", pg. 4‐229)
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15.7 Creating new program
Generally, a processing program for a 3D contour is created with
a programming system, for example, with TruTops Cell.
If no 3D programming system is available, the contour can be
manually programmed by teaching.
Creating a new program
1.
2.
3.
4.
5.
Press Program and select "Manage programs".
For the "Storage location", select Internal management.
Press New.
Enter the program name.
Press OK.
A new program is created with the following Header:
N100
;$ProgramName$
N110
;------ TruLaser Cell 8030
;insert variable
N120
TC_RESET
Revert
N130
G71
Metric programming
N140
TC_USERDYN(4.0,4.0); OVL,
ACC
Set the calculation factor;
make a selection
Note:
TC_USERDYN is only evaluated if
TC_DYNAMIC_LEVEL(1) is
programmed.
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N150
TC_DYNAMIC_LEVEL(0)
N160
TC_OST(5.0)
N170
TC_ADC_ON(10)
Activate ADC axis
N180
TRAORI(1)
Switch on transformation
N190
TC_LASER_REQUEST(1)
Request laser in the network
N200
SET_G54( 0.00, 0.00, 0.00,
0,0,0 )
Setting the zero point
N210
; TM_LTTNAME = "????"
Define table name
N220
F = 173000
Feed Rate
N230
;GOTOF ENTRY_LASER
N240
TRAFOOF
Switch off transformation
N250
G500
Activate machine zero point
N260
G01 Z = 600.00 F = 173000
Define safety position
N270
G01 B = 0.00 C = 0.00
Align the B and C axes
N280
TRAORI(1)
Switch on transformation
N290
G54
Setting the zero point
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N300
; END_OF_HEADER
N310
N320
M00
Program stop
;insert contour machining
N330
N340
; END_OF_PROGRAM
N350
TC_LASER_OFF(2)
Switching off the laser
N360
TC_RESET
Revert
N370
M30
End of main program
Standard program
Tab. 4-61
6. Afterwards: Activate teach mode, teach the zero point and
then teach the contour.
Setting the zero point
A zero point is set for the current axis position. The current axis
coordinates are written in the program with the SET_G54 cycle.
The zero point offset is immediately effective.
Condition
■
Kinematic transformation is active.
Notes
■
■
The zero point is always taught with active transformation.
If the zero point that is available in the program is to be
used, then the "Automatic zero point search during replacement" must be activated in the >Settings > Editor menu.
1. Move the TCP to zero point position
2. Switch on the distance regulation system.
3. On the teach panel Press the ZERO POINT button.
Zero point is set with SET_G54. The zero point offset is immediately active.
Approach edge incrementally.
A possible variant is described below how a workpiece edge
(inner or outer) can be incrementally approached with the laser
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beam switched on. To approach the workpiece edge, two teach
points are set and the macro EDGE_APPROACH is inserted:
■
■
The Macro center defines the position on the workpiece surface where the distance regulation is switched on and the
contour machining started.
The Macro help point defines the laser ignition position
beyond the workpiece surface. The laser is switched on by
laser method 12 (cutting without distance regulation).
During the machining, the workpiece edge is approached as follows:
■
■
■
■
■
■
First, approach the taught macro center above the workpiece.
Then, the TC_SHEET_THICK cycle is applied to approach
the tool center point with distance regulation in the beam
direction. The Z axis moves to the nozzle distance (synonym:
cutting distance) programmed in the LTT.
Then the axes move from the center macro to the taught
macro help point outside the workpiece surface (in the beam
direction, offset to the macro center).
Outside the workpiece surface, the laser is switched on, the
distance regulation remains switched off.
The macro center is approached with the laser beam
switched on (but without distance regulation).
Once the macro center is reached, the distance regulation is
switched on. The contour machining starts.
Condition
■
Teaching the macro center
Kinematic transformation is active.
1. Switch off the distance regulation.
2. Approach the position on the workpiece surface at which the
distance regulation is to be switched on during the machining.
3. Select the "Macro center" interpolation type.
4. Press TEACH IN button.
An NC block is inserted in the current position in the
program with the center coordinates R1 = .. R2 = .. R3 = ..
R4 = .. R5 = ...
Teach macro help point
5. Approach the laser ignition position outside the workpiece
surface.
6. Select "Macro help point" interpolation type.
7. Press TEACH IN button.
An NC block is inserted at the current position in the program with the help point coordinates R6 = .. R7 = .. R8 = ...
Insert the macro "Approach
edge incrementally"
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8. Press Cycles.
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9. Select EDGE_APPROACH macro at the path 'Laserschneiden' in the cycle editor.
The following NC blocks are inserted at the current position:
TC_SHEET_THICK (TM_LTTNAME)
G01 X=IC(R6-R1) Y=IC(R7-R2) Z=IC(R8-R3)
TC_LASER_ON (12,TM_LTTNAME,0,100)
G01 X=IC(R1-R6) Y=IC(R2-R7) Z=IC(R3-R8)
TC_LASER_ON (11,TM_LTTNAME,0,100)
Tab. 4-62
Result of the programming:
...
...
...
;approach edge incrementally
N ..
R1 = ... R2 = ... R3 = ... R4
= ... R5 = ...
Center coordinates
N ..
R6 = ... R7 = ... R8 = ..
Help point coordinates
N ..
G01 X=R1 Y=R2 Z=R3 B=R4
C=R5
Approach center coordinates
N ..
TC_SHEET_THICK
(TM_LTTNAME)
The distance regulation is
switched on. The TCP moves
to the cutting distance programmed in the LTT. As soon
as the cutting distance has
been reached, the distance
regulation is switched off.
N ..
G01 X=IC(R6-R1) Y=IC(R7-R2)
Z=IC(R8-R3)
Approach the laser ignition
position outside the workpiece
at sheet height (corresponds to
the help point)
N ..
TC_LASER_ON
(12,TM_LTTNAME,0,100)
Switch on laser (without distance regulation)
N ..
G01 X=IC(R1-R6) Y=IC(R2-R7)
Z=IC(R3-R8)
Approach center coordinates
without distance regulation at
sheet height
N ..
TC_LASER_ON
(11,TM_LTTNAME,0,100)
Switching on the distance regulation
Tab. 4-63
Tip
The R parameter values for help and center can be corrected, if
need be. (see "Correct path", pg. 4‐229)
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Incorporating the contour
If there is still no programmed tool path or an NC program, the
contour must be completely re-taught. To do this, it is necessary
to precisely draw the contour on the workpiece.
Conditions
■
■
Zero point is set.
Kinematic transformation is active.
Notes
■
■
■
Recommendation: to prevent a collision of the processing
optics with the workpiece or with the fixture, a suitable safety
position should be taught before the first contour is
approached.
For the teaching of a new contour: deactivate "Replace NC
block" mode.
The procedure described below is meant as an example.
The contour is recorded in the order of the subsequent processing sequence: first the inner contours are taught, then the outer
contour.
A
Workpiece zero point
7
End point of straight line
1
Safety position
8
End point of straight line
2
Circle center
9
Arc help point
3
Rectangle center
10 Arc end point
4
Rectangle help point
11 End point of straight line
5
Outer contour starting point
12 End point of straight line
6
End point of straight line
13 Contour machining end point
Example of recording contour
Teaching safety position
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Fig. 71599
1. Approach suitable safety position.
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2. Record a teach point with the G01 interpolation type.
Teaching circular contour
3. Approach the center of the circular contour.
4. Select the Makro Mittelpunkt interpolation type and record a
teach point.
5. Either now or later: insert the TC_CIRC2 cycle and process
the parameter.
Teaching the rectangle
contour
6. Approach the center of the rectangle contour.
7. Select the Makro Mittelpunkt interpolation type and record a
teach point.
8. Approach the help point of the rectangle contour.
9. Select the Makro Hilfspunkt interpolation type and record a
teach point.
10. Either now or later: insert the TC_RECT2 cycle and process
the parameter.
Teaching the outer contour
11. Approach outer contour and record the teach points for the
switching on of the distance regulation and the laser beam.
12. Approach the first end point of the straight line (pos. 6) and
record a teach point with the G01 interpolation type.
13. Approach the second end point of the straight line (pos. 7)
and record a teach point with the G01 interpolation type.
14. Approach the third end point of the straight line (pos. 8) and
record a teach point with the G01 interpolation type.
15. Approach the help point on the arc (pos. 9) and record a
teach point with the "CIP help point" interpolation type.
16. Approach the end point on the arc (pos. 10) and record a
teach point with the "CIP end point" interpolation type.
17. Approach the end point of the straight line after the arc
(pos. 11) and record a teach point with the G01 interpolation
type.
18. Approach the next end point of the straight line (pos. 12) and
record a teach point with the G01 interpolation type.
19. Approach the outside end point of the straight line (pos. 13)
and record a teach point with the G01 interpolation type.
The contour is completely recorded. The operator inserts the
required NC cycles. Thereafter, the program must be tested and,
if necessary, corrected.
15.8 Editing a program
The NC text can be expanded or edited as desired in an existing
or newly created program in the NC editor.
■
■
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Manually edit NC texts.
Insert and process NC cycles.
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■
■
Select and replace laser technology tables.
Supplement block numbering.
Searching and replacing NC text
During teaching, a comment (;TODO ;TODO1 etc.) can be
inserted, for example, by pressing the FLAG button.
Regardless of this, any NC text can be replaced by search and
replace.
1. Select Search and replace in the "Display" selection field.
2. Enter the NC texts in the "Search for" and "Replace with"
input fields.
For example, the comment ;TODO is to be replaced by an
M00 program stop.
3. Optionally, the "Search direction upwards" can be activated.
4. Either
Ø Press Replace.
or
Ø Press Replace all.
NC text is replaced.
Insert and process cycles
The cycle editor is split up into function groups, such as 'Programmablauf', 'Laserschneiden', 'Positionieren' etc. At the respective path, the NC cycles are summarized that belong functionally
to this group.
The associated cycle description is automatically shown as
online help for a marked cycle.
Notes
■
■
■
If the marked NC block is to be replaced: activate the
"Replace block" function.
If a new NC block is to be inserted: deactivate the "Replace
block" function.
Regardless of the NC cycle, any NC text can be edited,
replaced or deleted.
1. Either
Ø Mark the NC block that is to be modified.
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or
Ø Mark the NC block after a new NC block has been
inserted.
2. Press Cycles.
3. Select function group and mark the cycle; e.g.: select 'Laserschneiden' and TC_LASER_ON.
NC cycle parameter input TC_LASER_ON
Fig. 71593
4. Process cycle parameters.
5. Press OK.
The cycle is inserted as its own NC block:
TC_LASER_ON(1, TM_LTTNAME, 10, 100).
Select value for the name variable laser
technology table.
The TM_LTTNAME variable is generally assigned a "table name"
value at the program start. The table is effective in all cycles in
which this variable is programmed.
During the course of the program, the variable can be assigned
a new value again and again.
1. Either
Ø Paste TM_LTTNAME = "????" NC block.
or
2.
3.
4.
5.
6.
7.
8.
Ø Mark TM_LTTNAME = "????" NC block.
Press Cycles.
In the cycle editor, select the TM_LTTNAME variable at the
'Laserschneiden' path.
Press Technology.
Select the "LTT" tab.
Activate "TM_LTTNAME".
Select table and press Apply.
Press OK.
Either a new NC block with the variable table name is inserted,
e.g.: TM_LTTNAME = "123456".
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Or the TM_LTTNAME = "????" NC block is supplemented with
the table name.
Selecting the laser technology table
Alternatively to programming a variable for the table name, the
name of the laser technology table can be programmed directly
in the NC cycle.
1. Mark the NC block in which the table name is to be supplements or changed.
2. Press Cycles.
3. Press Technology.
4. Select the "LTT" tab.
5. Activate "Specific".
6. If need be, a filter can be set.
7. Select table and press Apply.
8. Press OK.
The table name is supplemented in the cycle.
Inserting block numbering
If the processing of the program has been completed, a continuous block numbering can be inserted for all NC blocks.
1. Select Number in the "Display" selection field.
2. Enter the "Start number" and "Increment" for the block numbering.
3. If the commented out NC blocks are also to be numbered:
activate "With comment"
4. Press the Numbering button.
All NC blocks receive a block number.
15.9 Testing and correcting the program
Each new workpiece must be "run-in" on the machine. This
includes testing and correcting the programmed tool path and
transfer path, checking for collisions, checking workpiece geometry and the insertion or correction of process parameters.
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4‐227
A program created by teaching or with a 3D programming system program must be tested on the machine with the workpiece
and, if necessary, be corrected.
■
■
■
■
■
Correct the zero point.
Correct individual teach points.
Correct R parameter.
Insert H words.
Insert additional path and transfer points.
Correcting the zero point
A zero point that is present in the program should be corrected.
Condition
Kinematic transformation is active.
1. Either
Ø If the first zero point that is present in the program is to
be corrected:
− In the >Settings > Editor menu: activate "Automatic zero
point search during replacement".
■
or
Ø If another zero point present in the program is to be corrected: deactivate "Automatic zero point search during
replacement".
− Activate "Replace block" mode.
− Mark the NC block that is to be replaced.
2. Move the TCP to zero point position
3. Switch on the distance regulation system.
4. Either
Ø On the teach panel Press the ZERO POINT button.
or
Ø On the control panel:
− Press Actions.
− Press Set zero point.
The zero point coordinates are corrected. The zero point offset is
immediately effective.
Inserting H word
By inserting a H word, a nozzle distance can be programmed
block-by-block that varies from the laser technology table.
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1. Mark NC block.
2. Either
Ø At the teach panel: press the H WORD button.
or
Ø On the control panel:
− Press Actions.
− Press H word.
An H word is supplemented in the marked NC block.
3. To activate the H word, press the ENABLE KEY.
The TCP moves to the sheet surface and measures the nozzle
distance.
Correct path
A programmed tool path can be corrected by TruTops Cell Basic
(option) or also by reteaching.
Condition
■
Kinematic transformation is active.
Note
If a new NC block is to be inserted: deactivate the "Replace
block" mode.
If an available NC block is to be overwritten: activate the
"Replace block" mode.
Correct the R parameter
1. Position the TCP.
2. Mark NC block with R parameters.
3. Either
Ø Select the "Macro center" interpolation type.
or
Ø Select "Macro help point" interpolation type.
4. Press TEACH IN button.
The R parameters of the marked NC block are overwritten.
Correcting the available
teach point
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2017-11-17
5. Activate "Replace block" mode.
6. For example, move the TCP to the NC block to be changed
in the single block mode.
7. Select the G01 interpolation type.
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4‐229
Press TEACH IN button.
Overwrite the marked NC block with the current axis coordinates.
Inserting teach points
8. Deactivate the "Replace block" mode.
9. Position the TCP to, for example, insert a transfer point
between two contours.
10. Select the G01 interpolation type.
Press TEACH IN button.
A new NC block is inserted at the current position.
Save changes
11. Press Save.
The program is saved in the 'Inneren Verwaltung'.
Testing the program
The program can be tested in "Single block" mode or in "Blockby-block" mode:
During the test run, the geometry deviation between the programmed contour and the actual workpiece geometry can be
checked at the user interface.
Conditions
■
■
Program has been created.
The workpiece zero point has been corrected.
Notes
■
■
■
WARNING
As long as the program is active, it cannot be processed in
the NC editor.
Start the program in single block mode with the teach panel
during the first test run.
Before testing, save the program.
Risk of injury while a program is being tested, especially if
the clamping elements open and close a fixture.
Ø
Ø
While a program is being run in test mode, keep sufficient
distance to the fixture.
Do not step between the machine body and the barrel while
a program is being run in test mode.
1. Reduce the feed rate at the potentiometer to about 10%.
2. Either
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Ø Position the TCP at the contour start.
or
Ø Position the cursor in the NC editor at the program start.
3. Starting the program
Ø On the teach panel Press the START button.
or
Ø On the control panel: Press Start.
The program will run through in single block or in block-byblock.
Note
If No is pressed in the "Save" dialog box, all changes made
since the last saving will be lost.
4. If the program is completely tested and corrected: Press
Save.
The program is saved in the 'Inneren Verwaltung'.
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4‐231
4‐232
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Chapter 5
Setting work
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2017-11-17
Safety notes
5‐3
1
Overview of setting work
5‐4
1.1
Overview of cutting process setting work
5‐4
2
Tooling the processing optics
5‐6
2.1
Removing the processing optics
5‐6
2.2
Installing processing optics
5‐7
3
Checking the C and B axes and referencing
manually
5‐10
3.1
Checking the B and C axes
5‐10
3.2
Referencing the C and B axes manually
5‐13
4
Test sheet holder
5‐14
5
Smart Optics Setup
5‐17
5.1
Swiveling the test sheet holder into the setup
position and mounting a test sheet
5‐22
Setting work
5‐1
5.2
Swiveling the test sheet holder into the parking
position
5‐23
5.3
Approaching the start or reference position
5‐24
5.4
Resetting the reference position
5‐25
6
Wizard
5‐27
6.1
Test sheet holder: Starting the utility program
5‐29
6.2
Smart Optics Setup station: Starting the utility
program
5‐31
6.3
Defining new reference optics
5‐33
7
Cutting process setting work
5‐34
7.1
Centering the beam
5‐34
7.2
Mounting the protective cover
5‐36
Installing the setting device
5‐37
Dismantling the setting device
5‐38
Centering nozzle to beam
5‐38
Determining and setting the focal position
Start focus search
5‐2
Setting work
5‐41
5‐42
7.3
Calibrate the B and C axes
5‐46
7.4
Determining the joint offset
5‐50
Determining the Z-axis joint offset
5‐51
Determining X axis and Y axis joint offset
5‐53
8
Calibrating the measuring equipment
5‐57
8.1
Mounting and activating the sensor
5‐59
8.2
Calibrating the sensor
5‐60
9
Setting up the clamping fixture
5‐63
9.1
Starting the utility program
5‐66
9.2
Checking the measuring sequence (option)
5‐68
9.3
Entering the required position
5‐69
9.4
Measuring the required position
5‐71
9.5
Measuring the actual position
5‐72
9.6
Determining the correction frame
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Safety notes
Setting work in service mode may be carried out only by specially trained service personnel.
Invisible, high-energy laser radiation!
DANGER
Severe skin burns and eye injuries may occur.
Ø
Ø
Ø
Danger class
■
■
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2017-11-17
Setting work that requires 100% laser power may be carried
out only by specially trained service personnel.
Protective gloves and laser safety glasses must always be
worn during setting work if the laser is switched on.
The customer may have to take additional precautions to
secure the danger zone (e.g. using partition walls of sheet
steel or polycarbonate).
The danger class of the laser system in service mode is
class 4.
The setting work which the operator is allowed to carry out is
conducted in normal mode of the machine. The danger class
of the laser system in normal mode corresponds with
class 1.
Setting work
5‐3
1.
Overview of setting work
The setting work listed below is carried out by the operator in
the machine's normal mode. The protective devices are active
here.
The utility programs of the setting work are controlled and
started menu-driven via a Wizard dialog.
Valid from machine serial release S04.00.
Reference optics
The absolute position 0° for the B and C axes is referenced
when the machine is commissioned using the so-called reference
optics. Therefore, any further calibration of the B and C axes
must be carried out with the reference optics.
If only one set of processing optics is used on the machine,
these optics are the reference optics.
If several sets of processing optics are used on the machine,
any other mounted optics can be defined as the reference optics
if required, but not without an important reason.
Note
If new reference optics are defined using the wizard, the
tooling statuses of all other processing optics become invalid. In such a case, the joint offset must be re-determined
for all other optics.
1.1
Overview of cutting process setting
work
The following setting work must be carried out in the order
described here. Here, a distinction is made between reference
optics and other cutting optics which are used on the machine.
When?
Setting work
Manually checking and referencing
the B and C axes
Manual check
■
After every collision of the processing optics.
Setting work for the reference optics:
Centering nozzle to beam
Dialog-driven utility program
(CP_HEAD_SETUP)
■
After cleaning or exchanging the
lens in the processing optics.
Determining and setting the focus
position
Dialog-driven utility program
(CP_HEAD_SETUP)
■
In the event of cutting problems.
Dialog-driven utility program
(CP_HEAD_SETUP)
■
After every collision of the processing optics.
■
After manually referencing the B
and C axes.
Note: This is skipped for machines
without FocusLine.
Calibrate the B and C axes
5‐4
Overview of setting work
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B836en
Setting work
When?
Determine tool length (Z axis joint
offset)
Dialog-driven utility program
(CP_HEAD_SETUP)
Determining the joint offset of the X
and Y axes
Dialog-driven utility program
(CP_HEAD_SETUP)
■
After calibrating the B axis and
C axis.
Setting work for all other cutting optics:
Centering nozzle to beam
Dialog-driven utility program
(CP_HEAD_SETUP)
■
After cleaning or exchanging the
lens in the processing optics.
Determining and setting the focus
position
Dialog-driven utility program
(CP_HEAD_SETUP)
■
In the event of cutting problems.
Determine tool length (Z axis joint
offset)
Dialog-driven utility program
(CP_HEAD_SETUP)
■
After calibrating the B axis and
C axis.
Determining the joint offset of the X
and Y axes
Dialog-driven utility program
(CP_HEAD_SETUP)
Cutting process setting work
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Tab. 5-1
2017-11-17
Overview of setting work
5‐5
2.
Media adapter
Tooling the processing optics
The supply lines for the processing optics are connected to the
media adapter of the Z barrel.
Media adapter connections
Symbol
Fig. 71428
Description
Beam guideway ventilation
Cutting gas
CAN bus
Dynamic additional axis (ADC)
Connection not assigned.
Magnetic coupling
Sensor
Media connections legend
2.1
1.
2.
3.
4.
5.
Tab. 5-2
Removing the processing optics
Switch off the alignment laser.
Move the Z barrel to a good change position.
Press Setup, "Manual functions".
Select the General group.
Press "Optics replacement".
The magnetic coupling releases.
6. Remove the processing optics:
5‐6
Tooling the processing optics
2017-11-17
B836en
−
−
−
Remove the medium connections.
Release the catch strap.
Take off the processing optics and seal the beam orifice
with a protective cover or optical adhesive tape.
7. Seal the beam guidance on the angular gear with a protective cover or optical adhesive tape or mount different optics.
2.2
Installing processing optics
The processing optics are stuck on the B/C gear of the Z barrel
with a magnetic coupling and fastened with 3 knurled screws.
Conditions
■
■
The machine is ready for operation.
The setup state has been created.
Notes
■
■
■
■
The electromagnetic of the magnetic coupling at the Z
barrel presents a danger of life for persons with
pacemakers!
DANGER
Ø
Ø
Ø
B836en
As soon as the valid tooling status is activated, the additional
ADC axis of the optics references automatically.
If new optics are put into operation on the machine, for
which there is yet no valid tooling status, a new tooling status must be created first.
Damaged or contaminated pole and contact surfaces on the
magnetic coupling lead to a malfunction.
Tooling status: (see "Managing the tooling status", pg. 4‐171)
2017-11-17
Persons with a pacemaker must, regardless of whether the
machine is switched on, keep a minimum distance of 30 cm
from the magnetic coupling on the Z barrel.
Persons with a pacemaker may not perform any service,
maintenance or setting work on the Z barrel or on the processing optics (if installed).
Advise personnel, visitors or visiting personnel of the dangers for persons with a pacemaker.
Tooling the processing optics
5‐7
NOTICE
Damage to the processing optics when torn from the
magnetic coupling!
Ø
Ø
Ø
Ø
Mount the catch strap properly.
Exchange damaged catch strap.
Exchange damaged catch strap.
Before switching off the machine, set the B and C axes to
0°.
1
Catch strap
3
Knurled screw
2
Magnetic coupling
4
Bellows
Installing processing optics
Fig. 71427
1. Switch off the alignment laser.
2. Clean the pole and contact surfaces of the magnetic coupling
thoroughly.
3. Stick the processing optics on the magnetic coupling. Tighten
the 3 knurled screws by hand. Fasten the catch strap.
The green LED on the magnetic coupling lights up when the
processing optics are docked correctly.
If the green LED does not light up, either there is no
electric contact with the magnetic coupling or the optics
are not seated properly on the flange.
Ø Shake the seating of the optics.
Ø If electrical contact can still not be established, then
remove the optics and clean the pole and contact surfa-
5‐8
Tooling the processing optics
2017-11-17
B836en
ces of the magnetic coupling thoroughly (see the "Maintenance" chapter in the "Mechanics" section).
1
Beam guidance ventilation
5
Magnetic coupling
2
CAN bus
6
Sensor (option)
3
ADC additional axis
7
Cutting gas
4
unassigned
Connecting the cutting optics
Fig. 71426
4. Install the media connections.
5. Acknowledge the danger zone and close the safety door.
6. Activate the tooling status:
− Press Technology, select "Tooling status management".
− Select the valid tooling status.
− Press Activate.
The optics are now registered. The additional ADC axis references as long as the safety door is closed.
7. Record the characteristic curve for the distance regulation:
− Press Setup, "Manual functions".
− Select Distance regulation group.
− Press "Recording charac. curve".
The characteristic curve will be recorded. Afterwards, the optics
will be ready for operation.
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Tooling the processing optics
5‐9
3.
Checking the C and B axes and
referencing manually
The drive motors of the B and C axes are motors with absolute
encoders. These motors are referenced to the absolute position
0° during start-up. If this reference point run is lost, e. g. after a
collision, the NC axes must be referenced again.
The inclined position is checked and the C and B axes are referenced manually at first.
Due to the imprecision of a manual reference point run, the B
and C axes must recalibrated afterward. (see "Calibrate the B
and C axes", pg. 5‐46)
Note
Both the manual reference point run as well as the exact calibration of the C and B axes must be carried out with the reference
optics. Reference optics
The manual check and reference point run are described
below.
3.1
Checking the B and C axes
The positions of the B and C axes can be checked as needed,
e. g. after a collision.
The position is checked by positioning the B and C axes to 0°.
Any inclined position of the axes is determined by moving over a
reference surface with a dial gauge.
Conditions
■
■
■
The tooling status is valid and has been activated.
The reference optics are installed.
At least the "Advanced" user group is active.
Means, Tools, Materials
■
5‐10
Dial gauge and support.
Checking the C and B axes and referencing
manually
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Checking the C axis
1. In MDA operation mode: Move the processing optics to
C = 0 and B = 0.
A
Starting point
B
End point
Reference surface, C axis
Fig. 71429
2. Mount the dial gauge and align the C axis with the reference
surface at starting point "A" and zero the dial gauge.
3. Move the X axis with the teach panel by approx. 50 mm
from "A" to "B". While moving over the reference surface,
check the dial gauge.
4. Either
Ø If no inclined position is determined, no other setting
work is required.
or
Ø If an inclined position is determined: Correct the position
of the axis until the dial gauge no longer shows a deviation from zero when moving along the reference surface.
The axis position determined this way now corresponds to
the new absolute position of 0°. The axis will be referenced
later in this position.
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Checking the C and B axes and referencing
manually
5‐11
Checking the B axis
A
Start position
B
End position
B axis reference area
Fig. 71431
5. Mount the dial gauge and align the B axis with the reference
surface at starting point "A" and zero the dial gauge.
6. Move the Z axis with the teach panel by approx. 50 mm from
"A" to "B". While moving over the reference surface, check
the dial gauge.
7. Either
Ø If no inclined position is determined, no other setting
work is required.
or
Ø If an inclined position is determined: Correct the position
of the axis until the dial gauge no longer shows a deviation from zero when moving along the reference surface.
The axis position determined this way now corresponds to
the new absolute position of 0°. The axis will be referenced
later in this position.
8. Afterwards, reference the B and/or C axis at the absolute
position of 0°. (see "Referencing the C and B axes manually", pg. 5‐13)
5‐12
Checking the C and B axes and referencing
manually
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3.2
Referencing the C and B axes
manually
Referencing means: The axis position of 0° determined manually
with the dial gauge is set to the absolute value "0" in the control.
Conditions
■
■
■
The tooling status is valid and has been activated.
The reference optics are installed.
At least the "Advanced" user group is active.
Note
The position of the axis is exclusively corrected by the software.
Mechanical adjustment is not required.
1.
2.
3.
4.
5.
6.
7.
Press Setupand select "Manual functions".
Select the Setting work group.
Press the manual function button "Set position".
Press Absolute position.
In the dialog for "Specification position", enter 0.
Activate "Status position referenced" for the B and/or C axis.
Press Finish.
The control system sets the absolute position of the B and C
axes in the machine data to 0°.
The control system forces a warm start. After control system
start-up the set absolute positions for the axes are effective.
8. Afterwards, calibrate the B and C axes with the service program. (see "Calibrate the B and C axes", pg. 5‐46)
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Checking the C and B axes and referencing
manually
5‐13
4.
Test sheet holder
The setting work is usually carried out with a test sheet or a reference part. The test sheet is clamped in a holder. The holder is
mounted in the work area of the machine, preferably to the workpiece changer.
This standard test sheet holder belongs to the scope of delivery
of the machine.
NOTICE
Risk of collision between processing optics and fixtures or
assemblies in the work area!
Ø
Ø
Ø
Ø
Installation
Firmly clamp the test sheet in the holder.
If the small holder is mounted to a fixture, the reference part
must project over the fixture.
There must be clearance of at least 500 mm available to the
left and right of the holder.
Remove the holder again after completing setting work.
There are 2 holders in the scope of delivery of the machine,
which can be mounted at a suitable place. Only one holder is
used at a time.
■
■
Large holder: installation preferably on the workpiece
changer or on the fixture holder.
Small holder: installation preferably on the fixture, e.g. on a
clamp.
Note
The test sheet holder must be mounted axially parallel.
5‐14
Test sheet holder
2017-11-17
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A
Small holder
1
Vertical test sheet
B
Large holder
2
Horizontal test sheet
3
Sacrificial plate
Example: Mounting the sheets in the holder
Fig. 62013
Note
Recommendation: To protect the holder, a sacrificial plate can be
clamped in: mild steel, max. 8.5 mm thick, 190 mm x 110 mm.
Fig. 62012
Installation dimensions small holder
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2017-11-17
Test sheet holder
5‐15
Installation dimensions large holder
5‐16
Test sheet holder
Fig. 62014
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5.
Smart Optics Setup
Smart Optics Setup is an option for the laser machine.
Setting work for the machine as well as for the processing optics
can be done using the Smart Optics Setup function and the
Smart Optics Setup station.
Basic variant scope of
delivery
The scope of delivery of the Smart Optics Setup Basic option
includes the following components:
■
■
■
Smart Optics Setup station
The Smart Optics Setup station, consisting of a swivel arm
and test sheet holder, in which the test sheets for carrying
out setting work can be clamped.
"Measuring ball" setting device (material number 2248971)
for calibrating the sensor (option), see section "Calibrating
measuring equipment" Smart Optics Setup Station.
Three sets of sacrificial plates (2 sheets per set) for protecting the test sheet holder from laser radiation.
The Smart Optics Setup station is a swivelable fixture (referred
to as the setting device in the following), which can alternatively
be used for setting work instead of the standard test sheet
holder (see "Test sheet holder", pg. 5‐14).
1
Holder with swivel arm
3
Test sheet holder
2
Measuring ball fixture
4
Sacrificial plates (2 pieces)
Smart Optics Setup station
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2017-11-17
Fig. 87510
Smart Optics Setup
5‐17
Setup position and parking
position
A
The setting device is permanently mounted on the machine
frame and is swiveled into the working area of the machine for
setting work.
Setup position
B
Parking position
Smart Optics Setup station
CAUTION
Fig. 86915
Risk of crushing or hitting when swiveling the
Smart Optics Setup station!
Ø
Ø
Ø
When swiveling, make sure that no parts of the body get
caught.
Touch the swivel arm at the handle to swivel it.
Lock the swivel arm in the set-up position and in the parking
position.
Both the setup position and the parking positions are monitored
by the machine control by touch switches.
■
■
The test sheet holder is swiveled into the setup position in
the working area. The swivel arm is locked into this position
with a toggle clamp.
In the parking position, the test sheet holder is swiveled out
of the working range and is held in the parking position with
a stop pin.
Note
If the setting device is in the setup position, rotation is not enabled for the workpiece changer. The production plan or a processing program cannot be started.
Test sheets for utility
programs
5‐18
Smart Optics Setup
For the different setting work operations, the test sheets are
inserted either horizontally or vertically in the test sheet holder
and screwed tight.
2017-11-17
B836en
Note
A set of test sheets is part of the scope of delivery of the
machine. They can be used for Smart Optics Setup station and
also for the standard test sheet holder. They can be ordered as
consumables.
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2017-11-17
Smart Optics Setup
5‐19
Reference position
The cross-hairs on the flat, processed surface of the test sheet
holder serve as a reference position for starting the utility programs. The reference position is determined by the service engineer during the commissioning of the machine.
When using the Smart Optics Setup station: At the start of the
utility program, the axes position themselves automatically from
the current axis position to the respective start position for the
laser processing.
1
Cross-hairs
Smart Optics Setup station reference position
Fig. 87511
Notes
■
■
5‐20
Smart Optics Setup
Approach reference position: (see "Approaching the start or
reference position", pg. 5‐24).
Reset reference position: (see "Resetting the reference position", pg. 5‐25).
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B836en
Contact washers for
grounding the test sheet
holder
The test sheet holder is fastened to the flange plate on the
swivel arm of the Smart Optics Setup station with four screws.
The two lower fastening screws on the flange plates have contact washers. These two contact washers are functionally relevant components. They ground the test sheet holder, thus
ensuring the functional safety of the distance regulation.
1
Contact washer
Smart Optics Setup station contact washers
Risk of collision between the processing optics and the
setting device when approaching the reference position!
NOTICE
Ø
Ø
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Fig. 86911
2017-11-17
Do not remove the contact washers.
Replace any contact washers that are lost.
Smart Optics Setup
5‐21
5.1
Swiveling the test sheet holder into
the setup position and mounting a
test sheet
Before beginning with setting work, the Smart Optics Setup station is swiveled out of the parking position into the working range
of the machine.
NOTICE
Risk of collision of the processing optics when approaching
the reference position if the vertical test sheet is mounted
on the outer side of the test sheet holder.
Ø
NOTICE
The vertical test sheet must always be mounted to the side
facing the working area (inside of the test sheet holder).
Risk of collision when swiveling the Smart Optics Setup
station with the workpiece or with the fixture in the work
area!
Ø
1
Check whether a collision between the fixture or workpiece
with the workpiece changer is possible when the
Smart Optics Setup station is swiveling.
Toggle clamp
Securing the swivel arm in the setup position
Fig. 86914
1. Move the Z axis into the safety position (e. g. to Z = 600).
5‐22
Smart Optics Setup
2017-11-17
B836en
2. Unlock the swivel arm: pull the locking pin up and turn it.
3. Grasp the swivel arm at the handle and swivel it into the
work area.
4. Clamp the swivel arm in the setup position using the toggle
clamp.
5. Mount the test sheet horizontally or vertically in the test
sheet holder.
5.2
Swiveling the test sheet holder into
the parking position
After completing setting work, the Smart Optics Setup station is
swiveled back into the parking position and locked.
1
Stop pin
Locking the swivel arm in the parking position
Fig. 86913
1. Move the Z axis into the safety position (e. g. to Z = 600).
2. Open the toggle clamp on the swivel arm.
3. Grasp the swivel arm at the handle and swivel it into the
parking position.
4. Lock the swivel arm in the parking position: turn the locking
pin until it engages.
B836en
2017-11-17
Smart Optics Setup
5‐23
5.3
Approaching the start or reference
position
The reference position is determined and set by the service engineer during the commissioning of the machine.
To check, the user can approach the saved reference position as
needed or before starting a utility program.
Conditions
■
■
■
■
■
■
NOTICE
Processing optics are ready for operation.
The tooling status has been activated.
At least the "Advanced" user group is active.
The Smart Optics Setup function is applied.
The Smart Optics Setup station is in the set-up position.
Reference position is determined Reference position.
Risk of collision! NC axes move immediately to the
reference position along a direct path!
Ø
1
Before starting, check whether a collision is possible
between the barrel or processing optics and the fixture or
workpiece.
Cross-hairs
Smart Optics Setup station reference position
Fig. 87511
1. Press Production, select "Utility tools".
5‐24
Smart Optics Setup
2017-11-17
B836en
2. Select the utility program CP_HEAD_SETUP and press Execute.
The wizard starts.
3. Press the Smart Optics Setup button.
4. Press Approach position.
5. Check the collision behavior and confirm the dialog with Yes
or No.
The saved reference position is approached.
5.4
Resetting the reference position
The reference position is set by the service engineer during the
commissioning of the machine.
The user can reset and save the reference position as needed.
Conditions
■
■
■
■
■
1
Processing optics are ready for operation.
The tooling status has been activated.
At least the "Advanced" user group is active.
The Smart Optics Setup function is applied.
Smart Optics Setup station is in the setup position.
Cross-hairs
Smart Optics Setup station reference position
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2017-11-17
Smart Optics Setup
Fig. 87511
5‐25
1. Press Production, select "Utility tools".
2. Select the utility program CP_HEAD_SETUP and press Execute.
The wizard starts.
3. Press the Smart Optics Setup button.
4. Press Set position.
5. Either
Ø If the current axis position should be saved as the new
reference position:
− Select "Current axis position".
− Position the B and C axes at B0/C0.
− Position the tool center point at approx. 10 mm above
the cross-hairs with the teach panel.
or
Ø If "Stored values" is selected, the processing optics is
immediately positioned in the stored reference position.
6. Press OK.
The newly set reference position is saved.
5‐26
Smart Optics Setup
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B836en
6.
Wizard
With the help of the wizard, all setting work for the current tooling status can be started and carried out menu-driven.
The Wizard is started with the service program
CP_HEAD_SETUP.LST.
Program selection and
status
The individual setting work tasks are listed in tabular form in the
Wizard dialog and are marked with a status. The status shows
which setting work is mandatory and which is optional.
1
Setting work
2
Status
3
Wizard
Wizard start dialog
Symbol
Fig. 71596
Description
This setting work must be done next.
This setting work was already carried out, but can be carried out again, as needed.
This setting work must still be carried out, but the conditions for this have not yet been met.
The selection is currently not possible or the setting work
has already been done.
Tab. 5-3
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Wizard
5‐27
Wizard
Using the wizard, the program selection in the "Setting work"
table can be filtered. The Wizard filters according to the following
criteria:
■
■
■
■
Empty: The standard display for the activated tooling status
is shown.
Cleaning or replacement of the lens: In the table, only that
setting work is displayed which is required after cleaning or
replacing the lens.
Cutting problems: In the table, only that setting work is
shown which is to be carried out if there are cutting problems.
Collision: In the table, only that setting work is shown which
is required after a collision of the processing optics.
Reference optics
The currently mounted optics can be defined as the reference
optics (see "Defining new reference optics", pg. 5‐33). The reference optics are the processing optics with which setting work
is carried out on the machine.
Context button
Depending on the context, the following buttons will be shown:
Button
Description
Reference optics
Define the mounted optics as the reference optics. Dialog opens.
Smart Optics Setup (option)
Approach position: Approach the stored reference position. This position
corresponds to the stored cross-hairs position on the test sheet holder.
Note: This button is only visible
when the option is applied on the
machine.
Set position: Set and save a new reference position. Dialog opens.
Back
Back to the previous page.
Next
Continue the service program.
Finish
Exit the service program.
Cancel
Cancel service program.
Context button
Tab. 5-4
Test sheets for utility
programs
For the different setting work operations, the test sheets are
inserted either horizontally or vertically in the test sheet holder
and screwed tight.
Note
A set of test sheets is part of the scope of delivery of the
machine. They can be used for Smart Optics Setup station and
also for the standard test sheet holder. They can be ordered as
consumables.
5‐28
Wizard
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B836en
6.1
Test sheet holder: Starting the utility
program
This section applies if the standard test sheet holder is
used which is included in the scope of delivery of the
machine (see "Test sheet holder", pg. 5‐14).
The start position for a utility program can be approached with
the teach panel.
Alternatively, the start position can also be selected on the user
interface and approached from the control panel. The following
options will be described below:
■
■
■
■
The actual position is the start position.
The start coordinates are entered absolutely in the input
fields.
The start position is approached incrementally (step-by-step).
The last stored start position can be loaded and approached.
Conditions
■
■
■
■
Processing optics are ready for operation.
Laser device is ready for operation and assigned to the
machine.
The tooling status has been activated.
At least the "Advanced" user group is active.
Notes
■
■
■
B836en
2017-11-17
To start the wizard and the following utility program, it is not
essential for the tooling status to be valid.
The control stores the start position automatically for the
respectively selected setting work.
When starting the CP_HEAD_SETUP.LST utility program, an
active processing program is ended.
Wizard
5‐29
That axis position at which the laser processing of the reference
part is started is referred to as the start position.
Establish start position
Fig. 71597
The start coordinates can be changed incrementally (step-bystep) with the Plus or Minus button.
Description
Button
Load position
The last saved start position for this setting work is loaded automatically.
Approach position
The coordinates entered in the dialog are approached as the start position.
The axes start immediately; the optics move first to the crossover position
(Z = 600) and then to the start position. Afterwards, the dialog "Approach
start position" opens again.
Next
The coordinates entered in the dialog are approached as the start position.
The axes start immediately; the optics move first to the crossover position
(Z = 600) and then to the start position.
Context button
Tab. 5-5
Start the Wizard
1. Press Production, select "Utility tools".
2. Select the utility program CP_HEAD_SETUP and press Execute.
The wizard starts. The individual setting work and its status
are displayed in the table depending on the current tooling
status and the mounted processing optics.
3. In the table, select the setting work that should be started
next.
4. To start the selected setting work: Press Continue.
The utility program is started. The Start position dialog
appears.
Establish start position
5‐30
Wizard
5. Either
Ø If the current axis position is the start position: Press
Continue.
2017-11-17
B836en
or
Ø Enter the start coordinates in the input fields and press
Next.
or
Ø If the start position last saved in the control is to be
approached:
− Press Load position.
− Press Approach position or Next.
or
Ø If the new start position is to be approached incrementally:
− Enter the increment in the "Increment" input field.
− Select the start position with the Plus or Minus button.
− Press Approach position or Next.
The service program is continued.
6. Follow the wizard.
6.2
Smart Optics Setup station: Starting
the utility program
This section applies if the Smart Optics Setup function is used
(option).
Instead of the standard test sheet holder, the Smart Optics
Setup station is used for setting work (see "Smart Optics Setup",
pg. 5‐17).
When the utility program is started for the respective setting
work, the axes position themselves automatically from the current axis position to the start position of the utility program.
That axis position at which the laser processing of the reference
part is started is referred to as the start position.
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2017-11-17
Wizard
5‐31
Conditions
■
■
■
■
■
■
■
Processing optics are ready for operation.
Laser device is ready for operation and assigned to the
machine.
The tooling status has been activated.
At least the "Advanced" user group is active.
The Smart Optics Setup function is applied.
The Smart Optics Setup station is in the set-up position.
Reference position is determined Reference position.
Notes
■
■
NOTICE
In order to start the wizard and the following utility programs,
a valid tooling status is not mandatory.
When starting the CP_HEAD_SETUP.LST utility program, an
active processing program is ended.
Risk of collision! The NC axes move immediately to the
start position for laser processing along a direct path after
the utility program starts.
Ø
Ø
Before starting the utility program, check whether a collision
with the fixture or workpiece is possible.
Recommendation: Before starting a utility program, position
the processing optics above the cross-hairs.
1. Press Production, select "Utility tools".
2. Select the utility program CP_HEAD_SETUP and press Execute.
The wizard starts. The individual setting work and its status
are displayed in the table depending on the current tooling
status and the mounted processing optics.
3. In the table, select the setting work that should be started
next.
4. Check the collision behavior and confirm the dialog with Yes
or No.
5. Press Continue.
The utility program is started.
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Wizard
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6.3
Defining new reference optics
Conditions
■
■
Processing optics are ready for operation.
The danger zone has been acknowledged and the access
door has been closed.
Note
Do not define other optics as the reference optics without a
compelling reason. All tooling statuses will become invalid
as a result. The joint offset must be redetermined for all
optics used on the machine.
1.
2.
3.
4.
5.
Mount the processing optics.
Start the Wizard.
Press Reference optics.
Activate "Apply reference optics".
Press Continue.
The mounted optics are now the new reference optics.
6. Recalibrate the B and C axes. (see "Calibrate the B and C
axes", pg. 5‐46)
7. Determine the tool length for the new reference optics. (see
"Determining the Z-axis joint offset", pg. 5‐51)
8. Determine the joint offset for the X and Y axes for the new
reference optics. (see "Determining X axis and Y axis joint
offset", pg. 5‐53)
9. Afterwards, redetermine the joint offset for the X and Y axes
for all other optics used on the machine. The tool length
does not have to be determined again for the other optics.
(see "Determining the joint offset", pg. 5‐50)
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2017-11-17
Wizard
5‐33
7.
Cutting process setting work
Note
In order to be able to carry out the setting work described below,
the authorized user group must be logged on. If there is no
authorization, a message will be output.(see "User administration", pg. 4‐75)
7.1
Centering the beam
The beam centering must be checked:
■
■
■
after cleaning or exchanging the lens in the cutting optics.
after every change of the laser light cable.
After each basic adjustment of the beam.
The laser beam must be guided through the center of the nozzle
to achieve good cutting results, regardless of the direction. At
the same time, this ensures that the beam will not reflect on the
nozzle wall and that the flow of the cutting gas will be guided
evenly around the focus spot.
1
Nozzle orifice
a
Centered laser beam
2
Laser beam
b,c Off-center laser beam
Centering the laser beam to the nozzle
Fig. 32545
Service program
The utility program is started via the Wizard. The utility program
triggers a laser pulse.
Setting device
The sensor body, and therefore the nozzle, are adjusted using a
setting device.
The sensor body is fastened to a slide with a path movement in
the X and Y directions of +1.0 mm each way. The sensor body
and slide are fixed with clamping screws. The sensor body and
nozzle are joined rigidly; the beam is centered to the nozzle center by adjusting the sensor body.
5‐34
Cutting process setting work
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B836en
1
Adjusting screw
4
Knurled screw
7
Sensor body
2
Dial gauge
5
Cutting insert
8
Red marking
3
Alignment pin
6
Clamping screw
Setting device
B836en
Fig. 23177
2017-11-17
Cutting process setting work
5‐35
Mounting the protective cover
The protective cover is an option for the dynamic processing
optics.
The protective cover protects the cutting insert and prevents the
very fine cutting dust from being able to penetrate into the cutting insert and tapping holes.
Note
The protective cover can only be used for the new cutting optics
of the TruLaser Cell 8030 (L60). The protective cover cannot be
used for cutting optics of predecessor machines due to the form
fit between the bushing and the cutting insert.
1
Notch in the cutting insert
2
Cutting insert
3
Fixing screw
4
Protective cover
Mounting the protective cover
Fig. 73821
1. To mount the protective cover:
− Stick the protective cover over the cutting insert from
below; in the process, the fixing screw in the flange of
the protective cover targets the notch in the cutting insert.
− Tighten the fixing screw in the flange of the protective
cover hand-tight.
2. To remove the protective cover: Loosen the fixing screw on
the flange of the protective cover and pull the protective
cover off of the cutting insert.
5‐36
Cutting process setting work
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B836en
Installing the setting device
The setting device is fitted on the cutting insert of the cutting
optics from below and fastened. The contact surfaces must be
clean. The device may not be tilted.
Means, Tools, Materials
■
■
Setting device (mat. no. 1425940) for moving the sensor
body in X and Y direction.
Allen key SW 3.
1
Adjusting screw
3
Setting device
2
Knurled screw
4
Dial gauge
Installed setting device
Fig. 71591
1. Move the NC axes in JOG mode into an easily accessible
position.
2. Rotate the B axis to -90°.
3. Remove the protective cover (option) from the cutting insert.
4. Rotate the anodized cover ring on the cutting insert so that
the 4 clamping screws are visible.
5. Screw the adjusting screws and the dial gauges out of the
fixture up to the red marking.
6. Fit the setting device on the cutting insert from below. Center
it with the alignment pin.
7. Tighten both knurled screws hand-tight.
8. Screw in the adjusting screws first and lightly tighten.
9. Afterwards, screw in the dial gauges hand-tight and zero.
10. Finally, tighten the adjusting screws until the dial gauges
deflect slightly.
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Cutting process setting work
5‐37
Dismantling the setting device
After the end of nozzle centering, the adjustment device is
removed again.
1. Loosen the dial gauges and the adjusting screws until the
red marking on the screws is completely visible.
2. Loosen the knurled screws.
3. Carefully pull off the adjustment device.
4. If available, remount the protective cover for the cutting
insert.
Centering nozzle to beam
The following four working steps are required for centering the
laser beam with respect to the nozzle:
■
■
■
■
Perform a reference shot to check the centering and to localize the beam.
Correct the nozzle and carry out a test shot.
Carry out test shot with the C axis in 4 different positions.
Carry out test shot with the B axis in 3 different positions.
Conditions
■
■
■
■
Processing optics are ready for operation.
Clean, new standard nozzle, ∅ 2.3 mm.
Clean, new standard nozzle ∅ 1.4 mm.
Laser device is ready for operation and assigned to the
machine.
Means, Tools, Materials
■
■
Measuring magnifier (10 to 20 times zoom).
Adhesive strips (Scotch Magic transparent film).
Notes
■
■
■
For each test shot, move the adhesive strip or use a new
adhesive strip.
The first test shot is usually carried out with a nozzle having
a nozzle diameter of 2.3 mm.
Change the nozzle after adjusting the laser beam for the first
time. The smaller the nozzle diameter, the more exactly the
beam can be adjusted to the nozzle orifice.
Recommendation: For each additional test shot, use a nozzle
with a nozzle diameter of 1.4 mm or smaller.
5‐38
Cutting process setting work
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B836en
Carrying out a reference
shot
1.
2.
3.
4.
5.
6.
Stick an adhesive strip on to the nozzle orifice.
Acknowledge the danger zone and close the safety door.
If the wizard has not been started yet: start the wizard.
In the table, select Centering nozzle to beam.
Press Continue.
Enter the parameters "Laser power" and "Duration" for the
laser pulse.
7. Press Trigger pulse.
The B and C axes turn to 0°. A laser pulse is triggered.
Then the B axis turns back into the initial position.
8. Do not remove the adhesive strip from the nozzle and check
the scorching in the adhesive strip with the magnifying glass.
Ø If the scorching is centered, the beam is centered. No
further centering is required.
or
Ø If the scorching is eccentric, the sensor body must be
adjusted.
Correct the nozzle and carry
out test shot
1
Clamping screws at the cutting insert (view from below)
Center the beam to the nozzle
Fig. 48388
9. Mount the setting device. (see "Installing the setting device",
pg. 5‐37)
10. Only slightly loosen the four clamping screws on the
cutting insert: max. 1/2 turn.
11. Adjust the sensor body using the set screws on the fixture.
The adjustment value can be read off on the opposite dial
gauge.
12. Stick new adhesive strip on the nozzle orifice.
B836en
2017-11-17
Cutting process setting work
5‐39
13. Acknowledge the danger zone and close the safety door.
14. Carry out another test shot: Trigger a laser pulse and check
the scorching. If the beam is still eccentric, correct the sensor body again.
The scorched hole and the scorched surrounding area on the
adhesive strip must be round and concentric to the nozzle. If
the hole and surrounding area are oval, then the beam
grazes the nozzle wall.
The test shot must deliver a satisfactory result; only
then can the test shots for the C and B axes be carried
out.
Carrying out test shot for C
axis
15. Stick new adhesive strip on the nozzle orifice.
Acknowledge the danger zone and close the safety door.
16. Press Continue.
17. Press Check C axis.
4 laser pulses are triggered at different C-axis positions.
18. Check the adhesive strip.
The rotation about the C axis is OK if the scorching is completely concentric.
Carrying out test shot for B
axis
19.
20.
21.
22.
Stick new adhesive strip on the nozzle orifice.
Acknowledge the danger zone and close the safety door.
Press Continue.
Press Check B axis.
3 laser pulses are triggered at different B-axis positions.
23. Check the adhesive strip.
The rotation about the B axis is OK if the scorching is completely concentric.
24. Once the scorching for the B and C axes is OK: Press Finish.
The centering of the nozzle is complete.
25. Tighten the clamping screws on the cutting insert hand-tight
again (max. 4 Nm).
26. Remove the adjustment device. (see "Dismantling the setting
device", pg. 5‐38)
27. If available, remount the protective sleeve.
28. Then readjust the focal position. (see "Determining and setting the focal position", pg. 5‐41)
5‐40
Cutting process setting work
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B836en
7.2
Focal position
Determining and setting the focal
position
The focal position is the vertical position of the focus (also called
focus point) with respect to the sheet surface. The exact position
of the focus is essential for good cutting results.
Focus position
Fig. 7461
The focal position must be redetermined:
■
■
■
■
Machines without FocusLine
after cleaning the lens or the FocusLine mirror.
after installing a new lens or a new FocusLine mirror.
after basic beam adjustment.
for checking for cutting problems.
For machines without FocusLine, the exact focal position is
determined by means of cutting tests and is fixed manually
before machining. It is not possible to adjust the focal position
during machining (see: section "Setting the focal position without
FocusLine").
The parameter "FocusLine setting value" in the laser technology
table has no effect in this case.
Note
The following description for how to determine the focal
position only applies to machines with FocusLine.
FocusLine
The function FocusLine is a laser processing machine option.
FocusLine compensates the focus shift and controls the focal
position during machining.
The surface of the FocusLine mirror is deformed in a targeted
way using pressure. This changes the angle of divergence of the
laser beam in such a way that the focus point can be shifted
upwards or downwards systematically during machining.
The function FocusLine is controlled via characteristic curves.
Focus search
B836en
2017-11-17
The service program is started via the Wizard. It cuts a reference part with a comb structure with 20 slats. The individual
Cutting process setting work
5‐41
webs are cut consecutively with a new focal position each time.
This changes the kerf between the slats continuously.
The "Increment" parameter corresponds to an increment in the
beam direction by which the focal position is changed from web
to web.
The "Increment" parameter is only changed if the focal position
offset value is outside the valid tolerance of 0.3 mm during the
focus search.
The reference sheet for the focus search is clamped in a holder
(included in the scope of delivery of the machine) and can be
mounted at a suitable place on the workpiece changer.
Start focus search
The focal position offset is determined during the focus search.
The focal position offset is the value by which the control displaces the FocusLine characteristic curve in the software.
At the beginning of the service program, the operator can
choose whether the focal position should be redetermined or
whether it should be checked.
■
■
If the focal position is to be redetermined, the focus search is
started with the standard focal position offset value. This
might be required in the following situations:
− When starting up new optics.
− After replacing or cleaning the lens.
− After changing the LLK or after basic adjustment.
− If the focus search does not lead to a valid result.
If the focal position should only be checked, for example,
then the focus search is started with the current focal position offset value.
The control corrects the FocusLine characteristic curve with the
Focus position offset parameter for the processing optics
mounted.
Conditions
■
■
■
■
Processing optics are ready for operation.
Laser device is ready for operation and assigned to the
machine.
The nozzle is centered to the beam.
Clean, new standard nozzle, ∅ 2.3 mm.
Means, Tools, Materials
■
5‐42
Flat sheet 190 mm x 110 mm, 1 mm thick, stainless steel
(1.4301).
Cutting process setting work
2017-11-17
B836en
■
■
Feeler gage (recommendation 0.3 mm to 0.5 mm).
Test sheet holder for reference part (included in the scope of
delivery of the machine).
or
■
Smart Optics Setup station (option).
Notes
■
■
■
■
When using the Smart Optics Setup station: At the start of
the utility program, the axes position themselves automatically from the current axis position to the respective start
position for the laser processing.
The dynamic cutting optics moves 10 mm away from the
sheet surface at the time of program start.
If the comb structure is not cut out completely, reduce the
"Increment" parameter.
The focus search is carried out with a standard nozzle.
The service program cuts a reference part with this comb structure. A microjoint is set at the end of the contour.
S
Starting point
Reference part
Test sheet set up
Fig. 71594
1. Either
Ø Mount the test sheet holder on the workpiece changer.
or
Ø Swivel the Smart Optics Setup station into the set-up
position.
2. Clamp the test sheet horizontally in the test sheet holder.
B836en
2017-11-17
Cutting process setting work
5‐43
R
Reference position
S
Start position
Fig. 87505
3. Either
Ø If the standard test sheet holder is used: move the TCP
to the start position. Position it approx. 10 mm above the
sheet.
or
Ø When the Smart Optics Setup station is used: To avoid
collisions, the processing optics can be moved to the reference position (cross-hairs) before starting the utility program (recommendation).
4. Acknowledge the danger zone and close the safety door.
Cutting the reference part
5.
6.
7.
8.
If the wizard has not been started yet: start the wizard.
In the table, select Setting focal distance.
Press Continue.
Either
Ø If the focal position is to be checked, activate "Check
focus position and adjust".
or
Ø If the focal position is to be newly determined, activate
"Newly determine focal position and adjust".
9. Select laser technology table for engraving and cutting.
10. Press Continue.
11. Follow the wizard.
The focus search starts. The reference part is cut. Then the
dialog opens again.
5‐44
Cutting process setting work
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B836en
Note
Determining the smallest
kerf
The smallest kerf corresponds to the focal position F=0.
12. Determine the smallest kerf in the reference part:
− With the feeler gauge, starting from the left and right,
respectively, check every individual kerf.
− Mark the kerf and the left and right where the feeler
gauge sticks.
13. In the selection list "Upper limit" and "Lower limit", select the
kerf number for each where the feeler gauge sticks.
The control calculates the number of the smallest kerf as well as
the focal position offset value and visualizes the result:
1
Lower limit selection list
2
Result
3
Upper limit selection list
Fig. 73834
14. Either
Ø Once the focal position offset value lies in the green valid
range, the focus search is completed. Press Finish.
or
Ø If the focal position offset value lies outside of the valid
tolerance, the display is red. Press Continue. Change the
Increment parameter and start the focus search again.
Tip
If the repeated focus search does not lead to a valid result,
check the lens and redetermine the focal position: Select "Newly
determine focal position and adjust" and carry out focus search.
B836en
2017-11-17
Cutting process setting work
5‐45
7.3
Calibrate the B and C axes
The B and C axes are calibrated with a service program and the
reference optics. The service program is started via the Wizard.
The B and C axes must be recalibrated after each manual reference point run.
Conditions
■
■
■
■
■
Processing optics are ready for operation.
Laser device is ready for operation and assigned to the
machine.
The reference optics are installed.
The focal position is determined and set.
The nozzle is centered to the beam.
Means, Tools, Materials
■
■
■
Flat sheet, 150 mm x 100 mm, 3 mm thick, mild steel
Micrometer or slide gauge.
Test sheet holder for reference part (included in the scope of
delivery of the machine).
or
■
Smart Optics Setup station (option).
Notes
■
■
NOTICE
The dynamic cutting optics moves 10 mm away from the
sheet surface at the time of program start.
When using the Smart Optics Setup station: At the start of
the utility program, the axes position themselves automatically from the current axis position to the respective start
position for the laser processing.
Risk of collision of the processing optics when approaching
the reference position if the vertical test sheet is mounted
on the outer side of the test sheet holder.
Ø
The vertical test sheet must always be mounted to the side
facing the working area (inside of the test sheet holder).
The service program cuts a frame with a different B-axis position
(inner contour with B = -90° and outer contour with B = 90°).
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This so-called frame is the reference part. A microjoint is set at
the end of the contour.
Reference part (B frame)
Fig. 71592
The operator measures the 4 sides of the B frame and enters
the dimensions for Z1, Z2, Y1 and Y2 in the dialog.
The control determines the deviation from these measured values and, if required, resets the absolute position 0° for the B
and C axes.
Test sheet set up
1. Either
Ø Mount the test sheet holder on the workpiece changer.
or
Ø Swivel the Smart Optics Setup station into the set-up
position.
2. Clamp the test sheet vertically in the test sheet holder.
3. In MDA operation mode: Move the processing optics to
C = 0 and B = -90.
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Cutting process setting work
5‐47
R
Reference position
S
Start position
Fig. 86916
4. Either
Ø If the standard test sheet holder is used: move the TCP
to the start position. Position it approx. 10 mm above the
sheet.
or
Ø When the Smart Optics Setup station is used: To avoid
collisions, the processing optics can be moved to the reference position (cross-hairs) before starting the utility program (recommendation).
5. Acknowledge the safety circuit and close the safety door.
Cutting the reference part
6.
7.
8.
9.
10.
11.
If the wizard has not been started yet: start the wizard.
In the table, select Calibrate the B and C axes.
Press Continue.
Select the laser technology table for cutting.
Press Continue.
Follow the wizard.
The reference part is cut.
Evaluating the reference part
12. Exactly measure the dimensions for Z1, Z2, Y1 and Y2
(observe engraving and chamfer) and enter in the dialog.
The measurement result is visualized immediately.
If the measured values lie within the tolerance, the display is
green. The box "Apply values" is automatically activated.
If the measurement result is invalid, the display is red. The
values will not be saved.
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Measurement result
Fig. 72869
13. Press Finish.
When saving values, the control forces a warm start. The
new absolute position for the B and C axes takes effect after
a warm start and the booting up of the control. The calibration is completed.
14. Subsequently, the following setting work must be carried out
in this order:
− Determine the tool length for the reference optics. (see
"Determining the Z-axis joint offset", pg. 5‐51)
− Determine the joint offset for the X and Y axes for the
reference optics: (see "Determining X axis and Y axis
joint offset", pg. 5‐53)
− Determine the joint offset of the X and Y axes for all
other optics used on the machine: (see "Determining X
axis and Y axis joint offset", pg. 5‐53)
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Cutting process setting work
5‐49
7.4
Joint offset
Determining the joint offset
The offset value for the X, Y and Z axes between the beam center of the pivot of the B/C angular gear and the beam center of
the focus point (Tool Center Point) is referred to as the joint offset.
The joint offset of the Z axis is calculated from the tool length
plus 1 mm nozzle distance. The joint offset of the Z axis corresponds to the swivel radius of the optics.
1
Beam center of B/C gear pivot
Z
Z axis joint offset
2
Beam center (TCP)
L
Tool length
Y
Y axis joint offset
Joint offset
Fig. 54164
Due to the manufacturing tolerances of the processing optics,
the joint offset on the machine must be determined during the
commissioning of the optics.
The joint offset values are saved in the control and are loaded
automatically in the machine data when the optics are selected.
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Determining the Z-axis joint offset
Using the service program, the joint offset of the Z axis (same
thing as the tool length) is determined. The service program is
started via the Wizard.
A measuring point is recorded to the right and left of the sheet
surface. The control calculates the tool length from these measured values and the sheet thickness entered in the dialog.
Notice! If an incorrect value is entered in the dialog for the
sheet thickness, the calculated tool length will be incorrect!
Conditions
■
■
■
■
Processing optics are ready for operation.
Laser device is ready for operation and assigned to the
machine.
B and C axes are calibrated with the reference optics.
The focus position has been determined.
Means, Tools, Materials
■
■
Flat sheet, 150 mm x 100 mm, 3 mm thick, mild steel
Test sheet holder for reference part (included in the scope of
delivery of the machine).
or
■
Smart Optics Setup station (option).
Notes
■
■
■
Risk of collision of the processing optics when approaching
the reference position if the vertical test sheet is mounted
on the outer side of the test sheet holder.
NOTICE
Ø
B836en
The dynamic cutting optics moves 10 mm away from the
sheet surface at the time of program start.
The optics swivel above the sheet edge by 180° during the
measurement.
When using the Smart Optics Setup station: At the start of
the utility program, the axes position themselves automatically from the current axis position to the respective start
position for the laser processing.
2017-11-17
The vertical test sheet must always be mounted to the side
facing the working area (inside of the test sheet holder).
Cutting process setting work
5‐51
Test sheet set up
1. Either
Ø Mount the test sheet holder on the workpiece changer.
or
Ø Swivel the Smart Optics Setup station into the set-up
position.
2. Clamp the test sheet vertically in the test sheet holder.
3. In MDA operation mode: Move the processing optics to
C = 0 and B = -90.
R
Reference position
S
Start position
Fig. 86916
4. Either
Ø If the standard test sheet holder is used: move the TCP
to the start position. Position it approx. 10 mm above the
sheet.
or
Ø When the Smart Optics Setup station is used: To avoid
collisions, the processing optics can be moved to the reference position (cross-hairs) before starting the utility program (recommendation).
5. Acknowledge the danger zone and close the safety door.
Cutting the reference part
6.
7.
8.
9.
If the wizard has not been started yet: start the wizard.
In the table, select Determining the tool length.
Follow the wizard.
Press Continue.
The message will start immediately. After the end of the
measurement, a dialog will open.
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10. Enter the "Sheet thickness" for the reference part.
11. Press Finish.
The newly determined tool length is saved in the machine
parameter and takes effect immediately.
12. Then, determine the joint offset for the X and Y axes for the
reference optics: (see "Determining X axis and Y axis joint
offset", pg. 5‐53)
Determining X axis and Y axis joint offset
Using the service program, the joint offset of the X and Y axes
is determined. The service program is started via the Wizard.
Conditions
■
■
■
■
■
■
At least the "Advanced" user group is active.
B and C axes are calibrated with the reference optics.
The focus position has been determined.
The tooling status is valid and has been activated.
Processing optics are ready for operation.
Laser device is ready for operation and assigned to the
machine.
Means, Tools, Materials
■
■
■
Flat sheet, 150 mm x 100 mm, 3 mm thick, mild steel
Micrometer or slide gauge.
Test sheet holder for reference part (included in the scope of
delivery of the machine).
or
■
Smart Optics Setup station (option).
Note
The dynamic cutting optics moves 10 mm away from the sheet
surface at the time of program start.
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Cutting process setting work
5‐53
The service program cuts a reference part. The dimensions A, B,
C and D are the adjustment values for calculating the joint offset
values.
Reference part
Test sheet set up
Fig. 71595
1. Either
Ø Mount the test sheet holder on the workpiece changer.
or
Ø Swivel the Smart Optics Setup station into the set-up
position.
2. Clamp the test sheet horizontally in the test sheet holder.
3. In MDA operation mode: Move the processing optics to
C = 0 and B = 0.
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R
Reference position
S
Start position
Fig. 87505
4. Approaching the start or reference position
Ø If the standard test sheet holder is used: move the TCP
to the start position. Position it approx. 10 mm above the
sheet.
or
Ø When the Smart Optics Setup station is used: To avoid
collisions, the processing optics can be moved to the reference position (cross-hairs) before starting the utility program (recommendation).
5. Acknowledge the danger zone and close the safety door.
Cutting the reference part
6.
7.
8.
9.
10.
11.
If the wizard has not been started yet: start the wizard.
Select Determine joint offset XY from the table.
Press Continue.
Select the laser technology table.
Press Continue.
Follow the wizard.
The reference part is cut. Then the dialog opens again.
Evaluating the reference part
12. Exactly measure the webs A, B, C and D and enter the
measured values in the dialog.
The measurement result is visualized immediately.
If the measured values lie within the tolerance, the display is
green. The box "Apply values" is automatically activated.
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Cutting process setting work
5‐55
If the measurement result is invalid, the display is red. The
values will not be saved.
13. Press Finish.
When the values are saved, the determined joint offset values are saved in the machine parameters and take effect
immediately.
Tip
If no valid result is found, check the positions of the B and C
axes.
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8.
Measuring equipment
overview
Calibrating the measuring equipment
The following measuring equipment can be used for measurement:
■
■
Offline measurement with ControlLine (standard) distance
regulation, ControlLine can measure only in the beam direction (Z direction).
Offline measurement with sensor (option).
Danger of collision with work piece or fixtures due to nonauthorized measuring equipment!
NOTICE
Ø
Putting the measuring
equipment into service
Only the sensor is allowed to be used on the machine.
The sensor has to be activated and then calibrated each time it
is mounted at the B/C gearbox. The selection is made via the
tooling status administration.
After the activation, the actual joint offset values are determined
by calibration. After calibration, the sensor is ready for operation.
Instead of the processing optics, the sensor is installed on the B/
C gearbox.
The following functions are automatically deactivated as soon as
the sensor is activated:
■
■
■
■
■
The beam tube ventilation is switched off.
The cooling water monitoring is hidden.
ControlLine is deactivated.
Alignment laser is deactivated.
The laser switches to the laser test mode.
Note
A NC program can be started in the test mode using the sensor.
Programming of
measurement functions
Measuring ball fixture
The measurement and evaluation of the measuring data is programmed in the NC program with the measuring cycles (NC
cycles).
The measuring ball fixture (option) is used to calibrate the
sensor as an alternative if no Smart Optics Setup station (option)
is mounted on the machine Smart Optics Setup Station.
The measuring ball fixture is positioned in the working range on
the workpiece changer in such a way that no collision with the
fixture is possible during calibration.
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Calibrating the measuring equipment
5‐57
Sensor and measuring ball fixture
Smart Optics Setup Station
Fig. 78074
The Smart Optics Setup function is a machine option. It can be
used in combination with the "measuring ball" setting device to
calibrate the sensor.
1
Measuring ball
2
Reference position
"Measuring ball" setting device
Fig. 84222
The setting device is swiveled into the working position and
locked in place for the calibration. The "measuring ball" setting
device (material no. 2248971) is inserted in the setting device
horizontally and fixed with the knurled screws.
Note
Operate the Smart Optics Setup station: (see
"Smart Optics Setup", pg. 5‐17).
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8.1
Mounting and activating the sensor
When starting up the machine, the sensor (option) is activated in
the tooling status administration.
When retrofitting the probe's sensor by the Technical Service
TRUMPF, the probe must be, for example, activated by Teleservice so that the probe can be selected in the tooling status
administration.
Condition
■
1
2
The machine is ready for operation.
Connection of the magnetic
coupling
3
Cooling water bridging
4
Magnetic coupling
Sensor connection
Connecting the sensor
Installing the sensor
Fig. 62024
1. Remove the processing optics.
2. Install the sensor to the magnetic flange of the B-/C gearbox.
The green LED on the magnetic coupling lights up when the
processing optics are docked correctly.
Activating the sensor
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2017-11-17
3. Press Technology, select "Tooling status management".
4. Select the valid tooling status.
Calibrating the measuring equipment
5‐59
1
Sensor
Tooling status administration
Fig. 77375
5. Select "Sensor".
6. Select "Measuring probe".
7. Press Finish.
The sensor is activated but not yet ready for operation.
8. Then calibrate the sensor.
8.2
Calibrating the sensor
Every brand new sensor must be started up at the machine. At
the time of initial start-up, the control writes the default joint offset values for the sensor into the machine data. The actual joint
offset values must be determined by means of a calibration.
The sensor is calibrated with the utility program and a measuring
ball.
The utility program performs a measuring cycle and determines
the joint offset values of the sensor. The configuration in the control is immediately effective after the transfer of the geometric
data.
The sensor must be recalibrated:
■
■
5‐60
After the initial start-up.
After each assembly at the magnetic flange.
Calibrating the measuring equipment
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B836en
Condition
■
Sensor is activated.
Means, Tools, Materials
■
Measuring ball fixture (option).
or
■
"Measuring ball" setting device (Smart Optics Setup option).
Notes
■
■
■
The last determined geometric data is kept in case of a program interruption.
If the measuring ball and the measuring probe are not correctly screwed in, the measurement can be faulty.
To prevent a collision, a clearance of about 50 mm around
the measuring ball has to be maintained during the calibration.
1. Positioning the measuring ball fixture
Ø Swivel the Smart Optics Setup station into the work area
and lock it in place. Mount the measuring ball setting
device.
or
2.
3.
4.
5.
6.
7.
Ø Position the measuring ball fixture in the work area on
the workpiece changer.
In MDA operation mode: Move the processing optics to
C = 0 and B = 0.
Position the sensor about 10 mm above the measuring ball.
Start the wizard:
− Press Production, select "Utility tools".
− Select the utility program CP_HEAD_SETUP and press
Execute.
− Press the START button.
Under "Setting work", select "Determine joint offset XYZ".
Press Continue.
Either
Ø If the sensor is already positioned: Press Finish.
or
Ø If the start position or the reference position is to be reapproached or corrected:
− Follow the wizard.
− Press Continue.
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Calibrating the measuring equipment
5‐61
The measuring cycle starts. After the end of the measurement, the newly determined joint offset values and the previously saved values are displayed.
1
Previous values
2
Newly determined values
Joint offset values sensor
Fig. 77376
8. Press Finish.
The newly determined geometric data is saved in the tooling status administration. The sensor is ready for operation.
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9.
Clamping fixture
Setting up the clamping fixture
A clamping fixture can be used on different machines or different
production places without having to change the NC program.
In order to compensate for the system tolerances, the fixture
position must be remeasured on the workpiece changer every
time it is remounted. The prerequisite for this is that there be
at least 3 reference elements on the fixture or workpiece, e.g.
measuring balls.
Measuring position
The measuring ball positions are determined during the start-up
of the clamping fixture on the machine and remain saved in the
control until they are changed either by entering or by re-measuring the ball position.
1
Measurement nozzle
2
Measuring ball
Measuring ball position
Fig. 78082
The utility program CP_FIXTURE_SETUP measures the position
of the vertex as well as 2 positions on the ball circumference,
while the measuring nozzle or sensor touches the measuring ball
at these places.
Thereby, the axes carry out a compensating movement about
the Tool Center Point. The interference contour which arises due
to the cutting optics must be observed and can be tested in
advance with the teach panel.
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Setting up the clamping fixture
5‐63
Risk of collision during the measurement between
processing optics and fixture parts, e.g., from the clamp.
NOTICE
Ø
Ø
Measuring nozzle
There must be a clearance of at least 30 mm in all directions between the center of the measuring ball and clamping
fixture or fixture parts.
Before measurement with the teach panel, test the measuring sequence, and therefore interference contour, for each
measuring ball.
The ball position is normally measured with a measuring nozzle.
Instead of the cutting nozzle, the measuring nozzle is screwed
into the sensor body of the cutting optics.
Fig. 86277
The following operations have to be performed after mounting
the measurement nozzle:
■
■
Recording the characteristic curve again for ControlLine.
Activate LASER TEST.
Notes
■
■
Sensor
Up to the machine serial release S02, a longer measuring
nozzle (mat. no. 1821503) with a length of 11 mm was used.
Starting from machine serial release S03, a shorter measuring nozzle (mat. no. 2086798) with a length of 5.5 mm is
used.
Alternatively, the position of the measuring balls can be measured at the fixture using the sensor.
Prerequisites:
■
■
5‐64
The valid tooling status has been activated for the sensor.
The sensor has been calibrated.
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Note
To calibrate the sensor, see the operator's manual for the
machine, chapter "Setting work", section "Calibrating the measuring equipment".
Correction frame
Each ball position is measured sequentially and offset against
the required ball position with the CP_FIXTURE_SETUP.LST utility program.
The difference between the actual and required position results
in a correction frame, which is set in the NC program with a zero
point offset (SET_G54, SET_G55, SET_G56 or SET_G57) and
the NC cycle TC_FIXTURE_ACTIVATE for this fixture.
The position of the fixture, and therefore the workpiece zero
point, is corrected in the workpiece coordinate system (WCS)
through rotation and translation.
Displacement by rotation and translation
Fig. 78076
The correction frame must be re-determined under the following
conditions:
■
■
Determining and activating
the correction frame
To determine the correction frame, the following operations have
to be performed:
■
■
■
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2017-11-17
After every remounting of the fixture on the fixture place.
After a deletion or change of the zero point memory G54,
G55, G56 or G57.
Step 1: Start the CP_FIXTURE_SETUP.LST utility program.
Step 2: First determine the required position for all 3 measuring balls. There are two ways of doing this:
− Either measure the required position (see "Measuring the
required position", pg. 5‐71).
− Or enter the required position (see "Entering the required
position", pg. 5‐69).
Step 3: Afterwards, measure the actual position for all
3 measuring balls (see "Measuring the actual position",
pg. 5‐72).
Setting up the clamping fixture
5‐65
■
■
Step 4: If the required and actual positions of the measuring
balls are known, transfer the adjustment values to the control
(see "Determining the correction frame", pg. 5‐74).
Step 5: Afterwards, set the zero point offset in the processing program for the respective fixture and correct the zero
point memory with the NC cycle TC_FIXTURE_ACTIVATE.
Note
Activate the correction frame: see the programming manual,
chapter "Automation", section "Clamping fixture".
9.1
Starting the utility program
The fixture position is measured using the utility program
CP_FIXTURE_SETUP.LST. The utility program is started in the
main operation Production.
After starting the utility program, a dialog appears. The following
operations are started and executed one after the other:
■
■
■
■
"Measure nominal position": The required positions of the
three measuring balls are measured.
"Enter nominal position": As an alternative to measuring, the
required positions can be input in the dialog, assuming they
are known.
"Measure actual position": The actual positions of the three
measuring balls are measured.
"Transfer correction values to control": After the required and
actual positions are determined, these are transferred to the
control, the control calculates the correction frame.
Conditions
■
■
■
■
■
■
Laser test function is active: The LASER TEST button lights
up.
Cutting optics with measuring nozzle are installed.
Characteristic curve for ControlLine has been recorded (with
mounted measuring nozzle).
The distance regulation is switched on.
The measuring ball diameter and the fixture designation are
known.
At least the "Advanced" user group is active.
Notes
■
5‐66
First check which measuring nozzle is used: the short nozzle
(length 5.5 mm), material number 2086798, or the long nozzle (length 11 mm), material number 1821503.
Setting up the clamping fixture
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B836en
■
■
The fixture must be created in the utility program. The operator can add or remove a fixture designation in the "Measure
nominal position" or "Enter nominal position" dialog.
Recommendation: Before a measuring sequence is started,
the interference contour should be checked for every measuring ball with the teach panel in order to prevent collisions
during the measurement.
1. Press Production, select "Utility tools".
2. Select the utility program CP_FIXTURE_SETUP and press
Execute.
The utility program starts. The "Measure fixture" dialog is
opened.
1
Operation
Fig. 84221
3. After changing the measuring nozzle:
− Press Select measuring nozzle.
− Select the material number of the measuring nozzle.
− Press OK.
4. Measure the required positions of the measuring balls (see
"Measuring the required position", pg. 5‐71).
or
Ø Enter the required positions of the measuring balls (see
"Entering the required position", pg. 5‐69).
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Setting up the clamping fixture
5‐67
9.2
Checking the measuring sequence
(option)
To avoid collisions between the cutting optics and the fixture or
the workpiece during the subsequent measurement, the measuring sequence and thus the interference contour around the
measuring ball can be tested first using the teach panel.
The test conditions must correspond to the measuring situation
later on. The following conditions must be met for this:
■
■
■
The test position of the axes corresponds to the nominal
position of the measuring balls. In particular, the position of
the B axis and of the C axis must be identical.
The test is carried out with the identical measuring nozzle.
The ball diameter must agree.
Conditions
■
■
The ball diameter is known and is correctly entered in the
utility program.
The utility program CP_FIXTURE_SETUP is started.
Notes
■
■
The ball diameter can only be changed in the utility program
on the control panel.
The function key F2 on the teach panel is preassigned with
the Check measuring sequence function.
1. Activate TEACHIN operating mode.
2. Position the measuring nozzle approx. 5 mm over the first
ball.
3. Press the F2 button.
The measuring sequence is started immediately and the
interference contour is tested.
4. Test the measuring sequence for the second ball:
− Position the measuring nozzle over the second ball.
− Press the F2 button.
The measuring sequence is started immediately.
5. Test the measuring sequence for the third ball:
− Position the measuring nozzle over the third ball.
− Press the F2 button.
The measuring sequence is started immediately.
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9.3
Entering the required position
As an alternative to measuring the required positions on the
three measuring balls, the required positions can be entered in a
dialog or also just be checked.
The positions of the linear axes, X, Y and Z, correspond to the
measuring ball center. The positions for the B and C axes correspond to the axis positions at the start of the measuring
sequence.
Conditions
■
■
■
The measuring ball diameter and the fixture designation are
known.
The ball positions are known for all linear axes.
The utility program CP_FIXTURE_SETUP is started.
Note
The last saved ball positions are always shown in the dialog.
1. Select "Enter required position" and press Continue.
The "Enter nominal position" dialog is opened.
1
Fixture designation
3
Ball diameter
2
Ball number
4
Required position
Fig. 86906
2. If the fixture has not yet been created in the utility program:
− Press Add designation.
− Enter the fixture designation.
− Press OK.
3. Determine the fixture and the measuring ball:
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Setting up the clamping fixture
5‐69
4.
5.
6.
7.
5‐70
− Select the "Designation" of the fixture.
− Select "Ball roller number" 1.
− Enter "Ball diameter".
Enter the axis positions for ball number 1 and press Next.
Select "Ball roller number" 2, enter the axis positions and
press Next.
Select "Ball roller number" 3, enter the axis positions and
press Next.
Afterwards, measure the actual positions of the measuring
balls (see "Measuring the actual position", pg. 5‐72).
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9.4
Measuring the required position
As an alternative to entering the required position, the required
positions of the measuring balls can be determined through
measurement.
Conditions
■
■
The measuring ball diameter and the fixture designation are
known.
The utility program CP_FIXTURE_SETUP is started.
Notes
■
■
Measuring the first ball
position
The last saved ball positions are always shown in the dialog.
The ball positions can be approached with the teach panel,
for example, or by using the JOG buttons.
1. Position the measuring nozzle above the first measuring ball.
2. Press the START button.
3. Select "Measuring required position" and press Continue.
The "Measure nominal position" dialog appears.
1
Fixture designation
2
Ball number
3
Ball diameter
Fig. 84215
4. If the fixture has not yet been created in the utility program:
− Press Add designation.
− Enter the fixture designation.
− Press OK.
5. Determine the fixture and the measuring ball:
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Setting up the clamping fixture
5‐71
− Select the "Designation" of the fixture.
− Select "Ball roller number" 1.
− Enter "Ball diameter".
6. Press Continue.
The measuring starts.
Measuring the second ball
position
7. Once the measurement has finished, position the measuring
nozzle over the second measuring ball.
8. Press the START button.
9. Select "Measuring required position" and press Continue.
10. Select "Ball roller number" 2 and press Next.
The measuring starts.
Measuring the third ball
position
11. Once the measurement has finished, position the measuring
nozzle above the third measuring ball.
12. Press the START button.
13. Select "Measuring required position" and press Continue.
14. Select "Ball roller number" 3 and press Next.
The measuring starts.
15. Afterwards, measure the actual positions of the measuring
balls (see "Measuring the actual position", pg. 5‐72).
9.5
Measuring the actual position
To calculate the correction frame, the actual positions of the
three measuring balls must be determined.
Conditions
■
■
■
The measuring ball diameter and the fixture designation are
known.
The required positions for the three measuring balls are
determined.
The utility program CP_FIXTURE_SETUP is started.
Note
The ball positions can be approached with the teach panel, for
example, or by using the JOG buttons.
When the "Measure actual position" dialog opens, the last saved
ball positions for the actual and required positions are displayed.
If there are no valid position values for a ball, the display fields
5‐72
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B836en
of the required position are marked with this error symbol .
Here, a distinction is made between the following cases:
■
■
If an error symbol is displayed for the axes, there are no
saved required positions for this measuring ball. In this case,
the required position must be entered or measured first.
If an error symbol is displayed for the B and/or C axis, the
current position of the B axis and/or C axis deviates by more
than 3° from the saved required position. In this case, the
position of the respective axis must be corrected.
Fig. 86907
Measuring the first ball
position
1. Position the measuring nozzle above the first measuring ball.
2. Press the START button.
3. Select "Measuring actual position" and press Continue.
The "Measure actual position" dialog is opened.
1
Fixture designation
3
Ball number
2
Fixture place
4
Ball diameter
Fig. 86908
B836en
2017-11-17
Setting up the clamping fixture
5‐73
4. Determine the fixture, fixture place and measuring ball:
− Select the "Designation" of the fixture.
− Select a "Fixture place".
− Select "Ball roller number" 1.
− Enter "Ball diameter".
5. Press Continue.
The measuring starts.
Measuring the second ball
position
6. Once the measurement has finished, position the measuring
nozzle over the second measuring ball.
7. Press the START button.
8. Select "Measuring actual position" and press Continue.
9. Select "Ball roller number" 2 and press Next.
The measuring starts.
Measuring the third ball
position
10. Once the measurement has finished, position the measuring
nozzle above the third measuring ball.
11. Press the START button.
12. Select "Measuring actual position" and press Continue.
13. Select "Ball roller number" 3 and press Next.
The measuring starts.
14. Once the required and actual positions have been determined for all measuring balls, calculate the correction frame
(see "Determining the correction frame", pg. 5‐74).
9.6
Determining the correction frame
The control calculates a correction value for the rotary and translational offset of the fixture or workpiece position from the stored
required and actual positions.
Condition
■
The required and actual positions for all measuring balls are
determined.
1. Press the START button.
2. Select "Transfer the correction values to the control".
3. Press Finish.
The determined required and actual values are transferred to
the control and the correction frame is calculated. The utility
program is ended. This completes the setup of the clamping
fixture.
5‐74
Setting up the clamping fixture
2017-11-17
B836en
4. Set the zero point offset in the processing program and activate the correction frame with the NC cycle TC_FIXTURE_ACTIVATE.
B836en
2017-11-17
Setting up the clamping fixture
5‐75
5‐76
Setting up the clamping fixture
2017-11-17
B836en
Chapter 6
Machine maintenance
1
General guidelines
6‐5
2
Maintenance Overview
6‐6
3
Safety device
6‐10
3.1
Overview
6‐10
3.2
Maintenance Instructions
6‐12
Light grid
6‐12
Laser scanner
6‐13
4
Laser protection device
6‐16
4.1
Overview
6‐16
4.2
Maintenance Instructions
6‐18
Safety cabin
B836en
2017-11-17
6‐18
5
Lubrication
6‐24
5.1
Overview
6‐24
5.2
Maintenance Instructions
6‐25
Machine maintenance
6‐1
X axis drive
6‐25
Y axis drive
6‐31
Z axis drive
6‐37
Device panel: Low-viscosity grease reservoir central lubrication
6‐44
6
Mechanical elements
6‐46
6.1
Overview
6‐46
6.2
Maintenance Instructions
6‐47
Machine and workspace
6‐47
Magnetic coupling
6‐56
Smart Optics Setup station
6‐58
Z barrel
6‐60
7
Pneumatic system
6‐61
7.1
Overview
6‐61
7.2
Maintenance Instructions
6‐62
Device panel: Maintenance unit basic
machine
6‐62
Device panel: Maintenance unit cutting gas
air (option)
6‐64
Device panel: service unit for expanded
compressed air supply or vacuum ejectors
(option)
6‐65
Device panel: Condensation collection tank
6‐66
Cutting optics: disposable filter, pneumatic
connection
6‐67
8
Gas
6‐68
8.1
Maintenance Instructions
6‐68
Cutting optics: disposable filter, gas connection
6‐2
Machine maintenance
6‐68
9
Water
6‐69
9.1
Overview
6‐69
9.2
Maintenance Instructions
6‐72
Cooling circuit of the machine
6‐72
Machine cooler (option), water/air chiller
6‐74
Machine cooler (option), water/water chiller
6‐81
10
Optics
6‐86
10.1
Overview
6‐86
10.2
Maintenance Instructions
6‐88
2017-11-17
B836en
B836en
2017-11-17
Cutting optics with a focal length of 150 mm
6‐88
Cutting optics with a focal length of 200 mm
6‐101
Angular gear: FocusLine mirror
6‐114
11
Electrics
6‐118
11.1
Overview
6‐118
11.2
Maintenance Instructions
6‐118
Switch cabinet: Battery/fan unit, NC CPU
6‐118
Switch cabinet: Industrial PC
6‐119
Switch cabinet: Air conditioning unit
6‐120
12
Compact dust extractor
6‐122
12.1
Overview
6‐122
12.2
Maintenance Instructions
6‐123
Compact dust extractor: dust container/fine
dust bag
6‐123
Compact dust extractor: spark arrester
6‐127
Compact dust extractor: clean gas space
6‐128
Compact dust extractor: MultiCoater
6‐130
13
Scrap conveyor
6‐133
13.1
Maintenance Instructions
6‐133
Scrap conveyor: Sensors
6‐133
Scrap conveyor: pedestal bearing
6‐134
Scrap conveyor: lubricant container
6‐135
Scrap conveyor: conveyor belt
6‐136
Scrap conveyor: housing bottom
6‐137
14
Clamping fixture
6‐140
14.1
Maintenance Instructions
6‐140
Clamping fixture for hot-formed parts
6‐140
Clamping fixture for IHU workpieces
6‐141
15
TruDisk
6‐144
15.1
Overview
6‐144
15.2
Maintenance Instructions
6‐145
TruDisk cooling circuit
6‐145
16
Process cooler for TruDisk (chiller)
6‐146
16.1
Overview
6‐146
16.2
Maintenance Instructions
6‐147
Machine maintenance
6‐3
Process cooler: chiller (water-air)
6‐4
Machine maintenance
2017-11-17
6‐147
B836en
1.
Safety
General guidelines
Correct maintenance and cleaning are essential for maintaining
the quality of the machine. That prevents operational malfunctions and their consequences.
For maintenance work inside the safety cabin the work area
illumination must remain switched on, so do not switch the
machine's MAIN SWITCH off.
There is a risk of fatal injury during maintenance inside the
safety cabin.
DANGER
Ø
Ø
B836en
2017-11-17
If not expressly described otherwise: Before starting maintenance work, press the EMERGENCY STOP push-button.
Strictly comply with the safety regulations.
General guidelines
6‐5
2.
Maintenance Overview
Interval/
operating
hours
Maintenance point
Maintenance work
Page
Daily
Light grid
Checking the protected field
6‐12
Daily
Laser scanner
Checking the protected field
6‐13
Daily
Safety cabin
Check the safety cabin
6‐18
Daily
Safety cabin
Checking the sealing strips and the partition wall
6‐19
Daily
Safety cabin
Checking the viewing window
6‐19
Daily
Machine and workspace
Check the air extraction pipe protective
screen
6‐47
Daily
Clamping fixture for IHU workpieces
Check and clean the positioner
6‐141
Daily
Clamping fixture for IHU workpieces
Check and replace the ball roller
6‐142
Daily
Clamping fixture for IHU workpieces
Clean the fixture
6‐142
Weekly
Machine and workspace
Clean the air extraction pipe protective
screens
6‐47
Weekly
Machine and workspace
Cleaning the exhaust piping
6‐48
Weekly
Machine and workspace
Clean the control panel and monitor
6‐49
Weekly
Machine and workspace
Cleaning the dirt trap and bellows
6‐49
Weekly
Machine and workspace
Clean the machine and working area
6‐50
Weekly
Compact dust extractor: dust container/
fine dust bag
Checking the level and replacing the container or fine dust sack
6‐124
Weekly
Compact dust extractor: spark arrester
Cleaning the spark arrester
6‐127
Weekly
Clamping fixture for hot-formed parts
Cleaning the guard plates, slag channel
and cover
6‐140
Monthly
X axis drive
Checking the lubricating pinion
6‐25
Monthly
X axis drive
Clean the guide rails, stripper and rack
6‐26
Monthly
Y axis drive
Checking the lubricating pinion
6‐31
Monthly
Y axis drive
Clean the guide rails, stripper and rack
6‐32
Monthly
Z axis drive
Checking the lubricating pinion and the
rack
6‐37
Monthly
Z axis drive
Cleaning the grease collecting vessel and
drip tray
6‐38
Monthly
Z axis drive
Clean the guide rails and stripper
6‐39
Monthly
Z barrel
Checking hose connections and quickrelease couplings
6‐60
Monthly
Device panel: Maintenance unit basic
machine
Checking and setting the static operating
pressure
6‐62
Monthly
Device panel: service unit for expanded
compressed air supply or vacuum
ejectors (option)
Checking and setting the static operating
pressure
6‐65
Monthly
Device panel: Condensation collection
tank
Check filling level
6‐66
Monthly
Machine cooler (option), water/water
chiller
Check filling level
6‐81
Monthly
Scrap conveyor: housing bottom
Cleaning the housing bottom
6‐137
Every 6
months
X axis drive
Replacing the lubricating pinion
6‐28
6‐6
Maintenance Overview
2017-11-17
B836en
Interval/
operating
hours
Maintenance point
Maintenance work
Page
Every 6
months
X axis drive
Replacing strippers
6‐29
Every 6
months
Y axis drive
Replacing the lubricating pinion
6‐34
Every 6
months
Y axis drive
Replacing strippers
6‐35
Every 6
months
Z axis drive
Replacing the lubricating pinion
6‐40
Every 6
months
Z axis drive
Replacing strippers
6‐42
Every 6
months
Z axis drive
Cleaning the rack
6‐43
Every 6
months
Device panel: Maintenance unit basic
machine
Replace the filter element
6‐63
Every 6
months
Device panel: Maintenance unit cutting
gas air (option)
Replace the filter element
6‐64
Every 6
months
Device panel: service unit for expanded
compressed air supply or vacuum
ejectors (option)
Replace the filter element
6‐66
Every 6
months
Cutting optics: disposable filter, pneumatic
connection
Exchange filter insert or filter
6‐67
Every 6
months
Cutting optics: disposable filter, gas connection
Exchange filter insert or filter
6‐68
Every 6
months
Compact dust extractor: MultiCoater
Replacing the pressure regulating valve
filter cartridge
6‐132
Every 6
months
Scrap conveyor: conveyor belt
Checking and setting the chain tension
6‐136
Annually
Machine and workspace
Check the door seal
6‐50
Annually
Machine and workspace
Clean beneath the platform
6‐51
Annually
Cooling circuit of the machine
Checking the flow controller
6‐72
Annually
Machine cooler (option), water/air chiller
Replace cooling water
6‐76
Annually
Machine cooler (option), water/air chiller
Replace the filter element.
6‐80
Annually
Machine cooler (option), water/water
chiller
Replace cooling water
6‐81
Annually
Machine cooler (option), water/water
chiller
Replace the filter element.
6‐85
Annually
Switch cabinet: Battery/fan unit, NC CPU
Replacing the buffer battery
6‐118
Annually
Switch cabinet: Industrial PC
Replacing the buffer battery
6‐119
Annually
Switch cabinet: Air conditioning unit
Cleaning the air conditioning unit
6‐120
Annually
Compact dust extractor: clean gas space
Check and clean
6‐128
Annually
Compact dust extractor: MultiCoater
Checking and replacing the seal
6‐131
Annually
Scrap conveyor: pedestal bearing
Lubricate the pedestal bearing
6‐134
Annually
Scrap conveyor: housing bottom
Cleaning the bottom of the housing in the
area of the bend
6‐138
Annually
TruDisk cooling circuit
Replacing cooling water and cleaning the
tank
6‐145
Annually
Process cooler: chiller (water-air)
Replacing the filter mat
6‐147
Annually
Process cooler: chiller (water-air)
Replace cooling water
6‐149
B836en
2017-11-17
Maintenance Overview
6‐7
Interval/
operating
hours
Maintenance point
Maintenance work
Page
Every 5 years
Switch cabinet: Industrial PC
UPS module, replacing the rechargeable
battery pack
6‐120
As needed
Light grid
Cleaning the front screen
6‐12
As needed
Laser scanner
Cleaning the optical window
6‐14
As needed
Safety cabin
Cleaning the laser protection window
6‐20
As needed
Safety cabin
Replacing the monitor
6‐20
As needed
Safety cabin
Replacing the status indicator
6‐22
As needed
Machine and workspace
Replace the X axis bellows
6‐52
As needed
Machine and workspace
Replace the Y axis bellows
6‐54
As needed
Magnetic coupling
Clean and check
6‐56
As needed
Smart Optics Setup station
Cleaning the test sheet holder
6‐58
As needed
Smart Optics Setup station
Replacing the test sheet holder
6‐59
As needed
Cutting optics with a focal length of
150 mm
Clean the housing
6‐88
As needed
Cutting optics with a focal length of
150 mm
Checking, cleaning or replacing the lens
6‐91
As needed
Cutting optics with a focal length of
150 mm
Checking, cleaning or replacing the
deflection mirror
6‐97
As needed
Cutting optics with a focal length of
150 mm
Cleaning the sensor body and the nozzle
6‐98
As needed
Cutting optics with a focal length of
150 mm
Replacing the sensor body
6‐99
As needed
Cutting optics with a focal length of
200 mm
Clean the housing
6‐101
As needed
Cutting optics with a focal length of
200 mm
Checking, cleaning or replacing the lens
6‐104
As needed
Cutting optics with a focal length of
200 mm
Checking, cleaning or replacing the
deflection mirror
6‐110
As needed
Cutting optics with a focal length of
200 mm
Cleaning the sensor body and the nozzle
6‐111
As needed
Cutting optics with a focal length of
200 mm
Replacing the sensor body
6‐112
As needed
Angular gear: FocusLine mirror
Checking and cleaning the deflection mirror
6‐114
As needed
Scrap conveyor: Sensors
Cleaning sensors
6‐133
As needed
Clamping fixture for hot-formed parts
Replacing the wearing parts
6‐140
As needed
Clamping fixture for IHU workpieces
Replacing the wearing parts
6‐143
As needed
Process cooler: chiller (water-air)
Checking for coolant circuit leakage
6‐148
When indicated by the
control system
Device panel: Low-viscosity grease reservoir central lubrication
Filling the low-viscosity grease reservoir
6‐44
When indicated by the
control system
Machine cooler (option), water/air chiller
Checking and refilling the level
6‐74
6‐8
Maintenance Overview
2017-11-17
B836en
Interval/
operating
hours
Maintenance point
Maintenance work
Page
When indicated by the
control system
Machine cooler (option), water/air chiller
Clean the filter mat
6‐74
When indicated by the
control system
Compact dust extractor: dust container/
fine dust bag
Replacing the dust container
6‐125
When indicated by the
control system
Compact dust extractor: MultiCoater
Topping up dispensing material
6‐130
When indicated by the
control system
Scrap conveyor: lubricant container
Filling the lubricant container
6‐135
When indicated by the
control system
TruDisk cooling circuit
Cleaning or replacing the contamination
filter
6‐145
When indicated by the
control system
TruDisk cooling circuit
Replacing the water microfilter
6‐145
When indicated by the
control system
Process cooler: chiller (water-air)
Checking and refilling the level
6‐148
B836en
2017-11-17
Maintenance Overview
6‐9
1
Light grid
3.
Safety device
3.1
Overview
2
Laser scanner
3
Protective wall
Safety device for rotational changer, Basic Loading variant
1
Light grid
2
Mirror post/ deflection mirror
Fig. 71173
3
Laser scanner
Safety device for rotational changer, Comfort Loading variant
6‐10
Safety device
Fig. 74485
2017-11-17
B836en
1
Protective wall
2
Safety strip
3
Laser scanner
4
Light grid
Safety device height, rotary indexing table, Comfort Loading variant
Fig. 71174
The following devices will be used to safeguard the danger
zones:
■
■
■
B836en
2017-11-17
Safety light curtain made by Sick, C4000 transmitter, 40 mm
resolution (TRUMPF material no. 0370953).
Safety light curtain made by Sick, C4000 receiver, 40 mm
resolution (TRUMPF material no. 0373297).
S300 Mini safety laser scanner 3 m, made by Sick (TRUMPF
material no. 1803143).
Safety device
6‐11
3.2
Maintenance Instructions
Light grid
(see "Overview", pg. 6‐10)
105444:
Checking the protected field
Maintenance interval: Daily
The protected field must be checked every day, preferably at the
beginning of the shift. The light grid belongs to the machine's
safety equipment.
The machine may not be put into operation unless the operational safety of the protected field is ensured.
Maintenance work on the light grid may only be performed by
specialist personnel trained in these areas.
Means, Tools, Materials
■
Test rod (included in the scope of delivery of the light grid).
Ø Slowly move the test rod along the entire protected field,
while watching the display on the receiver.
The protected field is OK if the green or yellow operational status indicator on the receiver does not light up while the check is
being made.
105172:
Cleaning the front screen
Maintenance interval: As needed
If the operational status indicator on the receiver lights up in
orange, then the front screen must be cleaned.
Maintenance work on the light grid may only be performed by
specialist personnel trained in these areas.
Means, Tools, Materials
■
■
Anti-static plastic cleaner (SICK item no. 5600006)
SICK lens cloth (item no. 4003353)
Notes
■
■
Do not use any aggressive or abrasive cleaning agents.
If the operational status indicator on the receiver continues to
be illuminated in orange after cleaning, then realign the light
grid.
1. Remove the dust from the front screen using a clean and
soft brush.
6‐12
Safety device
2017-11-17
B836en
2. Afterwards, clean with a damp cloth and plastic cleaning
agent.
3. Check the protected field.
Laser scanner
(see "Overview", pg. 6‐10)
106689:
Checking the protected field
Maintenance interval: Daily
The protected field must be checked every day, preferably at the
beginning of the shift.
The laser scanner is a safety device of the machine. The
machine may only be put into operation if the protective device
is effective.
According to the applicable national regulations, the laser scanner must be checked by a skilled person within the required
period of time.
Conditions
■
■
1
The machine is ready for operation.
The protected field is not interrupted. The "Warning field"
indicator will not light up.
Warning field indicator light
Laser scanner
B836en
2017-11-17
Fig. 84214
Safety device
6‐13
1. Enter the protected field from the front in the direction of the
laser scanner. During this, check whether the "Warning field"
indicator lights up.
2. For machines with a rotational changer and with the Comfort Loading safeguarding device variant.
Then access the protected field from the left and then from
the right in the direction of the laser scanner while checking
the indicator light..
3. If the indicator lights up for all three test points, when
accessing the protected field, then the laser scanner is OK
and the safety device is effective.
or
Ø If the display does not light up for at least one test point
then there is a fault. The machine may only be put back
into operation once the error has been eliminated.
106792:
Cleaning the optical window
Maintenance interval: As needed
If the indicator for the optical window flashes or lights up, then
the optical hood and window must be cleaned.
If the optical hood or the window is damaged, then the complete
optical hood can be replaced (see the operator's manual from
Sick, S300 Mini type laser scanner).
Means, Tools, Materials
■
■
Anti-static plastic cleaner (SICK item no. 5600006)
SICK lens cloth (item no. 4003353)
Note
Do not use any aggressive or abrasive cleaning agents.
6‐14
Safety device
2017-11-17
B836en
1
Optical hood
2
Optical window
3
Optical window indicator light
Checking the laser scanner
Fig. 71177
1. Lift and remove the protective cover.
2. First remove the abrasive cutting dust using compressed air
or a soft brush.
3. Afterwards, clean the optical hood and window with a moist
cloth and plastic cleaner.
4. Refit the protective hood.
5. Then check the laser scanner.
B836en
2017-11-17
Safety device
6‐15
WARNING
4.
Laser protection device
4.1
Overview
Invisible, high-energy laser radiation!
Damage to your eyesight or even complete blindness can
be the consequence. Serious skin burns can occur.
Ø
Ø
Ø
Ø
Ø
6‐16
Laser protection device
The machine may only be used with active laser safety devices.
Laser safety devices must not be removed.
Every day, visually inspect the safety cabin, viewing window,
partition wall and sealing strips for damage, before switching
the machine on, or before starting the shift.
The machine must not be put into operation, if any of the
mentioned laser safety devices is damaged or missing.
With the exception of sealing strips, laser safety devices
may only be replaced by TRUMPF service staff.
2017-11-17
B836en
1
Safety cabin sealing strips
(green)
2
Partition wall sealing strips (red)
3
Rotational changer partition wall
4
Laser protective window
5
Conveyor/safety cabin interface
Overview of the safety cabin with a rotational changer
B836en
2017-11-17
Fig. 71420
Laser protection device
6‐17
1
Conveyor/safety cabin interface
3
Partition wall sealing strips (red) 5
2
Safety cabin sealing strips
(green)
4
Rotary indexing table partition
wall
Laser protection window
Overview of the safety cabin with a rotary indexing table
4.2
Fig. 71421
Maintenance Instructions
Safety cabin
(see "Overview", pg. 6‐16)
105170:
Check the safety cabin
Maintenance interval: Daily
A visual inspection is carried out.
1. Check the safety cabin for damage, especially the interfaces
to the scrap conveyor, to the rotational changer or the rotary
indexing table.
2. Do not put the machine into operation if a safety device is
damaged (deep scorching, hole, crack, etc.). Replace damaged parts immediately.
6‐18
Laser protection device
2017-11-17
B836en
106018:
Checking the sealing strips
and the partition wall
Maintenance interval: Daily
The interface between the partition wall of the rotational changer
and the safety cabin as well as between the partition walls of the
rotary indexing table and the safety cabin is sealed by sealing
strips.
These sealing strips and the partition wall belong to the
machine's laser safety equipment.
Note
The rotational changer's partition wall or the rotary indexing
table's partition walls may only be replaced by TRUMPF service
engineers.
If the sealing strips are damaged or deformed, invisible,
high energy laser radiation may escape.
WARNING
Ø
Ø
Ø
If laser radiation escapes, do not put the machine into operation.
Immediately replace the sealing strips.
The sealing strips may only be replaced by qualified personnel who have been specially trained in the process.
1. Check the sealing strips inside and outside of the safety
cabin for damage and deformation.
2. Check whether laser radiation can be emitted. If it can,
replace the sealing strips.
3. Mount new sealing strips correctly. No light gap may develop.
105168:
Checking the viewing
window
Maintenance interval: Daily
Note
Request TRUMPF customer service to replace the viewing windows.
Invisible, high-energy laser radiation!
DANGER
Severe skin burns and eye injuries may occur.
Ø
Ø
Replace the viewing window if scorching is 1 mm deep or
holes are discovered during inspection.
Do not put the machine back into operation until after the
defective viewing window has been replaced.
Ø Check the viewing windows for scorched areas, holes or
damage.
B836en
2017-11-17
Laser protection device
6‐19
106491:
Cleaning the laser protection
window
Maintenance interval: As needed
The laser protection window is made of a special mineral glass
that absorbs laser radiation (plastic glass).
Means, Tools, Materials
■
Water with mild soapy water
Note
If the window is cleaned using a dry cloth, the plastic glass will
be damaged and the protective effect may be lost.
Ø Clean the safety window with a soft cloth and lukewarm
water.
106820:
Replacing the monitor
Maintenance interval: As needed
In the front of the safety cabin, monitors for work area
monitoring (option) and/or for the remaining time display (option)
are used. If a monitor is defective, it can be replaced.
If the monitor cannot be replaced immediately, or if it is to be
removed permanently, the opening in the safety cabin must be
sealed with a cover.
Note
If this is not available, the cover (TRUMPF order number
1833736) can be ordered from TRUMPF Spare Parts Sales.
WARNING
Escape of invisible, high-energy laser radiation when the
monitor is removed!
Ø
6‐20
Laser protection device
Do not put the machine into operation without a monitor or
cover.
2017-11-17
B836en
1
Monitor holder
Monitor with monitor holder
Fig. 79715
1. Switch the machine off.
2. Loosen the four fastening screws for the monitor or monitor
holder on the inside wall of the safety cabin.
3. On the outside wall, pull the monitor out of the safety cabin
and disconnect from the cable.
4. Either
Ø Install a new monitor:
− Screw the existing monitor holder to the new monitor.
− Insert the monitor into the opening of the safety cabin
from the front again and connect it electrically.
or
Ø If there is no monitor available, mount the cover:
− Insert the cover into the opening of the safety cabin from
the front.
B836en
2017-11-17
Laser protection device
6‐21
1
Fixing screws
Monitor attachment from inside
Fig. 78930
5. Screw the cover or monitor firmly to the inside wall of the
safety cabin.
106822:
Replacing the status
indicator
Maintenance interval: As needed
If a light is defective, it can be replaced.
Notes
■
■
WARNING
Invisible, high-energy laser radiation will escape if a status
indicator is missing!
Ø
6‐22
Instead of the missing status indicator, the opening in the
safety cabin can be sealed with a cover.
The cover (TRUMPF order number 1834795) can be ordered
from the TRUMPF Spare Parts Sales.
Laser protection device
Do not put the machine into operation without a status indicator or cover.
2017-11-17
B836en
1
Fastening screws, cover
Status light
Fig. 78935
Ø Either
Ø Replace the status indicator.
or
Ø If no new status indicator is to be used, seal the created
opening in the safety cabin with the cover.
B836en
2017-11-17
Laser protection device
6‐23
5.
Lubrication
5.1
Overview
Notes
■
■
The rack will not be lubricated sufficiently!
NOTICE
This results in damage to the drive.
Ø
Do not install a new lubrication pinion in dry form.
Replace damaged or hardened lubrication pinions at once.
3
Lubricating pinion, Y axis
Ø
1
Lubricating pinion, X axis
2
Lubricating pinion, Z axis
Before starting maintenance work on the axis drives, move
the NC axes into a suitable position that is easy to access
by maintenance personnel.
To clean the racks and guide rails, only 2 propanol should be
used. Wear gloves and safety glasses when cleaning with
2 propanol.
4
Central lubrication lubricant container
Lubrication plan for TruLaser Cell 8030
Fig. 74486
Maintenance point
Volume (liters)
Lubricant
DIN 51502
coding
Viscosity
consistency
Guide rail, rack and lubricating
pinion X, Y and Z axes
-
Low-viscosity grease,
KLÜBER
Microlube GB 00
GP00 G-10
NLGI Nr. 00
Low-viscosity grease reservoir
central lubrication
1
Low-viscosity grease,
KLÜBER
Microlube GB 00
GP00 G-10
NLGI Nr. 00
Scrap conveyor low-viscosity
grease reservoir
1.5
Shell Tonna oil S3 M32
-
-
6‐24
Lubrication
2017-11-17
B836en
Maintenance point
Volume (liters)
Lubricant
DIN 51502
coding
Viscosity
consistency
Scrap conveyor pedestal bearing
-
Roller bearing grease
Mobiltemp SHC100
-
-
Lubricant table
Tab. 6-1
5.2
Maintenance Instructions
X axis drive
(see "Overview", pg. 6‐24)
100658:
Checking the lubricating
pinion
Maintenance interval: Monthly
The driving pinion of the axis is lubricated by a pinion made
of felt. The lubricating pinion is supplied from the central
lubrication system.
1
Cover plate
3
Lubricating pinion
2
Fixing screws
4
Connection central lubrication
5
Fixing screws, lubricating pinion
Lubricating pinion for the X axis drive
Fig. 59611
1. Move the extension arm to an easily accessible position.
Lower the Z axis to the Z = 0 position.
2. Press the EMERGENCY STOP push-button.
3. On the extension arm, remove the covering sheet (posn. 1).
4. Check the lubricating pinion:
− Is the lubricating pinion damaged, worn, hardened or
clogged with cutting dust?
− Is the driving pinion or the rack supplied with sufficient
low-viscosity grease?
B836en
2017-11-17
Lubrication
6‐25
5. Immediately replace damaged lubricating pinions (e. g. missing teeth).
6. Install the covering sheet again.
105183:
Clean the guide rails,
stripper and rack
Maintenance interval: Monthly
The guide carriage of the axis is protected by a pair of strippers.
Grease and dirt must be removed at regular intervals. After
2000 hours of operation, the outer plastic stripper must be
replaced. Damaged strippers must be replaced immediately.
The bellows protects the guide rails and the drive from contamination and thus from damage. Damaged bellows, e.g. by
holes or cracks, must be replaced.
Means, Tools, Materials
■
■
■
■
■
■
Torque screwdriver, material no. 1851934.
Clean, lint-free cloth.
Industrial vacuum cleaner.
Brush
2-propanol.
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Notes
■
■
■
6‐26
Lubrication
Do not use any solvents for cleaning the guide rails.
The inner stripper must not be removed.
It is not necessary to clean the upper guide rail of the X
drive.
2017-11-17
B836en
1
Dirt trap
4
Retaining nuts (2x)
2
Bellows guide plate
5
Guide rail
3
Stripper
Lower stripper guide carriage
Fig. 68258
1. First move the extension arm to the end of the working
range in the X direction: either to X = 0 or X = 3000.
2. Lower the Z axis to the Z = 0 position.
3. Press the FEED HOLD button.
4. Clean the bellows, remove the cutting slugs. Extract dust
from the bellows and check for damage.
5. Only on the lower guide rail, undo the bellows on the extension arm and slide it outwards, so that the drive guide is
open for its full length.
6. Clean the dirt trap and the deflector plate as well as the gap
between them with an industrial vacuum cleaner.
7. Clean the outermost stripper on the guide carriage:
− Remove the hexagonal nuts from the stripper.
− Remove the external stripper from the guide, tilt the stripper slightly to do so.
− Thoroughly clean the stripper and check for damage. If it
is damaged, replace the stripper immediately.
8. Refit the stripper. Tighten the retaining nuts to a torque of
0.4 Nm. If the retaining nuts are over-tightened, the
molded part in the stripper package will be deformed too
much.
9. Put some 2 propanol on a cloth and clean the guide rail as
well as the guide plates for the bellows over the entire
length.
10. Clean the rack with a brush and 2 propanol.
B836en
2017-11-17
Lubrication
6‐27
11. After the cleaning: lightly grease the rack and guide rail with
low-viscosity grease.
12. Then move the extension arm to the other end of the working range.
13. Press the FEED HOLD button.
14. Clean the bellows and then undo the bellows on the extension arm.
15. Clean the drive guide in the same way as the other side.
16. Finally, remount the bellows. Take care that the contour of
the bellows is aligned with the contour of the holder.
100660:
Replacing the lubricating
pinion
Maintenance interval: Every 6 months
24 hours before being installed, the new lubricating pinion
must be placed in low-viscosity grease, Klüber Microlube
GB 00.
Means, Tools, Materials
■
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Note
The lubricating pinion is secured with a locking washer. The locking washer is under tension, it can be removed with a screwdriver.
CAUTION
The washer securing the lubricating pinion is under
tension!
Ø
6‐28
Lubrication
While replacing the lubricating pinion, wear safety glasses.
2017-11-17
B836en
1
Cover plate
3
Lubricating pinion
2
Fixing screws
4
Connection central lubrication
5
Fixing screws, lubricating pinion
Lubricating pinion for the X axis drive
Fig. 59611
1. Move the extension arm to an easily accessible position.
Lower the Z axis to the Z = 0 position.
2. Press the EMERGENCY STOP push-button.
3. On the extension arm, remove the covering sheet (posn. 1).
4. Remove the lubricant line at the lubricating pinion.
5. Release the fastening screws (pos. 5). Take out the lubricating pinion.
6. Assembling a new lubricating pinion:
− Loosen the securing washer, remove the disk and pull
the lubricating pinion off upward.
− Insert the new, lubricating pinion, soaked in low-viscosity grease.
− Place the securing washer on the lubricating pinion,
lightly press it down and secure.
7. Reinsert the lubricating pinion and fasten.
8. Re-install the lubricant line and the cover sheet.
105467:
Replacing strippers
Maintenance interval: Every 6 months
The stripper kit consists of an inner and an outer stripper. Only
the outer plastic stripper is replaced.
Means, Tools, Materials
■
■
■
■
■
B836en
2017-11-17
Torque screwdriver, material no. 1851934.
Clean, lint-free cloth.
Industrial vacuum cleaner.
Brush
2-propanol.
Lubrication
6‐29
■
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Notes
■
■
Do not use any solvents for cleaning the guide rails.
The inner stripper must not be removed.
1
Dirt trap
4
Retaining nuts (2x)
2
Bellows guide plate
5
Guide rail
3
Stripper
Lower stripper guide carriage
Fig. 68258
1. First move the extension arm to the end of the working
range in the X direction: either to X = 0 or X = 3000.
2. Lower the Z axis to the Z = 0 position.
3. Press the FEED HOLD button.
4. Clean the bellows, remove the cutting slugs. Extract dust
from the bellows and check for damage.
5. Only on the lower guide rail, undo the bellows on the extension arm and slide it outwards, so that the drive guide is
open for its full length.
6. Clean the dirt trap and the deflector plate as well as the gap
between them with an industrial vacuum cleaner.
7. Replace the outer plastic stripper on the guide carriage:
− Remove the hexagonal nuts from the stripper.
− Remove the external stripper from the guide, tilt the stripper slightly to do so.
− Refit the stripper. Tighten the retaining nuts to a torque of
0.4 Nm. If the retaining nuts are over-tightened, the
molded part in the stripper package will be deformed
too much.
6‐30
Lubrication
2017-11-17
B836en
8. Put some 2 propanol on a cloth and clean the guide rail as
well as the guide plates for the bellows over the entire
length.
9. Clean the rack with a brush and 2 propanol.
10. After the cleaning: lightly grease the rack and guide rail with
low-viscosity grease.
11. Then move the extension arm to the other end of the working range.
12. Press the FEED HOLD button.
13. Clean the bellows and then undo the bellows on the extension arm.
14. Clean the drive guide in the same way as the other side.
15. Finally, remount the bellows. Take care that the contour of
the bellows is aligned with the contour of the holder.
Y axis drive
(see "Overview", pg. 6‐24)
Maintenance interval: Monthly
100663:
Checking the lubricating
pinion
1
Holder
The driving pinion of the axis is lubricated by a pinion made
of felt. The lubricating pinion is supplied from the central
lubrication system.
2
Fixing screw
3
Lubricating pinion
Lubricating pinion, Y axis
B836en
Fig. 59615
2017-11-17
Lubrication
6‐31
1. Move the extension arm to an easily accessible position.
Lower the Z axis to the Z = 0 position.
2. Press the EMERGENCY STOP push-button.
3. Remove the hood from the Y drive. Undo the 3 fixing screws
(one screw at the bottom, the top and at the side).
4. Undo the fixing screws (posn. 2) on the holder for the lubricating pinion. Pull out the lubricating pinion.
5. Check the lubricating pinion:
− Is the lubricating pinion damaged, worn, hardened or
clogged with cutting dust?
− Is the driving pinion or the rack supplied with sufficient
low-viscosity grease?
6. Immediately replace damaged lubricating pinions (e. g. missing teeth).
7. Insert a lubricating pinion and screw on holder.
8. Reinstall the hood.
105184:
Clean the guide rails,
stripper and rack
Maintenance interval: Monthly
The guide carriage of the axis is protected by a pair of strippers.
Grease and dirt must be removed at regular intervals. After
2000 hours of operation, the outer plastic stripper must be
replaced. Damaged strippers must be replaced immediately.
The bellows protects the guide rails and the drive from contamination and thus from damage. Damaged bellows, e.g. by
holes or cracks, must be replaced.
Means, Tools, Materials
■
■
■
■
■
■
Torque screwdriver, material no. 1851934.
Clean, lint-free cloth.
Industrial vacuum cleaner.
Brush
2-propanol.
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Notes
■
■
6‐32
Lubrication
Do not use any solvents for cleaning the guide rails.
The inner stripper must not be removed.
2017-11-17
B836en
1
Fixing screws
4
Grease drip tray
2
Stripper
5
Bellows guide plate
3
Guide rail
Stripper guide carriage
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
B836en
2017-11-17
Fig. 72855
Move the Y slide to the Y = 0 position.
Lower the Z axis to the Z = 0 position.
Press the FEED HOLD button.
Clean the bellows, remove the cutting slugs. Extract dust
from the bellows and check for damage.
On the guide carriage, undo the bellows for the upper and
lower guide rails on the holder.
Unscrew and clean the grease drip tray.
Clean the dirt trap and the deflector plate as well as the gap
between them with an industrial vacuum cleaner.
Clean the outermost stripper on the guide carriage:
− Remove the hexagonal nuts from the stripper.
− Remove the external stripper from the guide, tilt the stripper slightly to do so.
− Thoroughly clean the stripper and check for damage. If it
is damaged, replace the stripper immediately.
Refit the stripper. Tighten the retaining nuts to a torque of
0.4 Nm. If the retaining nuts are over-tightened, the
molded part in the stripper package will be deformed too
much.
Put some 2 propanol on a cloth and clean the guide rail as
well as the guide plates for the bellows over the entire
length.
Clean the rack with a brush and 2 propanol.
Lubrication
6‐33
12. After the cleaning: lightly grease the rack and guide rail with
low-viscosity grease.
13. Reinstall the grease drip tray.
14. Then move the Y slide to the other end of the working range.
15. Press the FEED HOLD button.
16. Clean the bellows and then undo the bellows from the Y
slide.
17. Clean the drive guide in the same way as the other side.
18. Finally, remount the bellows. Take care that the contour of
the bellows is aligned with the contour of the holder.
100664:
Replacing the lubricating
pinion
Maintenance interval: Every 6 months
24 hours before being installed, the new lubricating pinion
must be placed in low-viscosity grease, Klüber Microlube
GB 00.
Means, Tools, Materials
■
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Note
The lubricating pinion is secured with a locking washer. The locking washer is under tension, it can be removed with a screwdriver.
CAUTION
The washer securing the lubricating pinion is under
tension!
Ø
6‐34
Lubrication
While replacing the lubricating pinion, wear safety glasses.
2017-11-17
B836en
1
Holder
2
Fixing screw
3
Lubricating pinion
Lubricating pinion, Y axis
Fig. 59615
1. Move the extension arm to an easily accessible position.
Lower the Z axis to the Z = 0 position.
2. Press the EMERGENCY STOP push-button.
3. Remove the hood from the Y drive. Undo the 3 fixing screws
(one screw at the bottom, the top and at the side).
4. Undo the fixing screws (posn. 2) on the holder for the lubricating pinion. Pull out the lubricating pinion.
5. Assembling a new lubricating pinion:
− Loosen the securing washer, remove the disk and pull
the lubricating pinion off upward.
− Insert the new, lubricating pinion, soaked in low-viscosity grease.
− Place the securing washer on the lubricating pinion,
lightly press it down and secure.
6. Insert the lubricating pinion and screw the holder in place.
7. Reinstall the hood.
105468:
Replacing strippers
Maintenance interval: Every 6 months
The stripper kit consists of an inner and an outer stripper. Only
the outer plastic stripper is replaced.
Means, Tools, Materials
■
■
■
B836en
2017-11-17
Torque screwdriver, material no. 1851934.
Clean, lint-free cloth.
Industrial vacuum cleaner.
Lubrication
6‐35
■
■
■
Brush
2-propanol.
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Notes
■
■
Do not use any solvents for cleaning the guide rails.
The inner stripper must not be removed.
1
Fixing screws
4
Grease drip tray
2
Stripper
5
Bellows guide plate
3
Guide rail
Stripper guide carriage
1.
2.
3.
4.
5.
6.
7.
8.
6‐36
Lubrication
Fig. 72855
Move the Y slide to the Y = 0 position.
Lower the Z axis to the Z = 0 position.
Press the FEED HOLD button.
Clean the bellows, remove the cutting slugs. Extract dust
from the bellows and check for damage.
On the guide carriage, undo the bellows for the upper and
lower guide rails on the holder.
Unscrew and clean the grease drip tray.
Clean the dirt trap and the deflector plate as well as the gap
between them with an industrial vacuum cleaner.
Replace the outer plastic stripper on the guide carriage:
2017-11-17
B836en
−
−
9.
10.
11.
12.
13.
14.
15.
16.
17.
Remove the hexagonal nuts from the stripper.
Remove the external stripper from the guide, tilt the stripper slightly to do so.
− Refit the stripper. Tighten the retaining nuts to a torque of
0.4 Nm. If the retaining nuts are over-tightened, the
molded part in the stripper package will be deformed
too much.
Put some 2 propanol on a cloth and clean the guide rail as
well as the guide plates for the bellows over the entire
length.
Clean the rack with a brush and 2 propanol.
After the cleaning: lightly grease the rack and guide rail with
low-viscosity grease.
Reinstall the grease drip tray.
Then move the Y slide to the other end of the working range.
Press the FEED HOLD button.
Clean the bellows and then undo the bellows from the Y
slide.
Clean the drive guide in the same way as the other side.
Finally, remount the bellows. Take care that the contour of
the bellows is aligned with the contour of the holder.
Z axis drive
(see "Overview", pg. 6‐24)
106795:
Checking the lubricating
pinion and the rack
B836en
2017-11-17
Maintenance interval: Monthly
The driving pinion of the axis is lubricated by a pinion made
of felt. The lubricating pinion is supplied from the central
lubrication system.
Lubrication
6‐37
1
Cover plate
2
Lubricating pinion
Z axis drive
Fig. 74929
1. Move the extension arm to an easily accessible position.
Lower the Z axis to the Z = 0 position.
2. Press the EMERGENCY STOP push-button.
3. Remove the cover plate (posn. 1).
4. Check the lubricating pinion: Is the lubricating pinion damaged, worn, hardened or clogged with cutting dust?
Immediately replace damaged lubricating pinions (e. g. missing teeth).
5. Check whether the rack is supplied with sufficient low-viscosity grease. If the rack is damaged or heavily soiled, request
assistance from TRUMPF Technical Service.
6. After the check, install the covering sheet again.
100597:
Cleaning the grease
collecting vessel and drip
tray
Maintenance interval: Monthly
Excess grease will collect in the grease collecting vessel and in
the drip tray.
Means, Tools, Materials
■
■
6‐38
Lubrication
Clean, lint-free cloth.
2-propanol.
2017-11-17
B836en
1
Drop-in sheet
2
Grease collecting vessel
3
Grease drip tray
4
Belt
The grease collecting vessel and drip tray
Fig. 72859
1. Move the extension arm to an easily accessible position.
Lower the Z axis to the Z = 0 position.
2. Press the EMERGENCY STOP push-button.
3. Unscrew the grease collecting vessel and pull out the drop-in
sheet.
4. Clean the grease collecting vessel and drop-in sheet.
5. Reinstall the grease collecting vessel:
− Fit the grease collecting vessel with the tab in the lower
fixing screw, align and then slide it straight up as far as it
goes.
− Tighten the top and bottom fixing screws hand-tight.
6. Clean the grease drip tray with a clean cloth.
105182:
Clean the guide rails and
stripper
Maintenance interval: Monthly
The guide carriage of the axis is protected by a pair of strippers.
Grease and dirt must be removed at regular intervals. After
2000 hours of operation, the outer plastic stripper must be
replaced. Damaged strippers must be replaced immediately.
Means, Tools, Materials
■
■
■
■
B836en
2017-11-17
Torque screwdriver, material no. 1851934.
Clean, lint-free cloth.
2-propanol.
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Lubrication
6‐39
Notes
■
■
Do not use any solvents for cleaning the guide rails.
The inner stripper must not be removed.
1
Stripper
2
Retaining nut
3
Guide rail
Stripper guide carriage
Fig. 59989
1. Move the extension arm to an easily accessible position.
Lower the Z axis to the Z = 0 position.
2. Press the EMERGENCY STOP push-button.
3. Clean the outermost stripper on the guide carriage:
− Remove the hexagonal nuts from the stripper.
− Remove the external stripper from the guide, tilt the stripper slightly to do so.
− Thoroughly clean the stripper and check for damage. If it
is damaged, replace the stripper immediately.
4. Put some 2 propanol onto a clothe an clean the guide rail.
5. After the cleaning: lightly grease the guide rail with low-viscosity grease.
6. Refit the stripper. Tighten the retaining nuts to a torque of
0.4 Nm. If the retaining nuts are over-tightened, the
molded part in the stripper package will be deformed too
much.
7. Remove the excess grease in the drip pan.
106796:
Replacing the lubricating
pinion
6‐40
Lubrication
Maintenance interval: Every 6 months
24 hours before being installed, the new lubricating pinion
must be placed in low-viscosity grease, Klüber Microlube
GB 00.
2017-11-17
B836en
Means, Tools, Materials
■
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Note
The lubricating pinion is secured with a locking washer. The locking washer is under tension, it can be removed with a screwdriver.
The washer securing the lubricating pinion is under
tension!
CAUTION
1
Befestigungsschrauben
Ø
While replacing the lubricating pinion, wear safety glasses.
2
Cover plate
3
Lubricating pinion
Z axis drive
Fig. 72857
1. Move the extension arm to an easily accessible position.
Lower the Z axis to the Z = 0 position.
2. Press the EMERGENCY STOP push-button.
3. Remove the cover plate (posn. 2).
4. Remove the lubricant line at the lubricating pinion.
5. Undo the fixing screws on the holder for the lubricating pinion, tilt the holder to the back and pull out the lubricating pinion.
6. Assembling a new lubricating pinion:
− Loosen the securing washer, remove the disk and pull
the lubricating pinion off upward.
− Insert the new, lubricating pinion, soaked in low-viscosity grease.
− Place the securing washer on the lubricating pinion,
lightly press it down and secure.
7. Reinstall the lubricating pinion and align it so that the lubricating pinion is aligned to the rack.
B836en
2017-11-17
Lubrication
6‐41
8. Firmly screw the holder for the lubricating pinion in place.
Install cover plate.
105466:
Replacing strippers
Maintenance interval: Every 6 months
The stripper kit consists of an inner and an outer stripper. Only
the outer plastic stripper is replaced.
Means, Tools, Materials
■
■
■
■
Torque screwdriver, material no. 1851934.
Clean, lint-free cloth.
2-propanol.
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Notes
■
■
Do not use any solvents for cleaning the guide rails.
The inner stripper must not be removed.
1
Stripper
2
Retaining nut
3
Guide rail
Stripper guide carriage
Fig. 59989
1. Move the extension arm to an easily accessible position.
Lower the Z axis to the Z = 0 position.
2. Press the EMERGENCY STOP push-button.
3. Replace the outermost stripper on the guide carriage:
− Remove the hexagonal nuts from the stripper.
− Remove the external stripper from the guide, tilt the stripper slightly to do so.
4. Put some 2 propanol onto a clothe an clean the guide rail.
5. After the cleaning: lightly grease the guide rail with low-viscosity grease.
6‐42
Lubrication
2017-11-17
B836en
6. Mount a new stripper. Tighten the retaining nuts with a torque of 0.4 Nm. If the retaining nuts are over-tightened,
the molded part in the stripper package will be deformed
too much.
7. Remove the excess grease in the drip pan.
106797:
Cleaning the rack
Maintenance interval: Every 6 months
The belt protects the toothed rack from dirt. If the belt is damaged, or if the rack is too heavily soiled, ask for a service call.
Conditions
■
■
The Z axis is lowered to position Z = 0.
The machine's drives are switched on: The
MACHINE ON/OFF button lights up.
Means, Tools, Materials
■
■
■
1
Brush
2-propanol.
Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Cover plate
2
Rack
Z axis drive
Fig. 74632
1. Remove the cover plate (posn. 1).
2. Move the Z axis step by step upwards, cleaning each accessible area with a brush and 2 propanol. Then apply a thin
layer of grease.
3. Once the complete rack has been cleaned, remount the
cover plate.
4. Then clean the grease collecting vessel and the drip tray.
B836en
2017-11-17
Lubrication
6‐43
Device panel: Low-viscosity grease
reservoir central lubrication
(see "Overview", pg. 6‐24)
100672:
Filling the low-viscosity
grease reservoir
Maintenance interval: When indicated by the control system
The control system monitors the filling level in the low-viscosity
grease reservoir. As soon as the minimum filling level is
reached, the control system displays a message.
Note
The lubrication pressure must be at least 50 mbar. The lubrication cycle stops if the pressure is too low. An error message is
issued.
Causes of error could include: Air in the line, a broken hose or
the low-viscosity grease reservoir is empty.
NOTICE
Air in central lubrication!
The axis drives are not lubricated. Machine downtime.
Ø
1
Top up the low-viscosity grease reservoir when the message
appears.
Level sensor
2
Low-viscosity grease reservoir
Lubricant container lubricant pump
6‐44
Lubrication
Fig. 74468
2017-11-17
B836en
1. If a message appears or if the yellow LED display on the
low-viscosity grease reservoir is not illuminated, fill the reservoir.
− Remove the cover, pour the low-viscosity grease in
slowly to avoid bubbles.
− Close the cover.
2. Reset the lubrication counter:
− Press Maintenance, select "Manual functions".
− Select the Maintenance group.
− Press "Reset lubricat. count."
B836en
2017-11-17
Lubrication
6‐45
1
Bellows for X and Y axis
2
Dirt trap
6.
Mechanical elements
6.1
Overview
3
4
Air extraction pipe protective
screen
5
Magnetic coupling
6
Cable connections, barrel
Air deflecting plate on the body
of the machine
Overview of the mechanics
6‐46
Mechanical elements
Fig. 74471
2017-11-17
B836en
6.2
Maintenance Instructions
Machine and workspace
(see "Overview", pg. 6‐46)
106860:
Check the air extraction pipe
protective screen
Maintenance interval: Daily
The scrap conveyor is connected to the air extraction piping on
both sides. The interface where the air is sucked in is protected
by a screen. This prevents waste parts or other objects lying on
the scrap conveyor from being sucked up and thus getting into
the compact dust extractor.
1
Protective screen
Connection of the air extraction piping to the scrap conveyor
Fig. 74631
Ø Check the protective screen to the left and right of the conveyor belt's feed area and remove coarse dirt and any waste
parts stuck there.
106861:
Clean the air extraction pipe
protective screens
Maintenance interval: Weekly
Means, Tools, Materials
■
■
B836en
2017-11-17
Industrial vacuum cleaner.
Steel brush.
Mechanical elements
6‐47
1
Protective screen
Connection of the air extraction piping to the scrap conveyor
Fig. 74631
Ø Thoroughly clean the protective screens to the left and right
of the conveyor belt's feed area:
− Use an industrial vacuum cleaner to remove coarse dirt.
− Clean the protective screen with a brush.
107299:
Cleaning the exhaust piping
Maintenance interval: Weekly
Dust may accumulate in the pipeline between the machine and
the compact dust extractor.
Means, Tools, Materials
■
Industrial vacuum cleaner.
Fig. 84223
Cleaning opening of exhaust piping
1. Remove the cover of the cleaning opening.
2. Clean the pipeline with an industrial vacuum cleaner.
3. After cleaning, seal the pipeline opening again with the cover.
6‐48
Mechanical elements
2017-11-17
B836en
106145:
Clean the control panel and
monitor
Maintenance interval: Weekly
105464:
Cleaning the dirt trap and
bellows
Maintenance interval: Weekly
Ø Clean the monitor, control panel and keyboard with a moist
cloth.
The bellows protect the guide rails on the X and Y axes from
dirt. The bellows must be regularly cleaned of dust.
A dirt trap is installed behind the lower bellows on the X axis.
The purpose of the dirt trap is to collect dirt and protect the
guide rails and bellows.
Means, Tools, Materials
■
Industrial vacuum cleaner.
Notes
■
■
Do not remove the bellows.
The "air deflecting plates" on the body of the machine and
on the side of the scrap conveyor are bent functional sheets
which ensure that air is effectively extracted from the work
area.
1
Dirt trap
2
Air guiding plate
3
Air guiding plate
Fig. 74943
1. Vacuum clean the dirt trap and the bellows.
B836en
2017-11-17
Mechanical elements
6‐49
2. Check that the bellows are properly seated. The guides on
the bellows must easily run in the stainless steel guide.
105178:
Clean the machine and
working area
Maintenance interval: Weekly
The machine and the working area must be thoroughly cleaned
at regular intervals:
■
■
■
■
■
■
The machine frame, air guiding plate on the machine frame
and the bellows.
Rotational changer or rotary indexing table (option).
For machines with a rotary indexing table: hinged guide plate
and platform.
Devices (option).
Scrap conveyor and exhaust piping.
Safety cabin, inside and out.
Means, Tools, Materials
■
■
■
■
Industrial vacuum cleaner.
Soft brush.
Clean, lint-free cloth.
Universal cleaner.
Note
Do not use any solvents for cleaning.
NOTICE
Very fine or oily cutting dust can be deposited on the
components inside the safety cabin.
Destruction of the axis drives.
Ø
Regularly clean the work area and the machine's components.
1. For machines with a rotary indexing table: hinge up the
deflector plate along the body of the machine.
2. Remove coarse dirt and waste parts from the work area or
from the platform.
3. Use an industrial vacuum cleaner to vacuum up dust.
4. Remove slag with a soft brush.
5. Clean components with a moist, soft cloth.
106859:
Check the door seal
Maintenance interval: Annually
The service door is sealed all around with a sponge rubber seal,
so that the reduced pressure necessary for effective air extraction can be achieved inside the safety cabin.
6‐50
Mechanical elements
2017-11-17
B836en
The door seal is important for the proper functioning of the system. If it gets damaged or comes loose, then it must be
replaced.
Ø Check the door seal and replace if necessary.
106813:
Clean beneath the platform
Maintenance interval: Annually
Note:
This is only valid for machines with a rotary indexing table
(option).
The scrap conveyor is open near its lower bend, beneath the
platform. Waste parts and dust can collect in this area.
Means, Tools, Materials
■
1
Industrial vacuum cleaner.
Flap
Platform, open flap
Fig. 86909
1. Open the flap on the platform.
B836en
2017-11-17
Mechanical elements
6‐51
1
Cover, exhaust piping
2
Collecting pan
Clean beneath the platform
Fig. 86910
2. Pull out the collecting pan under the platform, remove the
large waste parts and clean the collecting pan with an industrial vacuum cleaner.
3. Afterwards, push the collecting pan back under the deflection
of the scrap conveyor.
4. Remove the cover from the exhaust piping and clean the
tube with an industrial vacuum cleaner.
5. After cleaning, seal the exhaust piping again with the cover.
105475:
Replace the X axis bellows
Maintenance interval: As needed
The bellows protects the guide rails and the drive from contamination and thus from damage. Damaged bellows, e.g. by
holes or cracks, must be replaced.
Each bellows has a velcro fastener on the side which moves.
When replacing the bellows, the holder with the velcro fastener
is also replaced. On the other, fixed, side the bellows is firmly
screwed to the holder
Notes
■
■
6‐52
Mechanical elements
The guiding parts can deform or jump out when engaging
them into the guide. Make sure that they are properly seated
and move easily.
The upper bellows on the X axis does not generally have to
be replaced.
2017-11-17
B836en
The X axis bellows are different on the left and on the right.
Inside each bellows on the extension arm side, there is a pullout stop on and a velcro fastener.
1
Pull-out lock
X axis bellows guide rail
Fig. 59996
1. Unscrew the bellows holder on the extension arm side.
1
Holder crewed in place
2
Bellows
3
Fixing screws, holder
4
Velcro fastened holder
X axis bellows
Fig. 68761
2. Remove the left bellows:
− Unscrew the bellows from the outer holder at the other
end.
− Unscrew the holder (posn. 1) and remove the bellows.
3. Remove the right hand bellows:
− Unscrew the bellows from the outer holder at the other
end and remove the bellows.
B836en
2017-11-17
Mechanical elements
6‐53
4. Before installing the new bellows: Clean the dirt trap and the
deflector plate as well as the gap between them with an
industrial vacuum cleaner.
5. Mount the new velcro fastened holder on the extension arm
side.
6. Install the left bellows:
− Introduce the correct bellows for the side into the guide
plates from the outside.
− Remount the outer holder again.
− Screw the bellows holder onto the outer holder.
7. Install the right hand bellows:
− First hook in the bellows from above into the upper guide
plate. Then engage the guide parts into the lower guide
plate, while slightly tilting them to the side.
− Screw the bellows holder onto the outer holder.
8. Check whether the bellows moves easily in the guide.
9. Close the bellows onto the velcro fastener. Take care that
the bellows' shape is aligned with the shape of the holder.
106793:
Replace the Y axis bellows
Maintenance interval: As needed
The bellows protects the guide rails and the drive from contamination and thus from damage. Damaged bellows, e.g. by
holes or cracks, must be replaced.
Each bellows has a velcro fastener on the side which moves.
When replacing the bellows, the holder with the velcro fastener
is also replaced. On the other, fixed, side the bellows is firmly
screwed to the holder
Note
The guiding parts can deform or jump out when engaging them
into the guide. Make sure that they are properly seated and
move easily.
6‐54
Mechanical elements
2017-11-17
B836en
1
Bellows, lower guide rail
2
Bellows, upper guide rail
3
Bellows, upper and lower guide
rail
Y axis bellows
Fig. 72856
1. Unscrew the Y slide bellows holder.
2. Remove the left bellows:
− Unscrew the bellows from the outer holder at the other
end and remove the bellows.
3. Remove the right hand bellows:
− Unscrew the bellows from the outer holder at the other
end.
− Unscrew the outer holder and remove the bellows.
4. Before installing the new bellows, clean the guide plates.
5. Mount the new velcro fastened holder onto the Y slide.
6. Install the left hand bellows:
− First hook in the bellows from above into the upper guide
plate. Then engage the guide parts into the lower guide
plate, while slightly tilting them to the side.
− Screw the bellows holder onto the outer holder.
7. Install the right hand bellows:
− Introduce the correct bellows for the side into the guide
plates from the outside.
− Remount the outer holder again.
− Screw the bellows holder onto the outer holder.
8. Check whether the bellows moves easily in the guide.
9. Close the bellows onto the velcro fastener. Take care that
the bellows' shape is aligned with the shape of the holder.
B836en
2017-11-17
Mechanical elements
6‐55
Magnetic coupling
(see "Overview", pg. 6‐46)
1
Catch strap
4
Foam rubber
2
Bellows
5
Plastic screws
3
Metal cable ties
6
Impact protection
Magnetic coupling with bellows
105174:
Clean and check
Fig. 60959
Maintenance interval: As needed
With each replacement of the processing optics and in the event
of a malfunction (missing electrical contact), the contact surfaces
on the flange and on the plate must be thoroughly cleaned.
In order to ensure proper functioning, the gap between the
flange and the plate must not exceed 0.1 mm. The pole and
contact surfaces must be absolutely clean. Dust, chips or welding beads can cause malfunctions.
The following components are functional elements and must be
exchanged when they are damaged:
■
■
■
■
■
Impact protection, including plastic screws.
Catch strap.
Foam rubber.
Bellows, including both metal cable ties.
Banjo screws.
Means, Tools, Materials
■
■
■
6‐56
Mechanical elements
Bar magnet
Cotton buds
Acetone or propanol
2017-11-17
B836en
Note
Do not use compressed air to clean, because then there would
be a danger of chips and dirt getting into the beam guidance,
onto the mirrors or into the processing optics.
The electromagnetic of the magnetic coupling at the Z
barrel presents a danger of life for persons with
pacemakers!
DANGER
Ø
Ø
Ø
Persons with a pacemaker must, regardless of whether the
machine is switched on, keep a minimum distance of 30 cm
from the magnetic coupling on the Z barrel.
Persons with a pacemaker may not perform any service,
maintenance or setting work on the Z barrel or on the processing optics (if installed).
Advise personnel, visitors or visiting personnel of the dangers for persons with a pacemaker.
Ferromagnetic attractive force (1000 N) due to the
permanent magnets!
CAUTION
Ø
Do not hold any metal objects or watches near the permanent magnets.
If there is a collision, the processing optics is separated
from the flange.
NOTICE
Ø
Ø
Replace damaged plastic strap.
Do not start processing without a properly mounted catch
strap.
1. Use a non-metal tool to remove slag or other impurities.
2. Clean the contact surfaces on the flange and on the plate
thoroughly with a rag.
3. Remove chips in the pole surfaces thoroughly using a bar
magnet.
4. Afterwards, subsequently clean the pole surfaces with cotton
swabs and acetone or propanol.
5. Check the catch strap for damage.
6. Exchange damaged components.
B836en
2017-11-17
Mechanical elements
6‐57
Smart Optics Setup station
(see "Overview", pg. 6‐46)
107309:
Cleaning the test sheet
holder
Maintenance interval: As needed
Means, Tools, Materials
■
Clean, lint-free cloth.
Notes
■
■
1
The sacrificial plates can be ordered in pairs as consumables.
Do not use the test sheet holder without sacrificial plates.
Sacrificial plates
Cleaning the test sheet holder
Fig. 87509
1. Swivel the setting device into the parking position and lock it
in place.
2. Remove the test sheets and sacrificial plates from the test
sheet holder.
3. Clean the test sheet holder thoroughly with a cloth.
4. Replace used sacrificial plates.
6‐58
Mechanical elements
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B836en
107310:
Replacing the test sheet
holder
Maintenance interval: As needed
If the test sheet holder is damaged, it can be ordered as a spare
part and replaced.
Means, Tools, Materials
■
Allen key SW 4.
Note
The two lower fastening screws on the flange plates have contact washers.
These two contact washers are functionally relevant components. They ground the test sheet holder, thus ensuring the
functional safety of the distance regulation.
Risk of collision between the processing optics and the
setting device when approaching the reference position!
NOTICE
Ø
Ø
Do not remove the contact washers.
Replace any contact washers that are lost.
1
Fixing screws
3
Contact washers
2
Flanged plate
4
Test sheet holder
Replacing the test sheet holder
B836en
2017-11-17
Fig. 86912
Mechanical elements
6‐59
1. Swivel the setting device into the parking position and lock it
in place.
2. Loosen the fastening screws and remove the test sheet
holder from the flange plate on the swivel arm. Observe the
contact washers!
3. Attach a new test sheet holder from above to the flange
plate and align it.
4. Tighten the fixing screws hand-tight. Observe the contact
washers!
5. Insert sacrificial plates.
Z barrel
(see "Overview", pg. 6‐46)
105177:
Checking hose connections
and quick-release couplings
6‐60
Mechanical elements
Maintenance interval: Monthly
Ø Check that there are no leaks in the air and gas connections.
2017-11-17
B836en
7.
Pneumatic system
7.1
Overview
The device panel is integrated into the front of machine's body.
To get to the device plate, the door must be opened.
1
2
Maintenance unit, extended
compressed air supply (option)
Maintenance unit machine
3
Maintenance unit cutting gas air
4
Condensate precipitation collecting tank
Instrument panel
B836en
2017-11-17
Fig. 73835
Pneumatic system
6‐61
7.2
Maintenance Instructions
Device panel: Maintenance unit basic
machine
(see "Overview", pg. 6‐61)
106837:
Checking and setting the
static operating pressure
Maintenance interval: Monthly
The required pressure is 5+1 bar.
Condition
■
MAIN SWITCH Basic machine is switched on.
Note
Set the pressure: Turn the knob while pulling it up.
1
Turning knob
2
Pressure gauge
Compressed air gauge for the operating pressure
Fig. 74478
Ø Check the operating pressure on the pressure gauge. If the
gauge is in the green area, the operating pressure is OK.
or
Ø If the gauge is in the red area then correct the operating
pressure: Press the FEED STOP button. Set the required
pressure of 5 bar.
6‐62
Pneumatic system
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B836en
105195:
Replace the filter element
Maintenance interval: Every 6 months
Condition
■
The MAIN SWITCH is switched off.
1
Prefilter
5
Slide
2
Main filter
6
Housing
3
Microfilter
7
Condensation screw
4
Activated carbon filter
Filter maintenance unit basic machine
Fig. 74479
1. Unlock the filter housing: Pull the slide downward while at
the same time rotating the housing counter-clockwise by 45°
and pulling it off from below.
2. Screw out the filter element.
3. Clean the housing with a lint-free cloth.
4. Screw in the new filter element.
5. Reinstall the housing.
B836en
2017-11-17
Pneumatic system
6‐63
Device panel: Maintenance unit cutting gas
air (option)
(see "Overview", pg. 6‐61)
105196:
Replace the filter element
Maintenance interval: Every 6 months
Condition
■
The MAIN SWITCH is switched off.
1
Main filter
5
Slide
2
Microfilter
6
Housing
3
Activated carbon filter
7
Condensation screw
4
Activated carbon filter
Filter maintenance unit cutting gas air
Fig. 74480
1. Unlock the filter housing: Pull the slide downward while at
the same time rotating the housing counter-clockwise by 45°
and pulling it off from below.
2. Screw out the filter element.
3. Clean the housing with a lint-free cloth.
4. Screw in the new filter element.
5. Reinstall the housing.
6‐64
Pneumatic system
2017-11-17
B836en
Device panel: service unit for expanded
compressed air supply or vacuum ejectors
(option)
(see "Overview", pg. 6‐61)
106840:
Checking and setting the
static operating pressure
Maintenance interval: Monthly
The required pressure is 5+1 bar.
Condition
■
MAIN SWITCH Basic machine is switched on.
Note
Set the pressure: Turn the knob while pulling it up.
1
Turning knob
2
Pressure gauge
Compressed air gauge for extended compressed air supply
Fig. 74481
Ø Check the operating pressure on the pressure gauge. If the
gauge is in the green area, the operating pressure is OK.
or
Ø If the gauge is in the red area then correct the operating
pressure: Press the FEED STOP button. Set the required
pressure of 5 bar.
B836en
2017-11-17
Pneumatic system
6‐65
106839:
Replace the filter element
Maintenance interval: Every 6 months
Condition
■
1
The MAIN SWITCH is switched off.
Main filter
Extended compressed air supply maintenance unit
Fig. 74482
1. Unlock the filter housing: Pull the slide downward while at
the same time rotating the housing counter-clockwise by 45°
and pulling it off from below.
2. Screw out the filter element.
3. Clean the housing with a lint-free cloth.
4. Screw in the new filter element.
5. Reinstall the housing.
Device panel: Condensation collection tank
(see "Overview", pg. 6‐61)
106838:
Check filling level
Maintenance interval: Monthly
Note
If a large quantity of condensate is precipitated, then the compressed air quality supplied is not OK.
Ø Check the level in the tank and empty it if necessary.
6‐66
Pneumatic system
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B836en
Cutting optics: disposable filter, pneumatic
connection
(see "Overview", pg. 6‐61)
105117:
Exchange filter insert or
filter
Maintenance interval: Every 6 months
The complete filter or just the filter insert can be exchanged.
Notes
■
■
1
Do not touch the filter element with your hand.
Only exchange the filter element under clean conditions so
that no dirt can get into the optics.
Disposable filter
Disposable filter, pneumatic connection
Fig. 74618
1. Release the quick-release coupling from the media adapter.
2. Disconnect the connection hose from the filter.
3. Exchange the complete filter.
or
Ø Replace the filter insert:
− Screw out the quick-release coupling connection.
− Remove the blue filter insert and insert a new one.
− Close the filter housing.
4. Reconnect the filter.
B836en
2017-11-17
Pneumatic system
6‐67
8.
Gas
8.1
Maintenance Instructions
Cutting optics: disposable filter, gas
connection
105662:
Exchange filter insert or
filter
Maintenance interval: Every 6 months
The complete filter or just the filter insert can be exchanged.
Notes
■
■
1
Do not touch the filter element with your hand.
Only exchange the filter element under clean conditions so
that no dirt can get into the optics.
Disposable filter
Disposable filter, gas connection
Fig. 74619
1. Release the quick-release coupling from the media adapter.
2. Disconnect the connection hose from the filter.
3. Exchange the complete filter.
or
Ø Replace the filter insert:
− Screw out the quick-release coupling connection.
− Remove the blue filter insert and insert a new one.
− Close the filter housing.
4. Reconnect the filter.
6‐68
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B836en
9.
Water
9.1
Overview
The following two variants are available for cooling the optical
components of the LLK machine, collimator and cutting optics,
as well as for cooling the switch cabinet:
■
■
Cooling by machine cooler (optional): The machine has
an internal machine cooler which cools the optical components of the machine as well as the switch cabinet.
Cooling by external laser cooling circuit (chiller): In the
standard variant, the cooling circuit of the machine is connected to the external cooling circuit of the laser device. In
this case, the water stopcocks in the laser device as well as
beneath the instrument panel on the machine, must be open
while the machine is operating. In the event of an error, the
status of the shut-off valve must be checked.
In the following sections, the maintenance work for the cooling
circuit of the machine (machine cooler) will be described.
Laser device maintenance work: see section "TruDisk".
Maintenance of the external cooling circuit of the laser device:
see section "Process cooler for TruDisk".
Notes
■
■
■
■
Cooling water specification
No antifreeze agent is required.
Replace all of the water filters which are part of the cleaned
cooling circuit after each replacement of the cooling water.
Always seal the water container tightly to ensure that no soiling gets into the water tank and that the water does not
evaporate.
If oil or coolant is leaking, request a service call.
The cooling system may only be filled with demineralized or
deionized water that meets the following requirements.
Specific conductivity prior to filling the process cooler tank
max. 10 μS/cm
Carbonate content
max. 100 mg/l
Cooling water data
Tab. 6-2
Water can also be used as cooling water if it complies with the
following standards:
■
■
B836en
2017-11-17
DIN ISO 3696, Quality Level 3 (and better).
ASTM D 1193-91, Type IV (and better).
Water
6‐69
Ensuring the cooling water
quality
To ensure that the required water quality specifications are
always complied with, the cooling water may only be treated
according to the following rules:
■
■
■
■
■
Conductivity limit values
Reduce storage time to a minimum, at best only a few days.
Only store it in suitable, clean plastic containers.
Cooling water should not be used under any circumstances if
it is discolored, cloudy or if it smells.
Only use pumps, hoses and other additional equipment that
are suitable for cooling water and intended solely for this purpose. Do not use these parts in any other way.
No other devices may be connected to the cooling circuits.
The following limit values apply:
Conductivity of freshly filled cooling water
after 10 minutes of circulation
Max. 20 μS/cm
Copper circuit conductivity limit.
Max. 200 μS/cm
Tab. 6-3
Note
The cooling water must be replaced when the conductivity limits
have been exceeded.
Dispose of cooling water
Note
The cooling water must be disposed of in coordination with
regional government authorities responsible for such matters.
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Water
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B836en
Cooling water additives
The cooling water additives are supplied in bottles (Easy Kit).
The apportionment per bottle corresponds to the amount of cooling water of respective cooling circuit. One Easy Kit is required
for each water change. Each Easy Kit contains one bottle with
anticorrosive agent (yellow) and one bottle with cleaning biocide
(red).
Application
Cooling water additive
Bottle top color code
Corrosion protection
Water Care-Copper
Yellow
Cleaning cycle
Cleaning biocide
Red
Cooling water additives
Tab. 6-4
Cooling water and cooling water additives are aggressive!
WARNING
Irritation to eyes and skin possible!
Ø
Ø
Ø
Avoid direct contact with cooling water and cooling water
additives.
Wear safety goggles and gloves.
Follow the safety instructions on the products and safety
datasheets.
Note
Refer to the machine's spare parts catalog for the Easy Kit material numbers (country-specific).
Cooling water requirements
for the machine's cooling
circuit
The following Easy Kits and the following water volumes are
required for cooling water replacement, depending on the configuration of the machine and the laser power:
Process cooler
Easy Ki
t
Volumetric
capacity of cooling circuit in l
Water requirement for cooling
water replacement in l
Type L 4/0 TR2
Type P 4/0 TR2
CU3
48
160
Cooling water requirement and Easy Kit for machine cooling
circuit
Tab. 6-5
Note
Cooling water requirement and Easy Kit for the cooling circuits of
the laser and chiller: see the section "TruDisk and process
cooler for TruDisk" .
B836en
2017-11-17
Water
6‐71
9.2
Maintenance Instructions
Cooling circuit of the machine
(see "Overview", pg. 6‐69)
106844:
Checking the flow controller
Maintenance interval: Annually
Note:
This maintenance work is only relevant, if the machine's components are cooled via the laser cooler: In this case, the machine
will not have its own cooler.
After replacing the cooling water in the laser device as well as in
its process cooler, the system checks whether the flow controller
in the machine's cooling circuit is still properly set.
Condition
■
1
Laser device is ready for operation and assigned to the
machine.
Supply/return stopcock
The water supply on the device panel
Fig. 74630
1. Open the door to the device panel and close both water
stopcocks.
2. Then check whether an error message is displayed on the
machine's control panel. If an error message is issued, then
the flow controller is properly set.
6‐72
Water
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B836en
or
Ø If no error message is issued, then the flow controller is
faulty and must be replaced when the next service work
is carried out.
B836en
2017-11-17
Water
6‐73
Machine cooler (option), water/air chiller
(see "Overview", pg. 6‐69)
106842:
Checking and refilling the
level
Maintenance interval: When indicated by the control system
Means, Tools, Materials
■
Demineralized water.
Note
Generally, little water is lost from the closed cooling circuit, as
long as the water tank has been closed properly. If the cooling
circuit loses water within a short period of time, then the cause
must be found.
1
Level indicator
Level in the machine cooler
Fig. 74624
Ø Check the filling level. When the minimum level is reached,
top up with water.
106843:
Clean the filter mat
Maintenance interval: When indicated by the control system
The degree of contamination of the filter mat depends on the
respective manufacturing conditions.
if the LED "E4" flashes on the display of the cooling unit, this
means the filter mat must be cleaned.
Note
The filter mat protects the condenser from dirt.
6‐74
Water
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B836en
1
Fixing screw
2
Grid sheet
3
Filter mat
The machine cooler filter mat
Fig. 74623
1. Screw out the grid sheet.
2. Remove filter mat.
3. Clean the metal filter mats with a high-pressure cleaner and
re-insert. Replace damaged filter mats.
4. Reinstall the grid plate.
B836en
2017-11-17
Water
6‐75
106841:
Replace cooling water
Maintenance interval: Annually
cleaning biocide is added to the cooling circuit 2 hours before
changing the cooling water. During the cleaning cycle, the
machine is ready for operation.
After the cleaning cycle, the water tank is cleaned and the cooling circuit is flushed with fresh water at least 3x.
After replacing the cooling water, replace the cartridge in the
water filter.
Conditions
■
■
Laser device is ready for operation and assigned to the
machine.
The machine's drives are switched on: The
MACHINE ON/OFF button lights up.
Means, Tools, Materials
■
■
■
■
■
■
160 l demineralized water.
Easy Kit CU-3.
Conductivity measuring device.
Protective gloves.
Safety glasses.
Flat blade screwdriver
Notes
■
■
■
NOTICE
For each rinse cycle, the tank is filled up to 60% with fresh
water.
The water in the cooling circuit will only be circulated if the
drives are switched on.
Switch off each of the drives before draining off the water
and switch back on again after filling up.
Corrosion and microbial contamination of the cooling
circuit!
Material damage to the cooling circuit of the machine.
Ø
Ø
Ø
Ø
6‐76
Water
Only use fresh and clean de-ionized water.
Thoroughly rinse the cooling circuit after the cleaning run.
Do not operate the cleaning circuit without corrosion protection.
Only use cleaning biocide when cleaning.
2017-11-17
B836en
1
Central cover plate
2
Lower cover plate
Machine cooling unit cover plate
1
Condenser
2
Cover
Fig. 74621
3
Water container
Replacing the water in the machine's cooling unit
B836en
2017-11-17
Fig. 74625
Water
6‐77
Starting the cleaning cycle
Draining water
1. Remove the cover plate from the rear side of the machine's
body, positions 1 and 2 (fig. 74621).
2. Open the water container and add cleaning biocide to the
water. Close the water container
3. Switch the drives on again: Press the MACHINE ON/OFF
button.
4. Production can continue while the cleaning biocide takes
effect.
5. After 2 hours end the cleaning cycle: Press the MACHINE
ON/OFF button.
1
Water outlet
Machine cooling unit water drain
Fig. 74626
6. If not yet done, remove the lower cover sheet, pos. 2
(Fig. 74621). Open the shut-off valve and drain the water
completely.
7. Close shut-off valve once again.
Flushing the cooling circuit
6‐78
Water
8. Fill the tank up to about 60% with fresh, demineralized water.
9. Close the water container
10. Switch the drives on again: Press the MACHINE ON/OFF
button.
11. Wait for approx. 10 minutes.
12. Switch off the drives: Press the MACHINE ON/OFF button.
13. Drain the water completely.
14. Carry out the second and third flushing processes, each with
fresh water.
2017-11-17
B836en
Measure conductivity
15.
16.
17.
18.
Fill the tank up to about 60% with fresh, demineralized water.
Wait for approx. 10 minutes. Drives must be switched on.
Measure the conductivity of the water.
If the conductivity of the water is less than or equal to 20 µS/
cm, completely fill the tank and add an anticorrosive agent
Water Care-Copper.
or
Ø If the conductivity of the water is greater than 20 µS/cm:
rinse the cooling circuit. Afterwards, fill with fresh water,
flush for approx. 10 minutes and measure the conductivity again.
19. After adding the anticorrosive agent wait for about 10
minutes.
20. Afterwards, measure the conductivity of the water again. If
the conductivity is still more than 200 µS/cm, the cooling
water must be completely replaced again.
The cooling water replacement is completed when the conductivity of the water does not exceed 200 µS/cm.
21. On completing the replacement of the cooling water, top up
the water container and close it.
22. On completing the replacement of the cooling water, clean
the condenser with compressed air and replace the insert in
the water filter.
23. After completion of the all of the maintenance work, reinstall
the cover plate.
B836en
2017-11-17
Water
6‐79
106845:
Replace the filter element.
Maintenance interval: Annually
Replace the filter element in the water filter each time the cooling water is replaced.
1
Stop cocks (2x)
2
Water filter
Machine cooling unit water filter
1.
2.
3.
4.
5.
6‐80
Water
Fig. 74620
Close the stop cocks on the water filter.
Screw out the filter container and clean it.
Replace the filter insert.
Screw the filter container back in.
Open the stop valves.
2017-11-17
B836en
Machine cooler (option), water/water chiller
(see "Overview", pg. 6‐69)
107301:
Check filling level
Maintenance interval: Monthly
Means, Tools, Materials
■
Demineralized water.
Note
Generally, little water is lost from the closed cooling circuit, as
long as the water tank has been closed properly. If the cooling
circuit loses water within a short period of time, then the cause
must be found.
Ø Check the filling level. When the minimum filling level is
reached: Top up with water.
107300:
Replace cooling water
Maintenance interval: Annually
cleaning biocide is added to the cooling circuit 2 hours before
changing the cooling water. During the cleaning cycle, the
machine is ready for operation.
After the cleaning cycle, the water tank is cleaned and the cooling circuit is flushed with fresh water at least 3x.
After replacing the cooling water, replace all water filters for the
cooling circuit.
Conditions
■
■
Laser device is ready for operation and assigned to the
machine.
The machine's drives are switched on: The
MACHINE ON/OFF button lights up.
Means, Tools, Materials
■
■
■
■
■
■
B836en
2017-11-17
160 l demineralized water.
Easy Kit CU-3.
Conductivity measuring device.
Protective gloves.
Safety glasses.
Flat blade screwdriver
Water
6‐81
Notes
■
■
■
NOTICE
For each rinse cycle, the tank is filled up to 60% with fresh
water.
The water in the cooling circuit will only be circulated if the
drives are switched on.
Switch off each of the drives before draining off the water
and switch back on again after filling up.
Corrosion and microbial contamination of the cooling
circuit!
Material damage to the cooling circuit of the machine.
Ø
Ø
Ø
Ø
Only use fresh and clean de-ionized water.
Thoroughly rinse the cooling circuit after the cleaning run.
Do not operate the cleaning circuit without corrosion protection.
Only use cleaning biocide when cleaning.
Preparing the cooling water
replacement
1. Remove the lower cover sheet of the machine cooler from
the rear side of the machine frame.
Starting the cleaning cycle
2. Open the water container and add cleaning biocide to the
water. Close the water container
3. Switch the drives on again: Press the MACHINE ON/OFF
button.
Draining water
4. After 2 hours end the cleaning cycle: Press the MACHINE
ON/OFF button.
6‐82
Water
2017-11-17
B836en
1
Water outlet
Machine cooling unit water drain
Fig. 74626
5. If not yet done, remove the lower cover sheet, pos. 2
(Fig. 74621). Open the shut-off valve and drain the water
completely.
6. Close shut-off valve once again.
Flushing the cooling circuit
Measure conductivity
7. Fill the tank up to about 60% with fresh, demineralized water.
8. Close the water container
9. Switch the drives on again: Press the MACHINE ON/OFF
button.
10. Wait for approx. 10 minutes.
11. Switch off the drives: Press the MACHINE ON/OFF button.
12. Drain the water completely.
13. Carry out the second and third flushing processes, each with
fresh water.
14.
15.
16.
17.
Fill the tank up to about 60% with fresh, demineralized water.
Wait for approx. 10 minutes. Drives must be switched on.
Measure the conductivity of the water.
If the conductivity of the water is less than or equal to 20 µS/
cm, completely fill the tank and add an anticorrosive agent
Water Care-Copper.
or
Ø If the conductivity of the water is greater than 20 µS/cm:
rinse the cooling circuit. Afterwards, fill with fresh water,
flush for approx. 10 minutes and measure the conductivity again.
18. After adding the anticorrosive agent wait for about 10
minutes.
B836en
2017-11-17
Water
6‐83
19. Afterwards, measure the conductivity of the water again. If
the conductivity is still more than 200 µS/cm, the cooling
water must be completely replaced again.
The cooling water replacement is completed when the conductivity of the water does not exceed 200 µS/cm.
20. On completing cooling water replacement, top up the water
container and close it tightly.
21. On completing the replacement of the cooling water, clean
the condenser with compressed air and replace the insert in
the water filter.
22. After completion of the all of the maintenance work, reinstall
the cover plate.
6‐84
Water
2017-11-17
B836en
106845:
Replace the filter element.
Maintenance interval: Annually
Replace the filter element in the water filter each time the cooling water is replaced.
1
Stop cocks (2x)
2
Water filter
Machine cooling unit water filter
1.
2.
3.
4.
5.
B836en
2017-11-17
Fig. 74620
Close the stop cocks on the water filter.
Screw out the filter container and clean it.
Replace the filter insert.
Screw the filter container back in.
Open the stop valves.
Water
6‐85
10.
Optics
10.1 Overview
General guidelines
Utmost cleanliness and the greatest care must be ensured when
handling optical components. A clean environment, a clean work
station, and clean additional equipment are absolutely essential.
■
■
■
■
■
■
■
■
■
Safety notes
All work involving the removal, installation and cleaning of
optical components, as well as the adjustment of the laser
beam after cleaning, if necessary, may only be carried out by
trained personnel.
Optical components should be cleaned in clean rooms and
not in the vicinity of the machine itself.
Cover all exposed maintenance points on the machine's
beam guidance or its optics with optical adhesive tape.
Only the auxiliary tools included in the cleaning set may be
used.
Only touch the lenses and mirror wearing disposable gloves;
use cushioned tweezers if necessary.
Touch the lenses only on their circumference! Do not touch
the surface of the lens.
The optical surfaces must remain free of oil, grease and
dust.
Do not clean the optics with compressed air. This will contaminate the optical components with dirt particles.
Do not adjust the marked reference screws.
Note
The optical components (lens, deflection mirror and protective
glass) of the processing optics for processing with the solid-state
laser are made of silica glass. They are cleaned exclusively with
methanol.
NOTICE
Damage to the optical components!
Ø
Ø
NOTICE
Fire hazard due to methanol!
Ø
Ø
6‐86
Optics
Use only methanol to clean the optical components made of
silica glass.
Do not use acetone , Topol or Optics Cleaner for cleaning.
Keep methanol away from ignition sources.
Do not smoke.
2017-11-17
B836en
Danger of poisoning due to methanol!
WARNING
Ø
Ø
Ø
Additional equipment, tools,
materials
■
■
■
■
■
■
■
■
■
■
■
Tool for the sensor body
and lens
Do not breathe in or ingest methanol fumes.
Make sure there is plenty of fresh air.
Wash your hands after the cleaning process.
Allen keys sizes 2.5, 3, 4, and 5 mm.
Face wrench.
Screwdriver.
Suction cups.
Bellows.
For cleaning all machine optical components: complete cleaning kit (TRUMPF order number 1675885).
LED lamp with white light.
Lens adapter device (TRUMPF order number 1652982).
Finger cots (TRUMPF order number 0145843) or Nietriel disposable gloves (TRUMPF order number 0352197).
Cleaning cloths (TRUMPF order number 0359506).
Optical adhesive tape (TRUMPF order number 1317829).
This tool is included in the scope of delivery of the cutting optics.
It is used to replace the lens and the sensor body.
Tool B
Tool A
Tool for sensor body/lens
Fig. 73822
Focal
length
Material no.
Tool A
Tool B
f = 150 mm
1846903
To replace
the lens.
To replace the sensor body.
-
■
To replace the lens.
■
To replace the sensor
body.
f = 200 mm
Application
B836en
2017-11-17
Tab. 6-6
Optics
6‐87
10.2 Maintenance Instructions
Cutting optics with a focal length of
150 mm
(see "Overview", pg. 6‐86)
106565:
Clean the housing
Maintenance interval: As needed
Particularly when processing high-tensile steels (hot-forming
parts), a very fine, oily cutting dust is produced, which gets stuck
in the housing of the dynamic processing optics. If the dust is
not cleaned from the housing, this leads to malfunction of
the additional axis.
The level of contamination of the optics depends on which materials are being processed.
The housing is cleaned with a spatula that has been dipped in
methanol and with cleaning cloths.
Recommendation: always clean the housing before cleaning the
lens.
Means, Tools, Materials
■
■
■
■
■
Cleaning cloths (TRUMPF order number 0359506).
Spatula.
Methanol.
Allen key size 2.
Allen key SW 3.
Notes
■
■
NOTICE
Damage to the optical components due to improper
maintenance.
Ø
6‐88
Optics
Only service the processing optics in a clean room area.
If the cutting insert and the deflection mirror are removed
before cleaning the spaces, cutting dust falls on the lens and
deflection mirror.
Do not clean processing optics and optical components with
compressed air.
2017-11-17
B836en
Clean the outer surface
1
Guard
1. Remove processing optics from the machine and close the
beam aperture in the optics using the protective cover.
2. Clean optics thoroughly from outside.
3. Remove the protective cover from the cutting insert.
4. Pull cutting insert forcefully in order to remove the mobile
section of the optics from the fixed housing section.
5. Undo the screws on the covering and pull it toward the cutting insert.
2
Cutting insert
Fig. 68902
6. Clean the spaces, edges and spindles
Fig. 68900
Clean internal surfaces
B836en
2017-11-17
7. If the optics need to be cleaned more thoroughly, remove the
deflection mirror and cutting insert.
8. Pull the bellows holder out of the housing and pull the bellows off of its holder.
9. Clean interior and exterior bellows thoroughly.
Optics
6‐89
A
Narrow lip
B
Wide lip
Fig. 74634
10. Either
Ø Put the cleaned bellows back onto the bellows holder,
make sure that it is the right way around: Pull the narrow
lip onto the bellows holder. The wide lip points upwards.
or
Ø Clean the lens.
11. Clean internal surfaces of the optics.
Fig. 68903
12. Clean the deflection mirror and insert it back into the optics.
13. Mount the cutting insert.
14. Screw the guard back on tightly.
6‐90
Optics
2017-11-17
B836en
106812:
Checking, cleaning or
replacing the lens
Maintenance interval: As needed
All optical components must be absolutely clean. Streaks, grains
of dust or scorching could influence the focus shift or the focal
position and thus lead to cutting problems.
In the event of cutting problems, first check the focal position
and then, if necessary, re-determine it. If this does not lead to an
improvement, clean the lens.
The lens must be cleaned even if it is contaminated only slightly.
The lens must be replaced immediately if damaged.
Means, Tools, Materials
■
■
■
■
■
■
■
Torque wrench.
AF 1.5 Allen key
Allen key SW 4.
Tool for sensor body and lens (belongs to the scope of delivery of the machine).
Cleaning cloths (TRUMPF order number 0359506).
Complete solid state laser cleaning set (TRUMPF order number 1675885).
The following additional equipment will be needed from the
cleaning set:
−
−
−
−
−
LED lamp (TRUMPF order number 1632115).
Lens adapter fixture (TRUMPF order number 1652982).
Methanol (TRUMPF order number 0764334).
Bellows (TRUMPF order number 0779473).
Spatula (TRUMPF order number 1222024).
Notes
■
■
■
■
B836en
2017-11-17
Only service the processing optics in a clean room area.
Each time, before opening the optical system, the spaces as
well as the outside of the housing must be cleaned, to prevent cutting dust from getting onto the lens or the mirror.
When the lens is cleaned, the bellows in the optical housing
should also be cleaned.
The sealing ring in the cutting optics seals the housing gas
tight. Make sure that the new sealing ring is properly seated.
Replace if damaged.
Optics
6‐91
Removing the lens
1. Remove processing optics from the machine and close the
beam aperture in the optics using the protective cover.
1
Mounting screws (2x)
3
Fixing screw
2
Protective cover
4
Cutting insert
Fig. 73673
2. Remove the protective cover from the cutting insert:
− Undo the two fixing screws (posn. 1 and diagonally
opposing) on the flange of the protective cover.
− Pull off the protective cover (posn. 2).
3. Undo the cutting insert:
− Undo four fixing screws (posn. 3) on the cutting insert.
− Pull the cutting insert off from the housing.
4. Remove the lens cartridge (fig. 73674):
− Undo the union nut (posn. 1).
− Pull the lens cartridge (posn. 2) out (don't unscrew
it).
6‐92
Optics
2017-11-17
B836en
1
Union nut
2
Lens cartridge
Fig. 73674
5. Remove lens (see "Fig. 73675", pg. 6‐93):
− Put tool B (see "Fig. 73822", pg. 6‐87) on the lens
adapter (pos. 4) and rotate until both pins engage.
− Only undo the lens holder in the lens cartridge
(posn. 1), do not completely unscrew it.
− Put the tool on a flat surface and carefully remove the
lens cartridge so that the lens is not damaged.
Caution! The lens lies loosely on its holder.
1
Lens cartridge
2
Tool
3
Lens
4
Lens adapter
Fig. 73675
B836en
2017-11-17
Optics
6‐93
Cleaning the lens
Notes
Clean the convex side first and the flat side afterward.
■
Use the spatula only once.
■
Do not look into the intensive, white light emitted by the
lamp.
■
Avoid streaking.
6. Switch on the LED lamp and place on the lens support. Blow
off the lens holder using the bellows.
■
Fig. 60299
7. First place the lens with the convex side facing up on the
lens holder and blow it clean using bellows.
8. Moisten the spatula with methanol.
9. Slowly and carefully, clean the lens with the spatula with circular movements.
10. Turn the lens over and clean the other side in the same way.
11. Check the lens using the white LED lamp, and while doing
this, gently rotate the lens on its support.
Installing the lens
Note
If the support ring is inserted with the wrong side facing
upward, the inside edge of the support ring will press against
the lens and damage it.
12. Blow off single parts with bellows.
6‐94
Optics
2017-11-17
B836en
1
Lens adapter
3
Support ring
2
Spring ring
4
Lens
Fig. 73676
13. Fit the lens (fig. 73676):
− Place the spring lock washer (posn. 2) into the lens
adapter (posn. 1).
− Place the support ring (posn. 3) into the lens holder with
the bevel facing upwards.
− Place the lens (posn. 4) in the lens holder with the convex side upwards (so that the labelling is legible) into the
lens holder.
14. Carefully screw the lens cartridge onto the lens holder and
tighten, hand-tight.
Cleaning the bellows
(option)
1
Bellows holder
Fig. 72874
B836en
2017-11-17
Optics
6‐95
15. Pull the bellows holder out of the optical housing and then
pull the bellows off.
16. Thoroughly clean the bellows and bellows holder with cleaning cloths inside and out.
17. Thoroughly clean the inner housing of the optics.
18. Pull the thin lip of the bellows over the bellows holder. The
bellows must lie fully on the shoulder of the bellows holder.
A
Narrow lip
B
Wide lip
Fig. 73678
19. Put the bellows and the bellows holder back into the housing.
Installing the cutting insert
The contacts and the flat surfaces must be absolutely clean.
1
Cylindrical pin/Mating hole
3
Lens cartridge
2
Sealing ring
4
Sealing ring
5
Union nut
Fig. 73677
20. Fit the lens cartridge (posn. 3) in the correct orientation into
the cutting insert and press down as far as it goes.
6‐96
Optics
2017-11-17
B836en
Make sure that the sealing rings (posn. 2 and 4) are properly
seated.
21. Screw the union nut (posn. 5) hand-tight to the cutting insert.
22. Mount the cutting insert back into the optical housing:
− Place the cutting insert in the housing and align it to the
cylindrical pin.
− Tighten the four fixing screws on the cutting insert with a
torque of 4 Nm.
− Remount the protective cover.
23. After the lens has been cleaned or replaced:
− Re-center the nozzle to the beam.
− Check and set the focal position.
105127:
Checking, cleaning or
replacing the deflection
mirror
Maintenance interval: As needed
If there are still cutting problems, despite cleaning the lens, this
can be because the mirror in the cutting optics (or the FocusLine
mirror in the angular gear) is dirty (particles or coating) or damaged.
The deflection mirror in the processing optics is a permanently
installed mirror. It is not necessary to adjust the beam after
cleaning the mirror or after replacing the entire mirror block.
The deflection mirror must be replaced if it is scratched or damaged. It is completely replaced with the mirror holder. The mirror
must be absolutely clean.
Means, Tools, Materials
■
■
■
■
Allen key SW 3.
Torque wrench.
Complete solid state laser cleaning set (TRUMPF order number 1675885).
The following additional equipment will be needed from the
cleaning set:
−
−
−
−
−
LED lamp (TRUMPF order number 1632115).
Methanol (TRUMPF order number 0764334).
Bellows (TRUMPF order number 0779473).
Spatula (TRUMPF order number 1222024).
Green optical adhesive tape (TRUMPF order number
1317829).
Notes
■
■
B836en
2017-11-17
Only service the processing optics in a clean room area.
Do not open or remove the cap (posn. 2, fig. 73672).
Optics
6‐97
1
Befestigungsschrauben
2
Sealing cap
3
Silica mirror
Fig. 73672
Checking the deflection
mirror
Cleaning the mirror
100048:
Cleaning the sensor body
and the nozzle
1. Remove processing optics from the machine and close the
beam aperture in the optics using the protective cover.
2. Undo the fixing screws (posn. 1) for the mirror holder.
3. Pull out the mirror holder carefully. Clean the mirror if it is
contaminated.
4. Use bellows to blast off the mirror.
5. Carefully clean the mirror surface with the spatula and methanol with circular movements.
6. Check the cleanliness with a white LED lamp.
7. Blow the mirror support area clean using bellows.
8. Carefully put the mirror back into the optical housing.
9. Tighten the four fixing screws on the mirror holder with a torque of 2.5 Nm.
Maintenance interval: As needed
The sensor body is a component important for the functioning of
the distance regulation. The sensor body, the nozzle and the
cover ring must be clean so that distance regulation functions
reliably. A damaged nozzle or a damaged sensor body must be
replaced.
Ø Remove the slag spatter using a flange; do not use any
sharp objects.
6‐98
Optics
2017-11-17
B836en
102281:
Replacing the sensor body
Maintenance interval: As needed
The sensor body is only replaced in the event of a malfunction.
Means, Tools, Materials
■
■
■
■
Allen key SW 4.
Tool for sensor body and lens (belongs to the scope of delivery of the machine).
Bellows.
Clean, lint-free cloth.
Notes
■
■
Damaged sealing rings must be replaced.
Hold the sensor body firmly while releasing it. It could fall off
as soon as it is released.
The anodized (brown) components on the sensor body are functional components which help with insulation. Check and clean
the anodized components before installing the new sensor body.
All mating surface must be clean and correctly seated. Damaged
components must be replaced.
1
Bushing
4
Insulation ring
2
Cutting insert
5
Sensor body
3
Cover ring
Replace the sensor body
B836en
2017-11-17
Fig. 48939
Optics
6‐99
Removing the sensor body
1
Bushing
1. Remove processing optics from the machine (see chapter
"Setting work").
2. Remove the protective cover from the cutting insert.
3. Undo the cutting insert from the housing and remove the
lens cartridge.
4. Unscrew the sleeve from the cutting insert:
− Place tool B into the sleeve so that all four pins are
engaged in the sleeve's slots.
− Rotate the tool to the left till the sleeve is loosened.
2
Tool for sensor body
3
Cutting insert
Fig. 51636
Installing a new sensor body
6‐100
Optics
5. Fit the cover ring, sensor body and insulation ring onto the
cutting insert. Turn the cover ring so that the four screws in
the cutting insert are covered.
6. Fit the sleeve into the cutting insert and screw, hand-tight, to
the body of the sensor.
7. Fit the lens cartridge into the cutting insert and screw into
place.
8. Return the cutting insert to the optical housing and tighten
the four fixing screws on the flange with a torque of 4 Nm.
9. If there is one, reinstall the protective cover from the cutting
insert.
2017-11-17
B836en
Cutting optics with a focal length of
200 mm
(see "Overview", pg. 6‐86)
106565:
Clean the housing
Maintenance interval: As needed
Particularly when processing high-tensile steels (hot-forming
parts), a very fine, oily cutting dust is produced, which gets stuck
in the housing of the dynamic processing optics. If the dust is
not cleaned from the housing, this leads to malfunction of
the additional axis.
The level of contamination of the optics depends on which materials are being processed.
The housing is cleaned with a spatula that has been dipped in
methanol and with cleaning cloths.
Recommendation: always clean the housing before cleaning the
lens.
Means, Tools, Materials
■
■
■
■
■
Cleaning cloths (TRUMPF order number 0359506).
Spatula.
Methanol.
Allen key size 2.
Allen key SW 3.
Notes
■
■
Damage to the optical components due to improper
maintenance.
NOTICE
Ø
B836en
Only service the processing optics in a clean room area.
If the cutting insert and the deflection mirror are removed
before cleaning the spaces, cutting dust falls on the lens and
deflection mirror.
2017-11-17
Do not clean processing optics and optical components with
compressed air.
Optics
6‐101
Clean the outer surface
1
Guard
1. Remove processing optics from the machine and close the
beam aperture in the optics using the protective cover.
2. Clean optics thoroughly from outside.
3. Remove the protective cover from the cutting insert.
4. Pull cutting insert forcefully in order to remove the mobile
section of the optics from the fixed housing section.
5. Undo the screws on the covering and pull it toward the cutting insert.
2
Cutting insert
Fig. 68902
6. Clean the spaces, edges and spindles
Fig. 68900
Clean internal surfaces
6‐102
Optics
7. If the optics need to be cleaned more thoroughly, remove the
deflection mirror and cutting insert.
8. Pull the bellows holder out of the housing and pull the bellows off of its holder.
9. Clean interior and exterior bellows thoroughly.
2017-11-17
B836en
A
Narrow lip
B
Wide lip
Fig. 74634
10. Either
Ø Put the cleaned bellows back onto the bellows holder,
make sure that it is the right way around: Pull the narrow
lip onto the bellows holder. The wide lip points upwards.
or
Ø Clean the lens.
11. Clean internal surfaces of the optics.
Fig. 68903
12. Clean the deflection mirror and insert it back into the optics.
13. Mount the cutting insert.
14. Screw the guard back on tightly.
B836en
2017-11-17
Optics
6‐103
106811:
Checking, cleaning or
replacing the lens
Maintenance interval: As needed
All optical components must be absolutely clean. Streaks, grains
of dust or scorching could influence the focus shift or the focal
position and thus lead to cutting problems.
If cutting problems arise first of all check the focal position. If
necessary, re-determine it. If this does not lead to an improvement: clean the lens.
The lens must be cleaned even if it is contaminated only slightly.
The lens must be replaced immediately if damaged.
Means, Tools, Materials
■
■
■
■
■
■
■
Torque wrench.
AF 1.5 Allen key
Allen key SW 4.
Tool for sensor body and lens (belongs to the scope of delivery of the machine).
Cleaning cloths (TRUMPF order number 0359506).
Complete solid state laser cleaning set (TRUMPF order number 1675885).
The following additional equipment will be needed from the
cleaning set:
−
−
−
−
−
LED lamp (TRUMPF order number 1632115).
Lens adapter fixture (TRUMPF order number 1652982).
Methanol (TRUMPF order number 0764334).
Bellows (TRUMPF order number 0779473).
Spatula (TRUMPF order number 1222024).
Notes
■
■
■
■
6‐104
Optics
Only service the processing optics in a clean room area.
Each time, before opening the optical system, the spaces as
well as the outside of the housing must be cleaned, to prevent cutting dust from getting onto the lens or the mirror.
When the lens is cleaned, the bellows in the optical housing
should also be cleaned.
The sealing ring in the cutting optics seals the housing gas
tight. Make sure that the new sealing ring is properly seated.
Replace if damaged.
2017-11-17
B836en
Removing the lens
1. Remove processing optics from the machine and close the
beam aperture in the optics using the protective cover.
1
Mounting screws (2x)
3
Fixing screw
2
Protective cover
4
Cutting insert
Fig. 73666
2. Remove the protective cover from the cutting insert:
− Undo the two fixing screws (posn. 1 and diagonally
opposing) on the flange of the protective cover.
− Pull off the protective cover (posn. 2).
3. Undo the cutting insert:
− Undo four fixing screws (posn. 3) on the cutting insert.
− Pull the cutting insert off from the housing.
4. Undo the union nut on the cutting insert (fig. 73837).
B836en
2017-11-17
Optics
6‐105
1
Lens cartridge
2
Union nut
Fig. 73837
5. Pull the lens cartridge out (don't unscrew it).
Note
Caution! The lens lies loosely on its holder.
6. Remove the lens (fig. 73667):
− Put tool "B" onto the lens holder and turn it until all of the
pins engage.
− Only undo the lens holder in the lens cartridge, don't
completely unscrew it.
− Put the lens holder on a flat surface and carefully remove
the lens cartridge so that the lens is not damaged.
6‐106
Optics
2017-11-17
B836en
1
Lens cartridge
3
Lens adapter
2
Lens
4
Tool
Fig. 73667
Cleaning the lens
Notes
Clean the convex side first and the flat side afterward.
Use the spatula only once.
■
Do not look into the intensive, white light emitted by the
lamp.
■
Avoid streaking.
7. Switch on the LED lamp and place on the lens support. Blow
off the lens holder using the bellows.
■
■
Fig. 60299
8. First place the lens with the convex side facing up on the
lens holder and blow it clean using bellows.
9. Moisten the spatula with methanol.
B836en
2017-11-17
Optics
6‐107
10. Slowly and carefully, clean the lens with the spatula with circular movements.
11. Turn the lens over and clean the other side in the same way.
12. Check the lens using the white LED lamp, and while doing
this, gently rotate the lens on its support.
Installing the lens
13. Blow off single parts with bellows.
Note
If the support ring is inserted with the wrong side facing
upward, the inside edge of the support ring will press against
the lens and damage it.
14. Fit the lens (fig. 73668):
− Place the spring lock washer (posn. 2) into the lens
adapter (posn. 1).
− Place the support ring (posn. 3) into the lens holder with
the bevel facing upwards.
− Place the lens (posn. 4) in the lens holder with the convex side upwards (so that the labelling is legible) into the
lens holder.
1
Lens adapter
3
Support ring
2
Spring ring
4
Lens
Fig. 73668
15. Carefully screw the lens cartridge onto the lens holder and
tighten, hand-tight.
Cleaning the bellows
(option)
6‐108
Optics
16. Pull the bellows holder out of the optical housing and then
pull the bellows off.
17. Thoroughly clean the bellows and bellows holder with cleaning cloths inside and out.
2017-11-17
B836en
1
Bellows holder
2
Bellows
Fig. 73670
18. Thoroughly clean the inner housing of the optics.
19. Pull the thin lip of the bellows over the bellows holder. The
bellows must lie fully on the shoulder of the bellows holder.
20. Put the bellows and the bellows holder back into the housing.
Installing the cutting insert
1
Cylindrical pin/Mating hole
The contacts and the flat surfaces must be absolutely clean.
2
Union nut
Fig. 73669
21. Fit the lens cartridge in the correct orientation into the cutting
insert and press down as far as it goes.
22. Screw the union nut (posn. 2) hand-tight to the cutting insert.
23. Mount the cutting insert back into the optical housing:
B836en
2017-11-17
Optics
6‐109
−
Place the cutting insert in the housing and align it to the
cylindrical pin.
− Tighten the four fixing screws on the cutting insert with a
torque of 4 Nm.
− Remount the protective cover.
24. After the lens has been cleaned or replaced:
− Re-center the nozzle to the beam.
− Check and set the focal position.
105127:
Checking, cleaning or
replacing the deflection
mirror
Maintenance interval: As needed
If there are still cutting problems, despite cleaning the lens, this
can be because the mirror in the cutting optics (or the FocusLine
mirror in the angular gear) is dirty (particles or coating) or damaged.
The deflection mirror in the processing optics is a permanently
installed mirror. It is not necessary to adjust the beam after
cleaning the mirror or after replacing the entire mirror block.
The deflection mirror must be replaced if it is scratched or damaged. It is completely replaced with the mirror holder. The mirror
must be absolutely clean.
Means, Tools, Materials
■
■
■
■
Allen key SW 3.
Torque wrench.
Complete solid state laser cleaning set (TRUMPF order number 1675885).
The following additional equipment will be needed from the
cleaning set:
−
−
−
−
−
LED lamp (TRUMPF order number 1632115).
Methanol (TRUMPF order number 0764334).
Bellows (TRUMPF order number 0779473).
Spatula (TRUMPF order number 1222024).
Green optical adhesive tape (TRUMPF order number
1317829).
Notes
■
■
6‐110
Optics
Only service the processing optics in a clean room area.
Do not open or remove the cap (posn. 2, fig. 73672).
2017-11-17
B836en
1
Befestigungsschrauben
2
Sealing cap
3
Silica mirror
Fig. 73672
Checking the deflection
mirror
Cleaning the mirror
100048:
Cleaning the sensor body
and the nozzle
1. Remove processing optics from the machine and close the
beam aperture in the optics using the protective cover.
2. Undo the fixing screws (posn. 1) for the mirror holder.
3. Pull out the mirror holder carefully. Clean the mirror if it is
contaminated.
4. Use bellows to blast off the mirror.
5. Carefully clean the mirror surface with the spatula and methanol with circular movements.
6. Check the cleanliness with a white LED lamp.
7. Blow the mirror support area clean using bellows.
8. Carefully put the mirror back into the optical housing.
9. Tighten the four fixing screws on the mirror holder with a torque of 2.5 Nm.
Maintenance interval: As needed
The sensor body is a component important for the functioning of
the distance regulation. The sensor body, the nozzle and the
cover ring must be clean so that distance regulation functions
reliably. A damaged nozzle or a damaged sensor body must be
replaced.
Ø Remove the slag spatter using a flange; do not use any
sharp objects.
B836en
2017-11-17
Optics
6‐111
102281:
Replacing the sensor body
Maintenance interval: As needed
The sensor body is only replaced in the event of a malfunction.
Means, Tools, Materials
■
■
■
■
Allen key SW 4.
Tool for sensor body and lens (belongs to the scope of delivery of the machine).
Bellows.
Clean, lint-free cloth.
Notes
■
■
Damaged sealing rings must be replaced.
Hold the sensor body firmly while releasing it. It could fall off
as soon as it is released.
The anodized (brown) components on the sensor body are functional components which help with insulation. Check and clean
the anodized components before installing the new sensor body.
All mating surface must be clean and correctly seated. Damaged
components must be replaced.
1
Bushing
4
Insulation ring
2
Cutting insert
5
Sensor body
3
Cover ring
Replace the sensor body
6‐112
Optics
Fig. 48939
2017-11-17
B836en
1. Remove processing optics from the machine (see chapter
"Setting work").
2. Remove the protective cover from the cutting insert.
3. Undo the cutting insert from the housing and remove the
lens cartridge.
4. Unscrew the sleeve from the cutting insert:
− Place tool B into the sleeve so that all four pins are
engaged in the sleeve's slots.
− Rotate the tool to the left till the sleeve is loosened.
Removing the sensor body
1
Bushing
2
Tool for sensor body
3
Cutting insert
Fig. 51636
Installing a new sensor body
B836en
2017-11-17
5. Fit the cover ring, sensor body and insulation ring onto the
cutting insert. Turn the cover ring so that the four screws in
the cutting insert are covered.
6. Fit the sleeve into the cutting insert and screw, hand-tight, to
the body of the sensor.
7. Fit the lens cartridge into the cutting insert and screw into
place.
8. Return the cutting insert to the optical housing and tighten
the four fixing screws on the flange with a torque of 4 Nm.
9. If there is one, reinstall the protective cover from the cutting
insert.
Optics
6‐113
Angular gear: FocusLine mirror
(see "Overview", pg. 6‐86)
106810:
Checking and cleaning the
deflection mirror
Maintenance interval: As needed
If there are cutting problems, apart from checking the lens in the
processing optics, the FocusLine mirror in the B/C angular gears
should also be checked.
If the mirror is soiled, then it needs to be cleaned. A damaged
mirror must be replaced.
The adaptive FocusLine mirror is air-cooled. Before removing the
mirror holder, the compressed air supply must be shut off.
Means, Tools, Materials
■
■
■
■
■
■
Flat-bladed screwdriver
Allen key SW 4.
Cleaning cloths (TRUMPF order number 0359506).
1-propanol.
Finger cots (TRUMPF order number 0145843) or Nietriel disposable gloves (TRUMPF order number 0352197).
Lens cleaning paper (Kodak) (TRUMPF order number
1687226).
Notes
■
■
6‐114
Optics
Use optical adhesive tape to close the opening in the
angular gear while the mirror is being cleaned.
There is a loose spring lock washer in the mirror housing.
2017-11-17
B836en
Checking mirrors
Removing and cleaning the
mirror
1. Remove the processing optics and check the mirror through
the opening in the angular gear with a pocket lamp. If there
are dirt particles or a coating on the surface of the mirror,
then remove the mirror and clean it.
2. Turn the C axis so that you have easy access to the angular
gear.
3. Shut off the compressed air supply: Press the MACHINE ON/
OFF button.
1
Mirror holder fixing screws
2
Mirror fixing screw
Removing the mirror
Fig. 71430
4. Remove the four fixing screws on the mirror holder and carefully pull it out.
5. Undo the central slotted screw and carefully remove the mirror from the housing. Do not touch the surface of the mirror.
6. On the back of the mirror, remove the supply connections
and put the mirror with its back down onto something
clean and flat.
7. Blow off mirror surface with bellows.
B836en
2017-11-17
Optics
6‐115
Pre-cleaning the mirror
Fig. 72870
8. Preclean the mirror surface with propanol and a spatula. The
propanol removes particles, as well as grease and oil residues.
− Moisten the spatula generously with propanol.
− Clean the surface of the mirror with the spatula, while
holding the spatula at a slight angle. With slow, circular
movements, clean the surface of the mirror from the center outwards, until there are no more particles to be seen
on the surface.
− Then with the spatula, run once around the outer flat
edge of the mirror.
− Then go once around the circumference of the mirror
with the spatula.
− With the white LED lamp check whether the mirror surface is completely clean.
Fig. 72872
Finally cleaning the mirror
9. The final cleaning will be done with methanol and lens cleaning paper.
− Apply methanol to the cleaned mirror surface and place
lens cleaning paper on it.
− With the moist lens cleaning paper, wipe several times
backwards and forwards over the surface of the mirror.
− Finally, pull the lens cleaning paper off from the mirror
surface in one direction.
− Repeat the final cleaning as required.
The cleaning is finished when there are no more particles or
smears on the mirror surface.
10. Re-attach the supply connections to the back of the mirror.
6‐116
Optics
2017-11-17
B836en
11. Put the mirror body back into the mirror holder.
− Clean the mirror housing with a cleaning cloth.
− Insert the spring lock washer.
− Carefully put the mirror, correctly oriented (supply and
return), the hole for the pin at the bottom, into the mirror
holder.
12. Hand tighten the central slotted screw.
13. Remove the adhesive optical tape and put the mirror holder
into the opening on the angular gear. Hand tighten the four
fixing screws.
14. Switch the supply of compressed air back on: Press the
MACHINE ON/OFF button.
15. Then check the focal position and adjust. (see "Start focus
search", pg. 5‐42)
B836en
2017-11-17
Optics
6‐117
11.
Electrics
11.1 Overview
DANGER
All components in the switch cabinet that have not been
de-energized are still live and dangerous for four minutes
after turning off the MAIN SWITCH!
Risk of fatal injury!
Ø
Ø
Ø
Maintenance work on the electrical system may only be performed once the machinery has been switched off and deenergized.
Do not touch components marked with warning signs.
Maintenance work on the electrical system may only be performed by qualified electricians.
Note
Batteries must not be charged or opened by force. Do not throw
batteries into fires!
11.2 Maintenance Instructions
Switch cabinet: Battery/fan unit, NC CPU
(see "Overview", pg. 6‐118)
106846:
Replacing the buffer battery
Maintenance interval: Annually
Notes
■
■
■
NOTICE
6‐118
Electrics
Three years beginning with the delivery date of the Siemens
control.
Acknowledge the danger zone and close the access door.
The complete fan unit is replaced.
Loss of data!
Ø
Replace battery within 15 minutes.
2017-11-17
B836en
1
Fan unit
2
Buffer battery
Fan unit buffer battery
1.
2.
3.
4.
5.
Fig. 74622
Switch off the MAIN SWITCH.
Open the left switch cabinet.
Pull the fan unit off downwards.
Fit a new fan unit.
Close the switch cabinet.
Switch cabinet: Industrial PC
(see "Overview", pg. 6‐118)
106847:
Replacing the buffer battery
Maintenance interval: Annually
The buffer battery on the Motherboard must be replaced after no
more than 5 years. It must be replaced when the system is powered down.
If it takes longer than 5 seconds to replace, then the time date
and basic settings will have to be set in the basic input/output
system (BIOS). Only the technical service can make these settings.
Notes
■
■
Five years from the delivery date of the control system by its
manufacturer, Beckhoff. If this time is exceeded, there is a
risk of data loss.
For machines with a maintenance contract, the battery will
be replaced during routine maintenance by the technical
service team.
Ø Have the buffer battery replaced by the technical service staff
during a maintenance or service call.
B836en
2017-11-17
Electrics
6‐119
107302:
UPS module, replacing the
rechargeable battery pack
Maintenance interval: Every 5 years
The Beckhoff IPC is equipped with an uninterruptible power supply (UPS) that temporarily supplies the industrial PC with power
in the event of a power failure in order to save data and shut
down the operating system correctly.
The UPS module is maintenance-free. The rechargeable battery
pack for the module should be replaced as a precautionary
measure.
Notes
■
■
Recommendation: Five years from the delivery date of the
control system by its manufacturer, Beckhoff. If this time is
exceeded, there is a risk of data loss.
For machines with a maintenance contract, the rechargeable
battery pack is replaced during routine maintenance by Technical Service.
Ø Have the rechargeable battery pack replaced by Technical
Service during a maintenance or service operation.
Switch cabinet: Air conditioning unit
(see "Overview", pg. 6‐118)
105405:
Cleaning the air conditioning
unit
Maintenance interval: Annually
The air conditioning units in both electrical cabinets are water-air
heat exchangers, which are connected to the cooling circuit of
the machine.
The condensate water is fed into the condensate tank via a
house at the device sheet.
Note
The cooling temperature is factory set and may not be
changed.
6‐120
Electrics
2017-11-17
B836en
1
Fixing screws
2
fan plate
3
Display plug
Air conditioning unit electrical cabinet
1.
2.
3.
4.
5.
6.
7.
8.
B836en
2017-11-17
Fig. 68764
Switch off the MAIN SWITCH.
Open the electrical cabinet doors.
Remove the display connector.
Release the fan plate and remove it carefully.
Blow out fan with compressed air.
Re-insert the fan plate and screw it firmly in place.
Re-insert the display plug.
Close the electrical cabinet.
Electrics
6‐121
12.
Compact dust extractor
12.1 Overview
The following maintenance may only be carried out by service
engineers from the manufacturer or other authorized and accordingly trained personnel.
■
■
■
Residual dust
WARNING
If the machine is used as intended, the filtered dust can be supplied for metal recycling. It does not have to be disposed of as
special waste. The relevant national and local regulations must
be observed.
Health hazard from inhalation of the residual dust.
Ø
Ø
Ø
Ø
Ø
Dust identification
Maintenance work on the extinguisher system (option).
Replacing valves, seals and filter inserts.
Checking the purging.
Wear a filter class P3 breathing mask.
Wear protective gloves.
Do not empty the dust container or fine dust bag.
Only transport the dust container or fine dust bag when
closed.
Before switching the machine off, wait for the lag time of the
exhaust system.
According to German national legal provisions, the dust container
or fine dust bag must be marked as follows for disposal:
Identification
Dust from steel machining
LAGA key 35101 (ferrous dust without harmful impurities)
or
EAK code 120102 (particles containing iron); EAK group: waste from
mechanical shaping (including welding and cutting)
Dust from aluminum machining
LAGA code 35304 (aluminum waste)
or
EAK code 120103 (chips and cuttings containing metals other than iron);
EAK group: waste from mechanical shaping (welding, cutting, among others)
Dust identification
6‐122
Compact dust extractor
Tab. 6-7
2017-11-17
B836en
Extinguisher system
The extinguisher system (CO2 or argon) is optional for the compact dust extractor. It is connected before the machine's main
switch.
The extinguisher system must be serviced and checked by its
manufacturer, every year. A record of the test must be produced.
The extinguisher system is only ready for use if the following conditions are met:
■
■
The extinguisher system is switched on.
The extinguishing gas cylinder is open and has been filled
with gas.
12.2 Maintenance Instructions
Compact dust extractor: dust container/fine
dust bag
(see "Overview", pg. 6‐122)
A fine dust bag that can be closed can be inserted in the dust
container. The dust that accumulates is collected in this special
fine dust bag (TRUMPF material number 1831493) and disposed
of. The sack for fine dust has a maximum capacity of 30 kg.
Fig. 68763
Dust container with fine dust bag
B836en
2017-11-17
Compact dust extractor
6‐123
105762:
Checking the level and
replacing the container or
fine dust sack
Maintenance interval: Weekly
Note:
This maintenance work is valid for the compact dust extractor without a level sensor.
The dust container is located below the dust discharge unit. The
fine dust sack or dust container can be replaced with the compact dust extractor switched on.
The amount of dust produced depends heavily on the
component and on the process. If a lot of dust is produced, it
may be necessary to check and empty the dust container on a
daily basis. The operator must adjust the maintenance interval at
regular intervals.
Means, Tools, Materials
■
Breathing mask 8833 FFP3 (mat. no. 0374270).
Notes
■
■
WARNING
There is a high fire risk in the dust container with
flammable, potentially explosive dust.
Ø
WARNING
Check the dust level in the container on a weekly or daily
basis.
Fire hazard in the dust container if an unsuitable fine dust
bag is used!
Ø
6‐124
Between the fine dust sack and the dust container, there is a
minimal gap to equalize the pressure. It is possible that small
amounts of dust fall through this gap into the container. If
there is dust in the container, empty it.
Misshapen dust containers must be replaced. The container
must be close to the dust discharge.
Compact dust extractor
Only the original fine dust bag (TRUMPF material number
1831493) may be used to collect the dust.
2017-11-17
B836en
A
Clamp container
1
Hand grip
B
Unscrewing the container
2
Dust container
Dust container (disposable container)
1.
2.
3.
4.
106277:
Replacing the dust container
Fig. 74615
Unlock and remove the dust container.
Check the level and replace the fine dust bag if necessary.
Seal the fine dust bag tightly with a lid and dispose of it.
Put a new fine dust bag in the container. Clamp the container under the dust discharge.
Maintenance interval: When indicated by the control system
Note:
This maintenance work is valid for the compact dust extractor with a level sensor (option).
The compact dust extractor is equipped with a level sensor at its
closing flap. In this case the control system will report when the
dust container has reached the maximum level and has to be
emptied.
The dust container is located below the dust discharge unit. The
fine dust sack or dust container can be replaced with the compact dust extractor switched on.
Means, Tools, Materials
■
Breathing mask 8833 FFP3 (mat. no. 0374270).
Notes
■
B836en
2017-11-17
Between the fine dust sack and the dust container, there is a
minimal gap to equalize the pressure. It is possible that small
Compact dust extractor
6‐125
■
WARNING
There is a high fire risk in the dust container with
flammable, potentially explosive dust.
Ø
WARNING
amounts of dust fall through this gap into the container. If
there is dust in the container, empty it.
Misshapen dust containers must be replaced. The container
must be close to the dust discharge.
Check the dust level in the container on a weekly or daily
basis.
Fire hazard in the dust container if an unsuitable fine dust
bag is used!
Ø
Only the original fine dust bag (TRUMPF material number
1831493) may be used to collect the dust.
A
Clamp container
1
Hand grip
B
Unscrewing the container
2
Dust container
Dust container (disposable container)
1.
2.
3.
4.
6‐126
Compact dust extractor
Fig. 74615
Unlock and remove the dust container.
Check the level and replace the fine dust bag if necessary.
Seal the fine dust bag tightly with a lid and dispose of it.
Put a new fine dust bag in the container. Clamp the container under the dust discharge.
2017-11-17
B836en
Compact dust extractor: spark arrester
(see "Overview", pg. 6‐122)
1
Inspection door
2
Tool cartridge
Spark arrester
106850:
Cleaning the spark arrester
Fig. 74617
Maintenance interval: Weekly
The spark arrester is a safety-relevant component. It consists of
a cartridge with porcelain balls. The balls prevent sparks or
smoldering or burning particles from being able to get into the filter elements with the raw gas flow.
During operation, fibers, dust and particles collect in the cartridge. If the cartridge is not regularly and thoroughly cleaned, a
fire can develop in the compact dust extractor.
Means, Tools, Materials
■
■
■
Breathing mask 8833 FFP3 (mat. no. 0374270).
Industrial vacuum cleaner.
Steel brush.
Note
The cartridge weighs 15 kg.
Fire hazard in the compact dust extractor due to deficient
maintenance of the spark arrester.
WARNING
Ø
B836en
2017-11-17
Thoroughly clean the spark arrester every week.
Compact dust extractor
6‐127
WARNING
Insufficient fire protection due to missing or damaged
porcelain balls in the cartridge.
Ø
Ø
Do not hit or knock the cartridge.
If any porcelain balls are damaged, replace the cartridge.
1. Switch off the MAIN SWITCH.
2. Open the inspection door of the compact dust extractor and
remove the cartridge.
3. Using a steel brush, loosen fiber residues on the lower and
upper sides of the cartridge.
4. Thoroughly vacuum off fiber residues and impurities.
5. Remove deposits from the plug-in unit and clean the decompression chamber.
6. Push the cartridge back in.
7. Close the inspection door.
Compact dust extractor: clean gas space
(see "Overview", pg. 6‐122)
105143:
Check and clean
Maintenance interval: Annually
A thick layer of dust or caking on the filter elements are a sign
that the dust discharge or purging effect is insufficient.
The accumulation of dust in the clean gas space or a trail of
dust on the clean gas outlet is a sign of damaged filter elements
or damaged seals. In this case, request a service call.
Means, Tools, Materials
■
NOTICE
Industrial vacuum cleaner.
The extinguisher system can be triggered unintentionally.
Ø
For a compact dust extractor with a fire extinguisher, before
opening the door, the extinguisher must first be switched off.
1. Switch off the MAIN SWITCH.
2. If there is an extinguisher, switch it off. Set the toggle switch
on the control panel to "Anlage Aus"/"Off System".
3. Open the door to the clean gas space.
4. Clean the clean gas space with an industrial vacuum cleaner.
6‐128
Compact dust extractor
2017-11-17
B836en
5. Check that the filter inserts and seals are undamaged. Have
damaged components replaced by their manufacturer, Herding.
6. After finishing all work: close the door. If present, switch the
extinguisher system back on again.
B836en
2017-11-17
Compact dust extractor
6‐129
Compact dust extractor: MultiCoater
(see "Overview", pg. 6‐122)
1
Knurled screw
2
Signal light
3
Mesh insert
Topping up dispensing material for the MultiCoater
106492:
Topping up dispensing
material
Fig. 68263
Maintenance interval: When indicated by the control system
A capacitive level sensor measures the level of the dispensing
material in the storage container. If the switching value for the
lower limit has been reached, a message is output.
Conditions
■
■
MAIN SWITCH Basic machine is switched on.
The pre-coating procedure is not active; the signal light is not
lit.
Means, Tools, Materials
■
■
Dispensing material: Calcium carbonate, CaCO3 or trass
powder.
Breathing mask 8833 FFP3 (mat. no. 0374270).
Notes
■
■
6‐130
Compact dust extractor
The maximum permissible filling height for the dispensing material is the lower edge of the grid insert.
A leaky cover seal must be replaced:
2017-11-17
B836en
1
Knurled screw
2
Signal light
3
Mesh insert
Topping up dispensing material for the MultiCoater
Fig. 68263
Name
Calcium carbonate
(CaCo3)
Trass powder
Grain size range
≥0 µm and ≤90 µm
≥0 µm and ≤150 µm
Average grain size
≥5 µm and ≤15 µm
≥20 µm and ≤40 µm
Purity level
99.1 %
-
Filling volume of storage container
55 liters
55 liters
Specification of dispensing material for MultiCoater
Tab. 6-8
1. Open the MultiCoater cover and lock it into place.
2. Fill dispensing material into the storage container up to the
lower edge of the grid insert.
3. Close the cover again.
106580:
Checking and replacing the
seal
Maintenance interval: Annually
Condition
■
The MAIN SWITCH is switched off.
Means, Tools, Materials
■
Breathing mask 8833 FFP3 (mat. no. 0374270).
Note
Dust accumulation on the cover or inside the MultiCoater is an
indication that the parameterization of the pre-coating procedure
is not correct. In this case, inform the manufacturer.
1. Open the MultiCoater cover and lock it into place.
B836en
2017-11-17
Compact dust extractor
6‐131
2. Check the cover seal and replace it if it is leaky or torn.
3. Check the interior space and the cover for dust accumulation.
4. Close the cover again.
106581:
Replacing the pressure
regulating valve filter
cartridge
6‐132
Maintenance interval: Every 6 months
1. Switch off the MAIN SWITCH Machine.
2. Remove left side panel at the MultiCoater.
3. Turn the condensation water plug counter-clockwise and
drain the condensation water. Then reclose the condensation
water plug.
4. Replace the filter cartridge.
5. Reclose the side part of the MultiCoater.
Compact dust extractor
2017-11-17
B836en
13.
Scrap conveyor
13.1 Maintenance Instructions
Scrap conveyor: Sensors
1
Discharge hopper sensor/
receiver
2
Scrap container sensor
Scrap conveyor sensors
106855:
Cleaning sensors
Fig. 74474
Maintenance interval: As needed
The scrap conveyor's rising and ejection areas are monitored by
sensors. The sensors are on the left side when looking in the
direction of transport. Each sensor consists of a transmitter and
a receiver (single beam light barrier). A reflector is fitted on the
opposing side.
If the sensor detects waste parts which could lead to a fault, an
error message will be issued and a FEED STOP will be triggered.
The sensors prevent waste parts, which get stuck on the conveyor belt or which are pulled out of the container by the belt,
from getting into the lower part of the conveyor or into its housing.
A sensor is also monitored in the scrap container under the conveyor's outlet. If the sensor doesn't detect a container, an error
message will be issued and a FEED STOP will be triggered.
Notes
■
■
B836en
2017-11-17
The scrap container is not supplied as part of the machine.
Empty the scrap container regularly.
Scrap conveyor
6‐133
1. Remove the scrap container.
2. If necessary, clean the area behind the scrap container.
3. Clean the sensor with a soft, clean cloth.
Scrap conveyor: pedestal bearing
1
Grease nipples
Scrap conveyor pedestal bearing
105135:
Lubricate the pedestal
bearing
Fig. 74476
Maintenance interval: Annually
Means, Tools, Materials
■
■
Anti-friction bearing grease, e.g. Mobiltemp SHC100
Manual grease gun.
Ø Use a grease gun to fill the grease nipple until grease oozes
out.
6‐134
Scrap conveyor
2017-11-17
B836en
Scrap conveyor: lubricant container
1
Lubricant container
Scrap conveyor lubricant container
105134:
Filling the lubricant
container
Fig. 74472
Maintenance interval: When indicated by the control system
The conveyor belt lubrication is automatically initiated by the
machine control via the central lubrication.
The lubricant container on the scrap conveyor has a level sensor. The control system will report when oil has to be topped up.
Means, Tools, Materials
■
1500 ml oil: Tonna S3 M32.
Notes
■
■
Always use the same oil.
After approx. 4 weeks, depending on the operating hours,
the lubricant container should be empty. Should this not be
the case, it can be an indication that the conveyor belt is not
being adequately lubricated.
1. Remove the cover from the lubricant container.
2. Pour the oil in slowly to avoid bubbles.
3. Close the lubricant container with the cover.
B836en
2017-11-17
Scrap conveyor
6‐135
Scrap conveyor: conveyor belt
106853:
Checking and setting the
chain tension
Maintenance interval: Every 6 months
If the chain tension is not set correctly, it will result in faster wear
of the mechanical components.
Signs that the chain tension is not correctly adjusted could
include:
■
■
■
■
Wear of the side boards. The chain is not evenly tensioned.
Severe wear of side chains. The tension is too high.
Wear in track roller guides in the curved sections. The tension is too high.
Compression of the belt/chain without blockage. The tension
is too low.
Means, Tools, Materials
■
■
■
Micrometer or slide gauge.
Torque wrench.
Bar or ruler.
Note
Two people are needed to remove the hood.
1
2
Cover
Bar
3
Conveyor belt
Scrap conveyor belt
Checking the chain tension
6‐136
Scrap conveyor
Fig. 74473
1. Switch off the electrical supply to the scrap conveyor by turning the key switch on the device box to its central position.
2. Undo the fixing screws on the hood. Lift off the hood working
together with someone else.
3. Check the sag of the chain with a bar or ruler.
2017-11-17
B836en
4. If necessary, readjust the chain tension.
Setting the chain tension
1
Befestigungsschrauben
2
Clamping screw
3
Lock nut
Setting chain tension
Fig. 74477
5. Slightly undo the fixing screws (posn. 1) on the bearing.
6. Loosen the lock nut and turn it approx. 15 mm toward the
screw head.
7. Adjust the clamping screw evenly on both sides with max.
27 Nm.
Ø To increase the tension, increase the X dimension.
or
Ø To reduce the tension, reduce the X dimension.
8. Once the tension is correctly adjusted:
− Check the X dimension on both sides.
− If the X dimension is the same, tighten the lock nut.
9. Tighten the fixing screws hand-tight.
10. After the work is complete, put the hood back on and screw
it in place.
Scrap conveyor: housing bottom
106851:
Cleaning the housing bottom
Maintenance interval: Monthly
Small parts and cutting dust collects in the housing bottom.
Using a cleaning carrier, dirt and waste can be removed from
the housing bottom.
B836en
2017-11-17
Scrap conveyor
6‐137
Conditions
■
■
MAIN SWITCH Basic machine is switched on.
Scrap conveyor is ready for operation.
Means, Tools, Materials
■
■
Vulkollan cleaning carrier.
Industrial vacuum cleaner.
Notes
■
■
■
NOTICE
Waste parts in the housing bottom block and damage the
conveyer belt!
Ø
Ø
Installing the cleaning
carrier
Starting the cleaning cycle
Make sure that no dust is stirred up. Use an industrial vacuum cleaner with activated carbon filter.
The cleaning pusher dog belongs to the accessories for the
scrap conveyor.
If the cleaning pusher dog is not removed after cleaning, this
will lead to the polyester urethane strip wearing very quickly.
Use the cleaning carrier to clean the housing bottom at regular intervals.
Dismantle the sheet skeleton into small parts.
1. Acknowledge the danger zone and close the access door.
2. Start and stop the waste conveyor belt in setup mode, as
soon as the plate marked in red on the conveyor belt's upper
run is visible in the conveyor's feed area.
3. Remove the fixing screws in the area marked in red.
4. Screw the cleaning carrier between the red and black bars.
5. Acknowledge the danger zone and close the access door.
6. Start the waste conveyor belt in setup mode.
Waste parts and dust in the lower run are ejected via the
discharge hopper.
7. After 2 to 3 loops, stop the conveyor belt so that the
cleaning pusher dog can be removed again.
8. Disassemble the cleaning carrier.
9. Screw the black bar back onto the conveyor belt.
10. Empty the scrap container and clean it.
106858:
Cleaning the bottom of the
housing in the area of the
bend
6‐138
Scrap conveyor
Maintenance interval: Annually
Note:
Only valid for machines with a rotational changer.
2017-11-17
B836en
Waste parts and dust can collect in the vicinity of the lower bend
in the waste conveyor belt.
Means, Tools, Materials
■
1
Industrial vacuum cleaner.
Befestigungsschrauben
2
Cover
The base of the housing and the scrap conveyor's lower
bend
Fig. 74945
1. Undo the screws on the cover and remove it.
2. Remove the large pieces of waste.
3. Clean the bottom of the housing with an industrial vacuum
cleaner.
4. After cleaning, reinstall the cover.
B836en
2017-11-17
Scrap conveyor
6‐139
14.
Clamping fixture
14.1 Maintenance Instructions
Clamping fixture for hot-formed parts
105379:
Cleaning the guard plates,
slag channel and cover
105380:
Replacing the wearing parts
Maintenance interval: Weekly
1. If the clamping fixture is maintained while mounted:
− Switch off the MAIN SWITCH.
− Disconnect the fixture from the fixture interface
electrically and pneumatically.
2. Remove slag spatter from all parts of the fixture using a soft
copper brush. Do not use sharp objects to clean the fixture.
3. Reconnect the clamping fixture.
Maintenance interval: As needed
All copper parts on the fixture are wear parts. They protect the
fixture against slag and damage by the laser beam.
1. If the wear parts are exchanged while mounted:
− Rotate the clamping fixture into the loading position.
− Press the EMERGENCY STOP push-button.
− Disconnect the fixture from the fixture interface
electrically and pneumatically.
2. Replace any worn components.
3. Reconnect the clamping fixture.
4. Unlock the EMERGENCY STOP push-button.
6‐140
Clamping fixture
2017-11-17
B836en
Clamping fixture for IHU workpieces
107333:
Check and clean the
positioner
Maintenance interval: Daily
The fork as well as the positioning bolt on the positioner are
functionally relevant components that significantly influence the
manufacturing accuracy.
The stop surfaces on the fork as well as the bolts must be regularly cleaned and tested for wear.
Means, Tools, Materials
■
Steel or brass brush.
Notes
■
■
1
Do not damage the protective plates when cleaning. Grooves
promote slag build-up.
A geometry deviation > 1 mm on the finished part can be an
indication of wear on the functional surfaces on the fork.
Positioning bolt
2
Fork stop surfaces
Fig. 86282
1. Thoroughly clean the fork surfaces (especially the support
areas) pads with a brush.
2. Thoroughly clean the positioning bolts. In the event of damage (notch), the bolt can at first be rotated by 180°. If, however, a notch is formed circumferentially, the bolt must be
replaced.
B836en
2017-11-17
Clamping fixture
6‐141
3. Clean the protective plate.
4. Replace any worn components.
107334:
Check and replace the ball
roller
Maintenance interval: Daily
The ball roller (TRUMPF material number 2238916) is a functionrelevant component, a mobile load ball.
1
Ball roller
Fig. 86283
1. Check whether the ball is still present, if it can be moved
and if it reacts to pressure.
2. Replace damaged ball roller.
107332:
Clean the fixture
Maintenance interval: Daily
Means, Tools, Materials
■
Steel or brass brush.
1. If the clamping fixture is maintained while mounted:
− Switch off the MAIN SWITCH.
− Disconnect the fixture from the fixture interface
electrically and pneumatically.
2. Remove slag spatter from all parts of the fixture using a soft
copper brush. Do not use sharp objects to clean the fixture.
3. Reconnect the clamping fixture.
6‐142
Clamping fixture
2017-11-17
B836en
105380:
Replacing the wearing parts
Maintenance interval: As needed
All copper parts on the fixture are wear parts. They protect the
fixture against slag and damage by the laser beam.
1. If the wear parts are exchanged while mounted:
− Rotate the clamping fixture into the loading position.
− Press the EMERGENCY STOP push-button.
− Disconnect the fixture from the fixture interface
electrically and pneumatically.
2. Replace any worn components.
3. Reconnect the clamping fixture.
4. Unlock the EMERGENCY STOP push-button.
B836en
2017-11-17
Clamping fixture
6‐143
15.
TruDisk
15.1 Overview
Pending maintenance work on the TruDisk is displayed on the
user interface of the machine in the maintenance wizard of the
laser control system.
Contamination of the water filter depends on the water quality.
Cooling water additives
The cooling water additives are supplied in bottles (Easy Kit).
The apportionment per bottle corresponds to the amount of cooling water of respective cooling circuit. One Easy Kit is required
for each water change. Each Easy Kit contains one bottle with
anticorrosive agent (yellow) and one bottle with cleaning biocide
(red).
Application
Cooling water additive
Bottle top color code
Corrosion protection
Water Care-Copper
Yellow
Cleaning cycle
Cleaning biocide
Red
Cooling water additives
WARNING
Cooling water and cooling water additives are aggressive!
Irritation to eyes and skin possible!
Ø
Ø
Ø
Cooling water requirement
of internal laser device
cooling circuit
Tab. 6-9
Avoid direct contact with cooling water and cooling water
additives.
Wear safety goggles and gloves.
Follow the safety instructions on the products and safety
datasheets.
Laser device
Easy Kit
Volumetric capacity
of cooling circuit in l
TruDisk 2000
CU2
approx. 30
TruDisk 3001
TruDisk 4001
CU3
approx. 70
Internal cooling circuit of the laser device
6‐144
TruDisk
2017-11-17
Tab. 6-10
B836en
15.2 Maintenance Instructions
TruDisk cooling circuit
(see "Overview", pg. 6‐144)
105200:
Replacing cooling water and
cleaning the tank
106209:
Cleaning or replacing the
contamination filter
Maintenance interval: Annually
Ø See Operator's manual TruDisk, Chapter "Maintenance".
Maintenance interval: When indicated by the control system
Note
After each cooling water replacement and if the message is displayed: "Temperature in the laser device too high".
Ø See Operator's manual TruDisk, Chapter "Maintenance".
105201:
Replacing the water
microfilter
Maintenance interval: When indicated by the control system
Note
After each cooling water replacement and if the message is displayed: "Pump has reached its capacity limit".
Ø See Operator's manual TruDisk, Chapter "Maintenance".
B836en
2017-11-17
TruDisk
6‐145
16.
Process cooler for TruDisk (chiller)
16.1 Overview
This section applies to external process coolers of type RLxx/0
SR/TR and type RWxx/0 SR/TR from Riedel.
Cooling water additives
The cooling water additives are supplied in bottles (Easy Kit).
The apportionment per bottle corresponds to the amount of cooling water of respective cooling circuit. One Easy Kit is required
for each water change. Each Easy Kit contains one bottle with
anticorrosive agent (yellow) and one bottle with cleaning biocide
(red).
Application
Cooling water additive
Bottle top color code
Corrosion protection
Water Care-Copper
Yellow
Cleaning cycle
Cleaning biocide
Red
Cooling water additives
WARNING
Cooling water and cooling water additives are aggressive!
Irritation to eyes and skin possible!
Ø
Ø
Ø
Cooling water requirement
of external laser device
cooling circuit
Tab. 6-11
Avoid direct contact with cooling water and cooling water
additives.
Wear safety goggles and gloves.
Follow the safety instructions on the products and safety
datasheets.
Process cooler
Easy Ki
t
Volumetric
capacity of cooling circuit in l
Water requirement for cooling
water replacement in l
Type RL10/0
Type RL13/0
CU3
80
260
Type RL17/0
Type RL20/0
CU4
150
500
Type RW13/0
CU3
80
260
Type RW17/0
Type RW20/0
CU4
150
500
External laser device cooling circuit (chiller)
6‐146
Process cooler for TruDisk (chiller)
2017-11-17
Tab. 6-12
B836en
16.2 Maintenance Instructions
Process cooler: chiller (water-air)
(see "Overview", pg. 6‐146)
1
Level indicator
2
Filter mat
Process cooler type RLxx/0 SR/TR (water-air)
105202:
Replacing the filter mat
Fig. 74218
Maintenance interval: Annually
Means, Tools, Materials
■
Filter mat, cut to size.
or
■
Filter mat in roll form.
Notes
■
■
The degree of contamination of the filter mat(s) depends on
the ambient conditions. The filter mat might have to be
replaced at shorter intervals.
If the laser device and/or process cooler have their own main
switches, these main switches must be additionally switched
on and off.
1. Switch off the MAIN SWITCH Machine.
B836en
2017-11-17
Process cooler for TruDisk (chiller)
6‐147
2. Remove the filter mat and replace with a new one.
107378:
Checking and refilling the
level
Maintenance interval: When indicated by the control system
Means, Tools, Materials
■
Demineralized water.
Note
Generally, little water is lost from the closed cooling circuit, as
long as the water tank has been closed properly. If the cooling
circuit loses water within a short period of time, then the cause
must be found.
Ø Check the filling level. When the minimum level is reached,
top up with water.
107380:
Checking for coolant circuit
leakage
Maintenance interval: As needed
It can be checked on the level indicator whether the coolant circuit is leaking, as needed or if coolant is escaping.
In the event of coolant leakage, a service mission must be
requested.
Note
If the laser device and/or process cooler have their own main
switches, these main switches must be additionally switched on
and off.
6‐148
Process cooler for TruDisk (chiller)
2017-11-17
B836en
1
Inspection glass
Checking for leaks
Fig. 87508
1. Switch off the MAIN SWITCH Machine.
2. Open the longitudinal side of the process cooler.
3. Check on the level indicator whether there is air in the coolant circuit.
107379:
Replace cooling water
Maintenance interval: Annually
cleaning biocide is added to the cooling circuit 2 hours before
changing the cooling water. During the cleaning cycle, the
machine is ready for operation.
After the cleaning cycle, the water tank is cleaned and the cooling circuit is flushed with fresh water at least 3x.
Condition
■
Laser device is ready for operation and assigned to the
machine.
Means, Tools, Materials
■
■
■
■
■
■
■
B836en
2017-11-17
Demineralized water.
Conductivity measuring device.
Protective gloves.
Safety glasses.
Water collecting container.
Clean cleaning cloth.
Easy Kit.
Process cooler for TruDisk (chiller)
6‐149
Notes
■
■
NOTICE
For each rinse cycle, the tank is filled up to 60% with fresh
water.
If the laser device and/or process cooler have their own main
switches, these main switches must be additionally switched
on and off.
Corrosion and microbial contamination of the cooling
circuit!
Material damage to the cooling circuit of the machine.
Ø
Ø
Ø
Ø
Only use fresh and clean de-ionized water.
Thoroughly rinse the cooling circuit after the cleaning run.
Do not operate the cleaning circuit without corrosion protection.
Only use cleaning biocide when cleaning.
1
Compressor
4
Water tank
2
Evaporator
5
Pump
3
Condenser
Cooling circuit for external laser device cooler
6‐150
Process cooler for TruDisk (chiller)
2017-11-17
Fig. 87506
B836en
Starting the cleaning cycle
1. Switch off the MAIN SWITCH Machine.
2. Open the process cooler on a longitudinal side.
3. Open the water container and add cleaning biocide (red bottle lid) to the water. Close the water tank and process cooler
again.
Note
Cooling water must circulate during the cleaning cycle.
4. Switch the machine and drives back on. Production can continue during the cleaning cycle.
Draining water
5. End the cleaning cycle after 2 hours.
6. Switch off the MAIN SWITCH Machine.
7. Open the longitudinal side on the process cooler again.
Note
The water container, pump and pipelines must be drained.
1
Drain, water tank
2
Drain, pump
3
Drain, pipeline
Emptying the tank
Fig. 87507
8. Open all 3 sealing caps and drain the water.
9. When the water tank is empty, mount the sealing caps again
and thoroughly clean the inside of the water tank.
Flushing the cooling circuit
B836en
2017-11-17
10. Fill the tank up to about 60% with fresh, demineralized water.
11. Close the water tank.
12. Switch the machine back on again.
Process cooler for TruDisk (chiller)
6‐151
13. Switch the drives back on: Press the MACHINE ON/OFF button.
14. Wait for approx. 10 minutes.
15. Switch off the drives: Press the MACHINE ON/OFF button.
16. Drain the water completely.
17. Carry out the second and third flushing processes, each with
fresh water.
Measure conductivity
18. After the third rinse cycle, measure the conductivity of the
water.
19. If the conductivity of the water is less than or equal to 20 µS/
cm, completely fill the tank and add an anticorrosive agent
Water Care-Copper.
or
Ø If the conductivity of the water is greater than 20 µS/cm:
rinse the cooling circuit. Afterwards, fill with fresh water,
flush for approx. 10 minutes and measure the conductivity again.
20. After adding the anticorrosive agent wait for about 10
minutes.
21. Afterwards, measure the conductivity of the water again. If
the conductivity is still more than 20 µS/cm, the complete
cooling water replacement must be repeated.
The cooling water replacement is completed when the conductivity of the water does not exceed 20 µS/cm.
22. After completing the cooling water replacement, close the
water tank with the tank cap.
23. After completing the cooling water replacement, clean the
condenser with an industrial vacuum cleaner.
Attention: No dirt may fall into the tank in the process!
24. Clean the interior space of the process cooler with a cloth.
25. Check the water pressure at the pressure gauge. The set
pressure is 4 bar.
If the pressure is greater than 4 bar, check the water microfilter in the laser device for contamination.
26. After completing all maintenance work, close the process
cooler again.
27. Document the cooling water replacement on the process
cooler.
6‐152
Process cooler for TruDisk (chiller)
2017-11-17
B836en
Chapter 7
Noise level test certificate
B836en
2017-11-17
1
Test report
7‐3
2
Measurement result
7‐4
3
Measuring point arrangement
7‐5
Noise level test certificate
7‐1
Output
2014-10-01
Drawing number
93964-7-82
Tab. 7-1
Note
The noise measurement record contains two measurements:
The noise measurement was carried out once with and once
without the soundproofing cover for the compact dust
extractor.
The "Noise level" test report contains the results for the component with the highest noise levels - the basic machine. The maximum values determined also apply for all variants of automated
machines. On average, the contribution of the automation parts
to the noise level for the loudest and the typical operating mode
can be neglected.
7‐2
Noise level test certificate
2017-11-17
B836en
1.
Noise measurement to DIN EN
ISO 11553-3 with DIN EN
ISO 3746 also applicable
Machine investigated
Measurement conditions
Test report
Location and
date of the
measurement
Measurement with soundproofing:
Ditzingen, April 11, 2014
Accuracy class
3
Responsible
Eike Cillis
Manufacturer
TRUMPF Laser- and Systemtechnik
Type
3D laser processing machine with solid-state laser
TruDisk 2000
Type
TruLaser Cell 8030 (L60)
Serial number S1631C0002
Year of manufacture 2013
Process cooler
for laser device
Type PC 161.1L4-D13L, made by Riedel
Compact dust
extractor
DELTA Comp 1500-14/9 SB, made by Herding
Measurement
surface, basic
machine
■
Length: 7.36 m
■
Width: 4.45 m
■
Height: 3.70 m
Installation site
In lightweight shed in Ditzingen
Installation
According to installation plan 93964-5-11
Operating status
Loudest operating mode:
Sound sources
active during
measurement
Acoustic measurement environment
Measurement without soundproofing:
Ditzingen, January 16, 2015
Description
■
High-pressure cutting
■
Material: mild steel, 2 mm thick
■
Nozzle diameter: 2.3 mm
■
Cutting gas pressure: 15 bar
■
Basic machine drives
■
Cutting unit
■
Integral switch cabinets
■
TruDisk chiller
■
Compact dust extractor
Size of the shed:
■
Length: 60 m
■
Width: 25 m
■
Height: 8 m
The machine is standing in a corner of the lightweight
shed.
Measuring device
Suitability
Ambience correction: K2A= 2.8 dB
Sound level
meter
Brüel & Kjaer, type 2250
Serial number 2645064
Calibration date: 19.4.2013
Microphone
Brüel & Kjaer, type 4189
Serial number 2631420
Calibration date: 19.4.2013
Test certificate
B836en
Tab. 7-2
2017-11-17
Test report
7‐3
2.
Acoustical data
Measurement result
Sound pressure level L'pi [dB] with and without soundproofing:
Acoustic data
Basic machine
Process cooler
with soundproofing
without soundproofing
Measuring distance
1.0 m
1.0 m
1.0 m
Number of measuring points
16
16
6
Position of the measuring points
See Fig. 73827
Extraneous noise adjustment
K1A = 0 dB
K1A = 0 dB
K1A = 0 dB
Environmental adjustment
K2A= 2.8 dB
K2A= 2.8 dB
K2A= 2.8 dB
Sound pressure level L'pi
see table "measurement result"
see table "measurement result"
Maximum sound pressure level
LPA = 73 dB
LPA = 76 dB
LpA = 75 dB
Sound pressure level at control
panel (MP 16)
69 dB
72 dB
-
Uncertainty
KpA = 4 dB
KpA = 4 dB
KpA = 4 dB
See Fig. 73828
Acoustic data
Tab. 7-3
Measurement result
Sound pressure level L'pi [dB] at the measurement points:
Basic machine
Measuring
point
Compact dust
extractor with
soundproofing
Compact dust
extractor without soundproofing
1
72.3
75.2
69.7
2
74.3
76.6
69.2
3
75.8
77.7
68.4
4
72.0
76.2
71.1
5
70.3
75.9
77.8
6
70.9
77.7
71.5
7
74.2
78.9
-
8
70.7
78.2
-
9
70.6
77.5
-
10
72.3
77.5
-
11
71.4
77.2
-
12
70.7
75.7
-
13
70.7
76.0
-
14
71.5
76.7
-
15
71.0
74.6
-
16
71.5
74.9
-
Sound pressure level
7‐4
Measurement result
Process cooler
Tab. 7-4
2017-11-17
B836en
3.
Measuring point arrangement
Measuring point arrangement base machine
B836en
2017-11-17
Fig. 73827
Measuring point arrangement
7‐5
Arrangement of the measuring points for process cooler (heat exchanger)
7‐6
Measuring point arrangement
Fig. 73828
2017-11-17
B836en
Index
3D working range ......................................3‐7
Core range ............................................ 3‐7
6D mouse .............................................. 4‐199
Axis group ......................................... 4‐199
A
Access Control Key System 4‐29, 4‐31–4‐33
Identification .........................................4‐31
Reading device ....................................4‐33
User groups .........................................4‐32
User management ...............................4‐29
Accessories ............................................. 1‐53
Acknowledging feed stop ........................ 4‐17
Actuation ..................................................3‐30
Additional axis ....................................... 4‐133
Advanced shop floor programming ...... 4‐165
Air cutting gas ........................................... 6‐7
Ambient conditions .................................. 2‐12
Ambient temperature ...............................2‐12
Assemblies .....................................3‐34, 3‐37
IHU .......................................................3‐37
WUF .....................................................3‐34
Automation ...............................................4‐99
Axes ........................................... 4‐126, 4‐135
Move continuously .............................4‐126
Move incrementally ........................... 4‐126
Moving manually ............................... 4‐126
Park ................................................... 4‐135
Axis group ............................................. 4‐198
Axis position .......................................... 4‐117
Switching over ................................... 4‐117
B
Backspace ............................................... 4‐15
Base plate ............................................... 2‐10
Beam guidance ....................................... 3‐12
Bookmarks .............................................4‐190
Edit .....................................................4‐190
Buffer battery ................................. 6‐7, 6‐118
Siemens fan unit ........................6‐7, 6‐118
Buttons .....................................................4‐79
Production plan ................................... 4‐79
B836en
2017-11-17
C
Cable rack ............................................... 2‐24
Calibrating the sensor ............................. 5‐60
CE marking ................................................1‐5
Ceiling plate .............................................2‐10
Change of application ............................. 4‐15
Change of sign ........................................4‐15
Characteristic curve ....................... 2‐20, 2‐22
Cooling water requirement ..................2‐20
Differential pressure ............................ 2‐22
Clamping device ............................ 3‐35, 3‐39
Emergency triggering ................ 3‐35, 3‐39
Clamping error .........................................4‐61
Clamping fixture ....3‐29, 3‐34, 3‐37, 5‐63,
6‐140
Hot-formed parts ................................. 3‐34
IHU .......................................................3‐37
Clamping unit .................................3‐35, 3‐39
Hot-forming .......................................... 3‐35
IHU .......................................................3‐39
Collimation ............................................... 3‐13
Cooling .................................................3‐13
Compact dust extractor ....2‐15, 3‐23, 4‐40,
6‐9,
6‐125
Controls ............................................... 4‐40
Exhaust air system ............................. 2‐15
Installation ............................................2‐15
Level sensor .............................. 6‐9, 6‐125
Compressed-air cutting ........................... 2‐44
Compressed air consumption ................. 2‐43
Basic machine ..................................... 2‐43
Compressed air supply ........................... 2‐43
Configurable control interface ................. 1‐22
Configuration ......................................... 4‐139
Automation interface ......................... 4‐140
Workpiece change .............................4‐139
Container transport ..................................2‐52
Context-sensitive help ........................... 4‐191
Start ................................................... 4‐191
ControlLine ............................................ 4‐134
Record characteristic curve .............. 4‐134
Cooling circuit ............................................6‐7
Machine ................................................. 6‐7
Cooling water .................................2‐46, 2‐48
Requirements ...................................... 2‐48
Cooling water additives ... 6‐71, 6‐144, 6‐146
Easy Kit ........................6‐71, 6‐144, 6‐146
Cooling water requirement ........ 6‐144, 6‐146
Index
8‐1
Cooling circuit, external laser device 6‐146
Cooling circuit, internal laser device 6‐144
Coordinate system .................................... 3‐4
Current program .................................... 4‐115
Edit .....................................................4‐115
Cutting gas .............................................. 2‐29
Consumption ........................................2‐29
Cutting gases .......................................... 2‐29
Purity ....................................................2‐29
Cutting parameters ................................4‐167
Cutting problems ..................................... 5‐41
D
Danger zone
Safeguarding device ........................... 1‐34
Date ......................................................... 4‐71
Day shift plan, create ............................4‐109
Day shift plan, deleting ..........................4‐111
Day shift plan, editing ........................... 4‐109
Deflection mirror
B/C gearbox ........................................ 3‐13
Deflection mirror, B/C gearbox ............... 3‐13
Dew point ................................................ 2‐13
Dew point diagram .................................. 2‐13
Differential pressure ................................ 2‐22
Display area ............................................ 4‐67
Distance regulation ................................4‐133
Activating ........................................... 4‐133
Door seal ......................................... 6‐7, 6‐50
Dusts ........................................................1‐32
Dynamic cutting optics ................ 3‐13, 4‐132
Dynamic distance regulation .................4‐132
F keys ....................................................4‐208
F1 key ....................................................4‐209
Fault current circuit breaker ....................2‐36
FEED HOLD .................................. 1‐41, 4‐16
Feedrate potentiometer ........................... 4‐17
File manager ......................................... 4‐178
Filtering installation ..................................3‐21
Fine dust bag .....................................6‐6, 6‐9
Fire safety ................................................1‐53
Firewall .................................................. 4‐145
Fixture ............... 5‐65, 5‐69, 5‐71, 5‐72, 5‐74
Actual position ..................................... 5‐72
Correction frame ........................ 5‐65, 5‐74
Required position .......................5‐69, 5‐71
Fixture port .............................................. 3‐29
Fixtures .................................................... 3‐23
Arrangement ........................................ 3‐23
Flatness ..................................................... 2‐9
Floor requirements .................................... 2‐9
Focal position ...............................4‐136, 5‐41
Without FocusLine .............................4‐136
Focus search ...........................................5‐41
Focus shift ............................................... 5‐41
FocusLine .......................................3‐13, 5‐41
Characteristic curve .............................5‐41
Frame .................................................... 4‐162
Free span base plate ..............................2‐10
G
Geometry deviation ............................... 4‐206
E
Embedded Help .....................................4‐166
EMERGENCY STOP push-button 1‐40, 4‐18
Enable key .............................................4‐199
Enter ........................................................ 4‐15
Escape .....................................................4‐15
Escape door ............................................ 1‐38
EU Declaration of Conformity ................... 1‐5
Exhaust air .............................................. 1‐32
Exhaust system ....................................... 3‐21
Extended compressed air supply ......6‐6, 6‐7
External cooling circuit ............................ 2‐18
Extinguisher system . 1‐53, 3‐24, 4‐40, 6‐123
Annual test .......................................... 1‐53
Controls ............................................... 4‐40
8‐2
F
Index
H
Hazardous materials ............................... 1‐67
Hydroforming package ............................ 3‐11
I
I/O monitor .............................................4‐181
Display ............................................... 4‐181
Identification .............................................3‐33
Clamping fixture .................................. 3‐33
Industrial PC .................................. 6‐7, 6‐119
Buffer battery ............................. 6‐7, 6‐119
Installation site ...........................................2‐9
2017-11-17
B836en
Installation surface .................................... 2‐9
Intended use ..............................................1‐8
Internal management ................. 4‐118, 4‐145
J
Job ........................................................... 4‐84
Disable .................................................4‐84
Job data
Edit .......................................................4‐84
Jobs
Program sequence .............................. 4‐90
Joint offset ....................................... 3‐5, 5‐50
K
Key-operated switch ................................1‐42
TEACHIN ............................................. 1‐42
Key switch ............................................... 4‐12
Under Voltage Trip .............................. 4‐12
Kinematic transformation ... 3‐5, 4‐134, 4‐161
KSS ..........................................................1‐22
KSS configuration ..................................4‐163
KSS modules .........................................4‐146
Import .................................................4‐146
L
Language .................................................4‐71
Laser ......................................................4‐131
Enabling .............................................4‐131
Requesting .........................................4‐131
Laser cutting ..........................................4‐167
Laser network .................................. 1‐9, 3‐44
Laser ON/OFF .........................................4‐16
Laser scanner .................................... 6‐6, 6‐8
Laser status lamp ....................................1‐43
laser technology tables ......................... 4‐166
Laser Test ................................................4‐16
Liability disclaimer ................................... 1‐53
List selection ............................................4‐67
Loading place .......................................... 4‐57
Loading status ............................... 4‐94, 4‐96
Log-in status ............................................4‐65
Machine ON/OFF .................................... 4‐16
Magnetic coupling .........1‐20, 1‐43, 3‐16, 6‐8
Ferromagnetic attractive force ............ 1‐20
magnetic flux density .......................... 1‐20
Magnifying glass ......................................4‐15
Main activities ..........................................4‐66
Main operation .........................................4‐43
PRODUCTION .....................................4‐43
Main switch .................................... 1‐40, 4‐11
Machine ............................................... 4‐11
Manual functions 4‐120, 4‐122, 4‐127, 4‐130,
4‐177
Call ......................................... 4‐122, 4‐130
Maintenance ...................................... 4‐177
Production ..........................................4‐120
Setup ................................................. 4‐127
Manual loading ........................................ 4‐99
Marking test mode ................................ 4‐123
Activating ........................................... 4‐123
Master file .................................. 4‐118, 4‐145
Import .................................................4‐118
MDA .......................................................4‐138
Block-by-block ................................... 4‐138
Single block ....................................... 4‐138
Measuring ball fixture ..............................5‐57
Measuring equipment ..............................5‐57
Measuring nozzle .................................... 5‐64
Measuring position .................................. 5‐63
Measuring system ........................4‐71, 4‐205
Imperial .............................................. 4‐205
Mechanics ................................................6‐46
Maintenance ........................................ 6‐46
Media adapter ........................................... 5‐6
Message details .................................... 4‐180
Message history .................................... 4‐180
Message line ........................................... 4‐65
Message types ...................................... 4‐180
Messages .............................................. 4‐180
Display ............................................... 4‐180
MobileControl ................................. 4‐19, 4‐20
Wireless Operating Point .................... 4‐20
WLAN .................................................. 4‐20
WPA key ..............................................4‐20
MobileControl App ......................... 1‐43, 4‐20
MobileControl software ............................4‐20
Motion unit ............................................... 3‐11
Mounting and activating the sensor ....... 5‐59
MultiCoater ........ 1‐17, 1‐18, 2‐16, 2‐49, 3‐24
Dispensing material .............................2‐49
Inertization ........................................... 3‐24
Precoating ............................................3‐24
M
Machine body .......................................... 3‐11
Machine cooler ...................................6‐6–6‐9
B836en
2017-11-17
Index
8‐3
N
Nameplate ................................................. 3‐9
Naming convention ................................4‐167
LTT .....................................................4‐167
NC program
Start ................................................... 4‐115
NC simulation ........................................ 4‐117
TruTops Cell Basic ............................ 4‐117
Network directory .................................. 4‐145
Number pad .............................................4‐15
O
On-screen keyboard ................................4‐72
Activate ................................................ 4‐72
Online help ................. I, 4‐189, 4‐190, 4‐204
Start ........................................4‐190, 4‐204
Operating materials ................................. 2‐46
Operating mode .......................................4‐43
AUTOMATIC ........................................ 4‐43
JOG ..................................................... 4‐43
MDA .....................................................4‐43
Operating modes .....................................4‐43
Operation mode, changing ....................4‐112
Optical laser cable .................................. 3‐43
Order .............................................. 4‐84, 4‐93
Delete .................................................. 4‐84
Exporting ..............................................4‐93
Order status .............................................4‐80
P
Page down .............................................. 4‐15
Page up ................................................... 4‐15
Partial backup ........................................4‐177
Parts backup ......................................... 4‐177
Password ................................................. 4‐75
User group ...........................................4‐75
Path ......................................................... 4‐67
Piece rate .............................................. 4‐102
Pilot laser .................................................3‐44
Planning aid ...............................................2‐5
Pneumatics .............................................. 6‐61
Positioning unit ........................................ 3‐41
IHU .......................................................3‐41
Power supply ........................2‐34, 2‐37, 2‐38
Central ........................................2‐34, 2‐37
decentralized ..............................2‐34, 2‐38
8‐4
Index
Process cooler ............................... 2‐17, 2‐18
Laser device ........................................ 2‐18
Outdoor installation ............................. 2‐18
Production place ......................................4‐57
Production plan . 4‐43, 4‐78, 4‐79, 4‐81, 4‐85
Automation interface ........................... 4‐87
Cell status ............................................4‐79
Clamping fixtures .................................4‐87
Create ........................................ 4‐81, 4‐82
Deleting ................................................4‐85
Job ....................................................... 4‐81
Loading acknowledgment ................... 4‐86
Loading place ...................................... 4‐86
Order ....................................................4‐78
Production ............................................4‐86
Production place ..................................4‐81
Production plan ................................... 4‐78
Program details ................................... 4‐78
Program sequence .............................. 4‐80
Run empty ........................................... 4‐93
Start ............................................4‐87, 4‐89
Program ....4‐85, 4‐115, 4‐116, 4‐119, 4‐146,
4‐147,
4‐150,
4‐151,
4‐219
Cancel ................................................4‐116
Copy .................................................. 4‐147
Create .................................... 4‐146, 4‐219
Delete .......................................4‐85, 4‐151
Exporting ............................................4‐150
Importing ............................................4‐151
Load ................................................... 4‐119
Number .............................................. 4‐150
Pausing .............................................. 4‐116
Prepare .............................................. 4‐119
Select .................................................4‐146
Text editor ..........................................4‐147
Program header .................................... 4‐219
Program status ........................................ 4‐69
Programming instructions ......................4‐189
Context sensitive help .......................4‐189
Programming system ............................ 4‐165
Programs ............................................... 4‐144
Management ......................................4‐144
Prepare .............................................. 4‐118
R
Ramp cycles ..........................................4‐170
Programming ..................................... 4‐170
Rechargeable battery pack ........... 6‐8, 6‐120
UPS module .............................. 6‐8, 6‐120
Reference optics ..............................5‐4, 5‐33
Reference point run ................................ 3‐31
Clamping fixture .................................. 3‐31
2017-11-17
B836en
Remaining time ..........................4‐102, 4‐103
Basic .................................................. 4‐103
Remaining time display .. 4‐101, 4‐103–4‐106
Basic .................................................. 4‐103
Comfort .............................................. 4‐104
Day shift plan .................................... 4‐106
Operation mode .................................4‐106
Piece rate .......................................... 4‐105
Screen ............................................... 4‐101
Shift plan ........................................... 4‐106
Required cooling water ........................... 2‐47
Requirements, space ................................ 2‐9
Reset ....................................................... 4‐16
Residual dust .........................................6‐122
Residual risks .......................................... 1‐55
Rotary indexing table ..................... 4‐58–4‐60
Automatic mode .................................. 4‐60
Loading place ...................................... 4‐58
Rotational direction ..............................4‐58
Setup mode ......................................... 4‐59
Rotational changer ......................... 4‐58–4‐60
Automatic mode .................................. 4‐60
Rotational direction ..............................4‐58
Setup mode ......................................... 4‐59
S
Safety cabin .............................................3‐19
Safety Integrated ........................... 1‐42, 4‐52
Safety position .........................................4‐58
Station change .................................... 4‐58
Safety test ............................................... 4‐53
Start ..................................................... 4‐53
Scrap conveyor .............3‐28, 4‐38, 4‐62, 6‐8
Controls ............................................... 4‐38
Production ............................................4‐62
Reverse mode ..................................... 4‐62
Sensors ..................................................6‐8
Set up .................................................. 4‐62
Scrap conveyors ......................................4‐62
Screen holder .......................................... 2‐25
Screen view ........................................... 4‐116
Switch ................................................ 4‐116
Sensor ..................................................... 5‐64
Sensor system .........................................3‐15
Operating status .................................. 3‐15
Set of drawings ....................................... 3‐29
Setting device ..........................................5‐34
Setup plan ............................................. 4‐146
Setup state ................................. 4‐172–4‐175
Activate .............................................. 4‐172
Create ................................................ 4‐173
Delete ................................................ 4‐175
B836en
2017-11-17
Edit .....................................................4‐174
Shift change .......................................... 4‐106
Shift goal ............................................... 4‐104
Shift plan, create ................................... 4‐106
Shift plan, editing .................................. 4‐108
Shift, extending ......................................4‐113
Shift, manually beginning and ending .. 4‐113
Single job .................................................4‐43
Smart Optics Setup ............. 5‐17, 5‐18, 5‐20
Basic .................................................... 5‐17
Parking position ...................................5‐18
Reference position .............................. 5‐20
Setup position ......................................5‐18
Smart Optics Setup Station .................... 5‐58
Measuring ball ..................................... 5‐58
Software ...................................................1‐53
Software version ....................................4‐181
Solid-state lasers ............................. 3‐3, 3‐43
Sound pressure level .........................7‐3, 7‐4
Test report ............................................. 7‐3
Spare parts ..............................................1‐53
Spark arrester ............................................6‐6
SPM ....................................................... 4‐154
Start ......................................................... 4‐17
Status bar ...................................... 4‐68, 4‐69
Status display ........................................ 4‐172
Setup state ........................................ 4‐172
Status indicators ......................................4‐37
Step-by-step ............................................ 4‐94
Start ..................................................... 4‐94
Stop after cycle end ................................4‐92
STOP push-button ...................................1‐41
Teach panel ......................................... 1‐41
Sub-operations ........................................ 4‐67
Sub program ..........................................4‐148
Program name ...................................4‐148
Subroutine
Create ................................................ 4‐148
Subroutine macro .......................4‐153–4‐156
Inserting ............................................. 4‐156
Macro editor ...................................... 4‐155
Programming ..................................... 4‐154
Support unit ................................... 3‐36, 3‐40
Hot-forming .......................................... 3‐36
IHU .......................................................3‐40
Switch cabinet cooling ............................ 2‐14
Swivel unit ............................................... 3‐38
IHU .......................................................3‐38
System settings ....................................... 4‐71
T
Tab ........................................................... 4‐15
Index
8‐5
Teach panel ......................1‐51, 4‐194, 4‐195
Function key ...................................... 4‐195
Safety ...................................................1‐51
Teach points .......................................... 4‐211
Teaching ...4‐201, 4‐203, 4‐211–4‐215, 4‐217
Arc ..................................................... 4‐212
Button ................................................ 4‐203
Circle ..................................................4‐214
Macro center ..................................... 4‐213
Macro help point ............................... 4‐213
Oblong hole ....................................... 4‐217
Rectangle ...........................................4‐215
Square ............................................... 4‐215
Straight line ........................................4‐211
User interface .................................... 4‐201
Teachpanel ............................................ 4‐195
Display ............................................... 4‐195
Technical data ......................................... 3‐45
Cutting optics ............................. 3‐14, 3‐15
Teleservice .............................................4‐182
............................................................ 4‐182
Modem ...............................................4‐182
Test sheet ...................................... 5‐18, 5‐28
Test sheet holder .....................................5‐14
Time ......................................................... 4‐71
Titanium ................................................... 1‐17
Tool changer ............................................4‐61
Malfunction, acknowledging ................ 4‐61
Tool length ............................................... 5‐51
Tooling setup ......................................... 4‐171
Tooling status ........................................ 4‐171
TOS ..........................................................4‐73
TRUMPF Operating System ............... 4‐73
Touchscreen ............................................ 4‐15
Transformation .......................................4‐159
Transformation accumulator ..................4‐160
Transport ..................................................2‐50
Transport regulation ................................ 2‐50
Tropical version ....................................... 2‐14
TruControl ................................................ 4‐74
Switching ............................................. 4‐74
TruDisk emergency stop push-button .....1‐40
TruTops Cell Basic ................................ 4‐165
User interface .......................................... 4‐73
Close ....................................................4‐73
User responsibility ................................... 1‐22
Utility tools ............................................. 4‐125
V
Vacuum ejectors ................................ 6‐6, 6‐7
Video monitoring ....................................... 3‐9
Visual Online Support ........................... 4‐184
VOS App ............................................... 4‐184
W
Warm start ............................................. 4‐136
Run .................................................... 4‐136
Warning signs ..........................................1‐44
Water protection ...................................... 1‐52
Weight load ..............................................2‐11
Wireless Operating Point ...................... 4‐184
Wizard ............................................ 5‐27, 5‐28
Reference optics ................................. 5‐28
Status ...................................................5‐27
Wizard ..................................................5‐28
Workpiece ................................................ 1‐18
Oil residue ........................................... 1‐18
Workpiece changer ...3‐25, 4‐57, 4‐59, 4‐141
Loading and unloading place ........... 4‐141
Manual functions ................................. 4‐59
Setup mode ......................................... 4‐59
Workpiece counter .....................4‐124, 4‐135
Display ............................................... 4‐124
Reset ................................................. 4‐124
Workpiece recognition .............................3‐30
Workpiece status ........ 4‐94, 4‐96, 4‐98, 4‐99
U
Uninterruptable power supply ................. 2‐36
User administration ................................. 4‐75
User consent ........................................... 4‐54
Issue .................................................... 4‐54
User event logfile .................................... 4‐70
User group ..................................... 4‐75, 4‐76
Log on ................................................. 4‐76
8‐6
Index
2017-11-17
B836en