Operator's manual

TruPulse 556
Operator's manual

TruPulse 556

Original operator's manual

Edition 2016-01
 Order Information Please specify when ordering this document:
Operator's manual
TruPulse 556
Edition 2016-01
Document number 20-06-12-A2-CR02

TRUMPF Laser GmbH

Address for orders Vertrieb
Aichhalder Straße 39
78713 Schramberg
Fon: +49 7422 515 - 0
Fax: +49 7422 515 - 436
Internet: http://www.trumpf-laser.com
E-Mail: [email protected]

TRUMPF Laser GmbH

Address for service Technischer Kundendienst
Aichhalder Straße 39
D-78713 Schramberg
Fon: +49 7156 303 - 37 444
Fax: +49 7422 515 - 148
Internet: http://www.trumpf-laser.com
E-Mail: [email protected]
E-Mail: [email protected]

© TRUMPF Laser GmbH

 Before you proceed ...

What do the operating These operating instructions contain important information on

instructions contain? your laser product, its functions, operation and maintenance. This
information will help you operate the laser product safely, avoid
any risks, reduce service costs and break-down times and
increase its reliability and service life.

Other regulations In addition to the operating instructions, also observe the

regional regulations regarding accident prevention, especially
laser safety, and environmental protection.

Target group of the These operating instructions regarding the laser product are
operating instructions intended for persons who are entrusted with working on the laser
product, for example with:
■ Transport
■ Operation
■ Maintenance

Further documentation Documents mentioned as reference are part of the delivery of

the laser product:
■ Installation instructions
■ Interface descriptions
■ Software manual

20-06-12-A2-CR02 2016-01 Before you proceed ... I

II Before you proceed ... 2016-01 20-06-12-A2-CR02
 Table of contents

Chapter 1 Safety

Safety is important 1‐3

1 Overview 1‐4

2 Warning instructions 1‐5

3 Terms 1‐6

4 Hazards 1‐9
4.1 Laser light 1‐9
4.2 Electrical energy 1‐10
4.3 Gases, aerosols, dusts 1‐11
4.4 Thermal energy 1‐12
Fire, explosion 1‐12
Temperature of the workpiece 1‐12
4.5 Noise 1‐12

5 Safety of the laser product 1‐14

5.1 Laser beam emission opening 1‐14
5.2 EMERGENCY STOP pushbutton 1‐15
5.3 Safety circuits 1‐16
5.4 Laser warning lamp 1‐18
5.5 Key-operated switch 1‐18
5.6 Labels and warning signs 1‐19
Required signs 1‐19
Labels on the laser device 1‐22
Labels in the area of the focusing optics 1‐22

6 Measures of the user 1‐23

6.1 Designated use of the laser product 1‐23
6.2 Technical measures 1‐23
6.3 Organizational measures 1‐24
6.4 Observing standards and regulations 1‐25
6.5 Behavior in certain operating stages 1‐25

20-06-12-A2-CR02 2016-01 Table of contents 0‐1

 6.6 Behavior in case of emergency 1‐26
6.7 Selecting and qualifying personnel 1‐26
6.8 Instructing the personnel 1‐27
6.9 Wearing personal protective equipment 1‐27

Chapter 2 Installation conditions, transport

1 Scope of delivery 2‐4

1.1 Components of the laser device 2‐4
1.2 Further accessories 2‐5
1.3 Documents 2‐5

2 Dimensions 2‐7
2.1 Laser device 2‐7
Type D 2‐7
Type D+ 2‐8
2.2 Free spaces for service work 2‐9
2.3 Operating panel 2‐9
2.4 Laser light cable 2‐10
2.5 Focusing optics 2‐10

3 Weight, floor at the installation site 2‐13

4 Connections 2‐14
4.1 External connections 2‐14
4.2 Electrical interfaces 2‐14

5 Electrical connected loads 2‐18

5.1 Electrical connection 2‐19
5.2 Electromagnetic compatibility 2‐19
5.3 Insulation resistance 2‐19

6 Cooling unit 2‐21

6.1 External cooling circuit 2‐21
Cooling water requirement for the tube 2‐22
dimensioning
Cooling water connections 2‐24
6.2 Data for chillers 2‐24

0‐2 Table of contents 2016-01 20-06-12-A2-CR02

 6.3 Installation examples 2‐26
6.4 Laser cooling circuit 2‐26

7 Ambient conditions 2‐28

8 Emissions 2‐30

9 Position of the user 2‐31

9.1 Position for switching on and off 2‐31
9.2 Position for operating the laser device 2‐31
9.3 Position for setting the focusing optics 2‐32
9.4 Position for maintenance work 2‐33

10 First measures to be taken after receipt of 2‐34

the laser device
10.1 Delivery of the laser device 2‐34
10.2 Commissioning 2‐34
Protecting the laser device against rolling 2‐34
away

11 Transport 2‐35
11.1 Moving the laser device on casters 2‐35
11.2 Transport by forklift truck / Transport by 2‐36
means of pallet jack
11.3 Packing the laser device 2‐38

Chapter 3 Description

1 Overview 3‐3

2 Laser 3‐4
2.1 Design 3‐4
2.2 Specifications 3‐4

3 Optical arrangement 3‐8

3.1 Components of the optical arrangement 3‐10
Central shutter (VZ) 3‐10
Shutter (V1, V2, ...) 3‐11
Switch (W1, W2, ...) 3‐11

20-06-12-A2-CR02 2016-01 Table of contents 0‐3

 Shutter switch (VW1, VW2, ...) 3‐13
Shutter switch with pilot laser 3‐14
Physical splitter with adjustable splitter 3‐15
ratio
Deflection (U1, U2, ...) 3‐16
Central pilot laser 3‐16
Incoupling optics 3‐17

4 Laser light cable 3‐18

5 Focusing optics 3‐20

6 Control 3‐22

7 Operating panel 3‐24

8 Control panel (Option) 3‐25

9 Mains distribution 3‐26

10 Laser cooler 3‐28

11 Lamp power supply 3‐30

12 Telepresence 3‐31
12.1 Connection via VPN TRUMPF to the laser 3‐31
device
12.2 Connection via VPN laser device to TRUMPF 3‐32
12.3 Connection via SSH 3‐32
12.4 Direct connection over an analog modem 3‐33

Chapter 4 Operation

1 Operating elements and indicators 4‐3

1.1 Case 4‐3
1.2 Operating panel 4‐5

0‐4 Table of contents 2016-01 20-06-12-A2-CR02

 2 Switching the laser device on and off 4‐7
2.1 Switching on 4‐7
2.2 Switching off in case of malfunction and 4‐7
emergencies
2.3 Switching on after EMERGENCY STOP 4‐7
2.4 Switching off after work 4‐8

3 Operating the laser device using TruCon- 4‐9

trol 1000
3.1 Selecting light path 4‐9
Select the light path in the parameter set 4‐9
Change the light path name 4‐11
3.2 Activating and deactivating the laser 4‐12
Switching the laser on and off 4‐12
Open or close the central shutter (VZ) in 4‐13
the parameter set
3.3 Responding to messages 4‐13
Resetting the message 4‐14
3.4 Generating pulse shapes 4‐15
3.5 Creating laser programs 4‐16
3.6 Programming light paths 4‐17
3.7 Pilot laser (option) 4‐17
Switching the switching functions of pilot 4‐18
laser on and off
Setting the pilot laser mode 4‐18
Switching the pilot laser in the light path 4‐20
on and off

4 Controlling the laser device from outside 4‐23

4.1 TRUMPF LaserNetwork (option) 4‐23

Chapter 5 Maintenance

1 Installation guideline 5‐4

2 Material 5‐5
2.1 Wearing parts 5‐5
2.2 Tools and auxiliaries 5‐5

20-06-12-A2-CR02 2016-01 Table of contents 0‐5

 2.3 Consumables 5‐6
2.4 Disposal 5‐7

3 Opening and closing the laser device 5‐8

3.1 Opening and closing doors 5‐8
3.2 Remove covers 5‐8
3.3 Open and close hood 5‐9

4 Hose connections 5‐10

4.1 Connecting the hose 5‐10
4.2 Disconnecting the hose 5‐10

5 Flash lamp 5‐11

5.1 Replacing the flash lamp 5‐11

6 Optical arrangement and laser light cable 5‐18

6.1 Check mirror and lenses 5‐18
6.2 Removing and mounting the laser light cable 5‐19
Dismount laser light cable 5‐19
Fitting a laser light cable 5‐23
6.3 Maintaining laser light cable 5‐28
Cleaning the protective sleeve with cover 5‐28
slide
Replacing the protective sleeve along with 5‐29
the cover slide

7 Fan at the control 5‐31

7.1 Check the function of the fan on the control 5‐31
unit
7.2 Clean the grids on top of the fans 5‐32

8 Lamp power supply 5‐34

8.1 Replacing the lamp power supply, TruPulse 5‐34
203 ... TruPulse 556

9 Laser cooler 5‐40

9.1 Topping up cooling water 5‐41
9.2 Replacing the water in the tank 5‐42
9.3 Cleaning the tank, cleaning or changing the 5‐44
filter of the tank
9.4 Replacing the deionizing filter 5‐47
9.5 Cleaning the particle filter 5‐50

0‐6 Table of contents 2016-01 20-06-12-A2-CR02

 9.6 Cleaning the contamination filter 5‐52
9.7 Checking the cooling unit for tightness 5‐54
9.8 Checking the solenoid valve 5‐55
9.9 Emptying and filling the cooling unit 5‐56
Emptying the cooling unit of the laser 5‐56
device
Filling the cooling unit 5‐62

10 Electrical system 5‐67

10.1 Identifying blown electrical fuses 5‐67
10.2 Replacing a microfuse 5‐69
10.3 Activating an automatic circuit breaker 5‐70

11 Operating panel 5‐71

11.1 Clean the screen of the operating panel 5‐71

Chapter 6 Conduct in case of service

interruptions

1 Service interruptions 6‐2

1.1 Measures in case of service interruptions 6‐2

2 Identifying causes 6‐3

3 Monitoring and faults 6‐4

3.1 Monitoring 6‐4
3.2 Fault 6‐5

4 Dealing with messages 6‐7

4.1 Structure of a message 6‐7
4.2 Message history 6‐9
Displaying the history of messages 6‐9
Setting the message filter 6‐9
Searching for a message 6‐10
Type of message 6‐12

20-06-12-A2-CR02 2016-01 Table of contents 0‐7

0‐8 Table of contents 2016-01 20-06-12-A2-CR02
 Chapter 1

Safety
Safety is important 1‐3

1 Overview 1‐4

2 Warning instructions 1‐5

3 Terms 1‐6

4 Hazards 1‐9
4.1 Laser light 1‐9
4.2 Electrical energy 1‐10
4.3 Gases, aerosols, dusts 1‐11
4.4 Thermal energy 1‐12
Fire, explosion 1‐12
Temperature of the workpiece 1‐12
4.5 Noise 1‐12

5 Safety of the laser product 1‐14

5.1 Laser beam emission opening 1‐14

20-06-12-A2-CR02 2016-01 Safety 1‐1

 5.2 EMERGENCY STOP pushbutton 1‐15
5.3 Safety circuits 1‐16
5.4 Laser warning lamp 1‐18
5.5 Key-operated switch 1‐18
5.6 Labels and warning signs 1‐19
Required signs 1‐19
Labels on the laser device 1‐22
Labels in the area of the focusing optics 1‐22

6 Measures of the user 1‐23

6.1 Designated use of the laser product 1‐23
6.2 Technical measures 1‐23
6.3 Organizational measures 1‐24
6.4 Observing standards and regulations 1‐25
6.5 Behavior in certain operating stages 1‐25
6.6 Behavior in case of emergency 1‐26
6.7 Selecting and qualifying personnel 1‐26
6.8 Instructing the personnel 1‐27
6.9 Wearing personal protective equipment 1‐27

1‐2 Safety 2016-01 20-06-12-A2-CR02

 Safety is important
This chapter contains important notes for operating your laser
product safely. Carefully read this information before starting to
operate the laser product.

20-06-12-A2-CR02 2016-01 Safety 1‐3

 1. Overview

This chapter summarizes all information that you should know in

order to operate your laser product safely.

Here you will find:

■ Information about risks involved in using the laser product
■ A description of devices and measures that we, as the man-
ufacturer, have already implemented and taken to allow you
to safely use the laser product.
■ Any instructions that you, the user, must observe and put
into practice to safely operate the laser product in your work
environment and to protect the health of persons.
In other chapters of these operating instructions, you will find
descriptions and instructions for an efficient use of the laser
product. If the actions involve any risks, warning instructions pre-
cede the instructions to warn against possible consequences.
This manual must always be at hand at the place where the
laser product is used.

1‐4 Overview 2016-01 20-06-12-A2-CR02

 2. Warning instructions

A warning instruction is information that:

■ Names the type and source of a danger.
■ Indicates possible consequences in case the danger is not
avoided.
■ Gives instructions for how to avoid any damage.
One of the signal words "Danger", "Warning", "Caution", or
"Attention" indicates the severity of the possible consequences in
case the instructions are not observed.
"Danger" warns against a great danger. If not avoided, it leads
to death or serious injuries.
"Warning" warns against a danger that may cause medium or
serious injuries with permanent damage.
"Caution" warns against a danger that may cause light or
medium injuries without permanent damage.
"Attention" warns against possible material damage.
Example of a warning instruction:

Eyes and skin may be exposed to laser radiation, if the

WARNING laser light is not placed under a protective cover!
Laser light can burn the skin. Direct or scattered laser light
can permanently damage the eyes.
Ø Take the necessary protective measures as specified below,
depending on the laser class.

It is absolutely necessary to observe and follow the warning

instructions!

20-06-12-A2-CR02 2016-01 Warning instructions 1‐5

 3. Terms

Laser product Laser products include devices, systems or components used for
generating, transmitting and using laser light.

TRUMPF products summarized under the term "laser product"

include:
■ Lasers (beam sources)
■ Laser machines
■ Laser workstations
■ Laser devices
■ Laser light cables
■ Focusing optics

Laser light Laser light is electromagnetic radiation with wavelengths from

100 nm to 1 mm produced as the result of controlled stimulated
emission.
Laser is an acronym, short for: Light Amplification by Stimulated
Emission of Radiation.

Laser The term "Laser" summarizes all components directly used for
generating laser light:
■ Resonator, comprising rear mirror and output coupling mirror
■ Laser material
■ Pump source

Other components of lasers might include:

■ Modulators
■ Q-switch
■ Converter for generating other wavelengths
With certain forms of lasers, the components mentioned above
can be integrated as structures in a basic material.
Examples:

Rear mirror and output coupling mirror:

■ in fiber lasers as Bragg gratings
■ in diode lasers as surfaces in semiconductor crystals.

Laser machine Laser machines are machines the main purpose of which is to
weld or cut material with laser light or to process it in any other
way. In laser machines, movements of the workpieces and
focusing optics are mainly controlled automatically.

Laser workstation Laser workstations are facilities at which workpieces are mainly
processed manually using laser light.

1‐6 Terms 2016-01 20-06-12-A2-CR02

 Laser device Laser devices include all components required for generating
laser light.

Laser device components include:

■ Laser with pump source
■ Energy supply for the pump source, e.g. diode power supply,
lamp power supply
■ Control
■ Cooling unit

Depending on the type and maximum power of the laser device,

it may have other components, such as:
■ Mains distribution
■ Cabinet cooler
■ Air cleaner or recirculating air dryer system
■ Gas purging unit

Laser light cable The laser light cable is a flexible connecting element between
laser device and focusing optics. The laser light is guided from
the laser to the focusing optics in a light guide. The light guide
is surrounded by several devices that prevent an uncontrolled
escape of laser light and protect the light guide.

Focusing optics Focusing optics are optical assemblies. Their main function is to
form the laser beam so that it achieves its maximum power den-
sity at a defined point, the focal point.
In the reflective focusing optics (RFO), the conical laser beam
coming out of the laser light cable hits the focusing mirror, which
guides the laser beam through the exit port and merges it in the
focal point.
The programmable focusing optics (PFO) includes one or two
scanner mirrors which allow the laser beam to be guided over a
processing field. It is thus possible to produce, for example,
welding seams without moving the focusing optics and the work-
piece.
The distance of the focal point from a certain edge or surface of
the focusing optics is called working distance. The working dis-
tance of the focusing optics determines the distance in which the
workpieces must be positioned so that they can be processed
with the laser.

Safety circuit A safety circuit is an electric circuit for monitoring protective cov-
ers and doors of laser protective casings and cabins. When the
contacts are looped in, the safety circuit should always be closed
when all monitored covers and doors are closed.
When a contact interrupts the safety circuit because a door is
opened, for example, laser light emission is immediately stopped.

20-06-12-A2-CR02 2016-01 Terms 1‐7

 The safety circuit, as a central shutter of a laser device, stops
emission of laser lights on all light paths of the laser device.
The safety circuit of just one light path only stops light emission
on this light path. Laser light can still be emitted on the other
light paths if these safety circuits are closed.

1‐8 Terms 2016-01 20-06-12-A2-CR02

 4. Hazards

The laser product has been built in accordance with state-of-the-

art standards and the recognized safety rules. However, there
might be dangers for persons or material property during use. If
you do not observe the accident prevention regulations, these
dangers may result in damage.
This section describes possible dangers that might be caused by
your laser product.

In the following sections, you will find information about:

■ how TRUMPF has reduced the risk by applying constructive
measures.
■ how you, as the user, can guarantee a safe operation of the
laser product by taking additional measures during its use.

4.1 Laser light

Solid state lasers generate laser light in the near infrared spec-
tral range (900 nm – 1250 nm). Using converters, the laser light
can also be produced in the visible range (400-700 nm) or in the
ultraviolet spectral region (< 400 nm).
Laser light may be hazardous to eyes and skin.
Depending on the severity of the danger, laser products are clas-
sified in laser classes.
The classification of the laser product in laser classes is defined
internationally in the EN 60825-1 and IEC 60825 standards.
The meaning of the laser classes is described briefly below. The
precise definition listing limit values can be found in the stand-
ards stated above.

Class 1 Class 1 means that the laser light of this laser product is not
dangerous in standard operation.
The laser device is classified as class 1M (acc. to EN 60825-1)
if there may be a risk when observing laser light through optical
instruments.

Class 2 A class 2 laser product only emits in the visible spectral region
(400-700 nm). A brief exposure does not involve any risk. Delib-
erate staring in the beam might be dangerous for your eyes.
Active reactions are sufficient to protect your eyes against dam-
age: Avert your eyes, move your head or close your eyes.
The laser device is classified as class 2M (acc. to EN 60825-1)
if there may be a risk when observing laser light through optical
instruments.

20-06-12-A2-CR02 2016-01 Hazards 1‐9

 Class 3 Class 3 is subdivided into class 3R and class 3B acc. to EN
60825-1. A previously existing restriction of class 3 to certain
spectral ranges no longer exists.
Class 3R laser products exceed the limits of class 2. In most
cases the risk is low. The risk of injury increases with the time of
exposure. A deliberate irradiation of your eyes is dangerous.
Class 3B laser products are normally dangerous when you look
directly into the beam. The observation of diffuse reflections is
usually not dangerous. Class 3B laser products the power of
which almost reaches that of class 4 might produce light skin
injuries; they might also ignite inflammable material.

Class 4 Exposure of the eye or skin to class 4 laser products is danger-

ous. Even diffuse radiation (scattered laser light) can be danger-
ous. Class 4 laser light can ignite inflammable material and
make explosive mixtures explode.

4.2 Electrical energy

While carrying out upkeep work, you can come into contact
DANGER with dangerous live parts!
Touching live electric parts can be life threatening.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Switch off the laser product prior to upkeep work.
Ø Secure the laser product against restart.
Ø Before touching electric parts, first check if they are de-ener-
gized.

Faults Switch the laser device off immediately if troubles occur in the
electrical system, turn the main switch to position OFF.

Stationary device According to the safety regulations for protection from electrical
energy, this laser product is considered a fixed device. The
regionally enacted safety standards and accident prevention reg-
ulations apply accordingly.

For you, as user of the laser product, this means:

■ The laser product may not be moved while switched on.

Regular check Check the electrical equipment of the laser product at regular
intervals. Defects such as loose connections or defective cables
must be eliminated immediately.
Electrical safety of the laser product must be checked regularly,
at least once every 4 years. The basis of the test is the German

1‐10 Hazards 2016-01 20-06-12-A2-CR02

 standard DIN VDE 0702. Beyond the scope of this standard, the
regulations for the corresponding region are to be applied.

This check must be carried out by a trained electrician. Among

other things, it consists of the following actions:
■ Visual check, for example the condition of the protective
grounding conductor and its terminal locations.
■ Test of the protective grounding conductor resistance
■ Check the insulation resistance.
− Due to the EMC measures, the values are below the
value required by the standard DIN VDE 0701-0702
(see chapter "Installation conditions, transport", section
"Electrical connected loads").

Fuses Use only original fuses with the specified characteristics and cur-
rent rating.

Voltage when main switch is Some components are still under dangerous voltage, even if the
off main switch is in position OFF. Therefore check first that the
parts that you will touch are dead.

Capacitors The discharge time of capacitors may be more than one minute.
Check if the parts live during operation carry voltage, after
switching off the machine. Start working on live parts only after
you have checked if they are de-energized.

4.3 Gases, aerosols, dusts

When workpieces are processed, gases, aerosols or dusts can

be produced; these are dangerous to health. The biggest risk is
caused when the substances enter your respiratory tract. But
even contact with your skin or mucous membranes in your
mouth, nose or eyes can be dangerous.
Dust:
Solid particles > 1 µm.
Aerosols:
Gases with finely distributed solid or liquid particles < 1 µm.
Some escaping substances may cause cancer. The cancer risk
depends mainly on the material of the workpieces and the emit-
ted quantity.

Carcinogenic substances include

■ beryllium compounds
■ zinc chromates

20-06-12-A2-CR02 2016-01 Hazards 1‐11

 The emitted quantity depends on:
■ the type of material.
■ the speed.
■ the laser power.
■ the cutting gas pressure, if applicable.

4.4 Thermal energy

Fire, explosion

Class 3B or 4 laser light may cause fires if it ignites inflammable

material.
If there is a potentially explosive mixture of gases or aerosols
(e.g. oxyhydrogen, wood or carbon dust) in the air, a laser beam
might cause an explosion, even if it does not hit solid material
with a high power density.

Temperature of the workpiece

Due to the processing by means of the laser beam, the work-

piece may be heated up. The degree of heating depends on the
material of the workpiece and the energy given off by the laser
beam to the workpiece during processing.

Risk of burns when touching the hot workpiece

WARNING
This may result in skin injuries.
Ø Remove hot workpieces using an appropriate tool.
Ø Wear protective gloves, if necessary.

4.5 Noise

Focusing optics The use of focusing optics in conjunction with lasers and process
gas produces noise.

Sources of noise in the area of the focusing optics include:

■ Material that evaporates as a result of the exposure to laser
light
■ Cutting gas or shielding gas passed to the processing point
■ Compressed air coming out of the crossjet

1‐12 Hazards 2016-01 20-06-12-A2-CR02

 During laser welding, compressed air comes out of a nozzle,
called crossjet, perpendicularly to the direction of the laser
beam. If there is a crossjet, it is often the biggest source of
noise. Measurements have given values > 90 dB(A).

High noise level when operating a focusing optics,

WARNING especially when using a crossjet!
Noise can result in permanent ear damage and other
unfavorable consequences to health, especially upon
prolonged exposure.
Ø Surround the processing point with a protective cover that is
sufficiently silencing.
Ø Wear ear protection if the noise levels are high.
Ø Operate the focusing optics only with the silencing protective
cover closed, if possible.

The room in which a focusing optics is operated should have the

following characteristics:
■ The processing point should be as far away as possible from
places where people stay permanently.
■ Walls and devices are particularly good absorbers of noise.
■ The areas that are at risk from noise are labeled.
■ Ear protection devices are available in sufficient numbers.

20-06-12-A2-CR02 2016-01 Hazards 1‐13

 5. Safety of the laser product

5.1 Laser beam emission opening

Fig. 1-1

The figure shows a laser device with focusing optics. The arrow
marks the place where the laser light is emitted.
Focusing optics are assembled by modules, your application
requires. The appearance may differ from the optics shown in
the picture. More than one laser light cable and focusing optics
can be connected to a laser device. In any case, the laser light
is emitted from the lenses of the focusing optics.
Laser light cannot be emitted from other places of the laser
device if all protective covers are closed.

Wavelengths Laser Wavelength Spectral range

Nd:YAG 1064 nm near infrared
pilot laser 630 - 680 nm visible, red
Tab. 1-1

Laser classes Device, component Laser class

Laser device with closed hood 1
Laser device with open hood 4
Laser light cables 1
Focusing optics under a closed protective cover 1
Focusing optics without protective cover 4
Laser machines with protective cover 1
Laser machines without protective cover 4
Pilot laser at the exit port (switch, deflection) 3R

1‐14 Safety of the laser product 2016-01 20-06-12-A2-CR02

 Laser classes Device, component Laser class
Pilot laser at the exit of the focusing optics 2
Tab. 1-2

5.2 EMERGENCY STOP pushbutton

E-Stop pushbuttons are located:

■ on the operating panel.
■ on the control panel.
■ on the front of the laser device.

EMERGENCY STOP pushbutton (arrows) Fig. 1-2

Operating the "E-Stop" pushbutton immediately stops all compo-

nents of the laser device which can be dangerous. In particular,
no laser light may be emitted any longer after having operated
the E-Stop pushbutton.

Note
The operating panel should be attached at the point easily
accessible for the operator. This guarantees that the EMER-
GENCY STOP pushbutton can be pressed immediately in case
of an emergency situation.

Further pushbuttons Further E-Stop pushbuttons can be additionally connected to the

laser device. Integration of the E-Stop circuit of the laser device
in an E-Stop circuit of the system is also possible. For further
information, see the interface description for E-Stop.

Checking the function Check the function of the EMERGENCY STOP push buttons if
you have modified the EMERGENCY STOP circuit of the laser
device. TRUMPF cannot be held liable for any damage resulting
from the incorrect wiring of the EMERGENCY STOP circuit.

20-06-12-A2-CR02 2016-01 Safety of the laser product 1‐15

 Operating panel without Do not connect an operating panel with pushbutton E-STOP
pushbutton E-STOP to the laser device if the laser device was previously oper-
ated by means of an operating panel without E-STOP push-
button. In this case, the E-STOP pushbutton has no func-
tion.

5.3 Safety circuits

The control of the laser device contains interfaces for safety cir-
cuits (SIK).

What is a safety circuit? A safety circuit is an electric circuit used to monitor the protec-
tive covers and safety doors. Under the protective cover moni-
tored by the safety circuit, laser light can only be emitted from
the focusing lens if the laser protective cover is closed.

Purpose Safety circuits allow entire systems to be operated as class 1

laser devices.

ASV board Each safety circuit is connected to an ASV board, which is

located in the control of the laser device. The ASV board con-
trols the optical shutter, which prevents the emission of laser
light when the safety circuit is open.
ASV: Operating and safety shutter (German for: Arbeits- und
Sicherheits-Verschluss.)

Operating principle The following picture shows the basic function of a safety circuit.

1‐16 Safety of the laser product 2016-01 20-06-12-A2-CR02

 WS-00101
1 Laser control unit 3 Door contact closed 4 Door contact open
2 Shutter
Safety circuit, principle Fig. 1-3

Work function In the picture above the safety circuit is closed. The laser
operates according to the running laser program or is controlled
manually by the operator.

Safety function In the figure below, the safety circuit is open because the door
of the protective cabin was opened. The shutter is changed to
CLOSED position via the ASV board in the control unit. No laser
light is emitted at the processing point anymore.

Laser light upon “Laser On” When the safety circuit is closed and the shutter is open, laser
light > 5 mW can be emitted from the laser beam emission
openings after having switched on the laser, even if the com-
mand to trigger the laser has not yet been started.

20-06-12-A2-CR02 2016-01 Safety of the laser product 1‐17

 5.4 Laser warning lamp

Fig. 1-4

Laser warning lamp The laser warning lamp is lit when:

■ laser light is emitted at the processing point.
■ the laser is ready for emitting laser light, even if no laser light
is emitted at the processing point yet ("laser on" status).

External laser warning lamp A further laser warning lamp can be connected to the laser
device and attached, e.g. near the workstation.
Further information can be found in the interface description for
E-STOP and ASV.

5.5 Key-operated switch

Fig. 1-5

1‐18 Safety of the laser product 2016-01 20-06-12-A2-CR02

 Key-operated switch

Fig. 1-6

Activation of the laser by an unauthorized person can be pre-

vented by means of the key-operated switch. To do so, turn the
key to the position 0 (chart A) and be withdrawn.
The key has to be inserted for operation. The key-operated
switch has to be turned to the right. The key-operated switch
must be turned to position I (chart B).

5.6 Labels and warning signs

The labels and warning labels attached to the laser product and
in the range of the focusing optics are described in this section.
The point of fastening is indicated for each label.

Required signs

Reference to laser product class Fig. 1-7

Warning against dangerous laser radiation Fig. 1-8

20-06-12-A2-CR02 2016-01 Safety of the laser product 1‐19

 C

Notes regarding power and wavelength of the pilot laser Fig. 1-9

Warning against dangerous electric voltage Fig. 1-10

Notes regarding power and wavelength of the laser (Exam- Fig. 1-11
ple)

WR-01002
DIN EN 60825-1:2006-08

Warning against dangerous laser radiation Fig. 1-12

Warning against dangerous electric voltage Fig. 1-13

1‐20 Safety of the laser product 2016-01 20-06-12-A2-CR02

 H

Warning against dangerous laser radiation Fig. 1-14

Note: "In case of frost, leakage of cooling water," Instruc- Fig. 1-15
tions: see operating instructions

Type plate of the laser device (example) Fig. 1-16

Warning against dangerous electric voltage Fig. 1-17

Warning against dangerous laser radiation Fig. 1-18

20-06-12-A2-CR02 2016-01 Safety of the laser product 1‐21

 Labels on the laser device

The following picture shows the location of the labels on the

laser devices. The letters are the same as those shown in sec-
tion "Required signs".

E F BG
H
C
H

D
D D D
B D D

J
K L

Fig. 1-19

Labels in the area of the focusing optics

Upon delivery, the label "Avoid Exposure" is enclosed in tripli-

cate.
The labels are adhesive lables with removable protective film.
The labels will not be attached yet, as the arrangement of the
station where the focusing optics are to be fitted to, is normally
not known at the time of delivery.

Obligation to identify As user of the laser device you are obliged to attach labels near
the focusing optics, so that they can be seen by the persons
staying within this area.

1‐22 Safety of the laser product 2016-01 20-06-12-A2-CR02

 6. Measures of the user

6.1 Designated use of the laser product

The laser device is intended exclusively for processing solid met-

als or metal alloys.

Operating the device within the limits of its designated use

requires you to:
■ observe the instructions set out in this operating manual.
■ wiring and connecting electric lines to the laser product in
compliance with the regulations regarding electromagnetic
compatibility.
■ not to move the laser device when it is switched on.
■ carry out necessary inspections and maintenance work.

Exceptions The laser device is not intended for processing metals or metal
alloys in connection with flammable or explosive materials
(example: containers filled with combustible gases or fuel, ammu-
nition).
The laser product must not be operated in an environment sub-
ject to explosion hazards.

6.2 Technical measures

Condition of the laser The laser product may only be used when it is in a technically
product perfect condition. Any faults, especially those affecting the safety
of the unit, should be rectified immediately!

Modifications Do not modify the laser product without the previous consent of
TRUMPF as this might impair the safety of the laser product.

Spare parts Spare parts must comply with the requirements specified by
TRUMPF. This is guaranteed with original spare parts.

Software Do not modify the software programs in programmable compo-

nents.

Cables Always lay the laser light cable and the electric cables so that
they are protected; observe the minimum bending radius.

Keep the cables away from:

■ transport paths.
■ moving or heavily vibrating machine parts.

20-06-12-A2-CR02 2016-01 Measures of the user 1‐23

 Protective covers Always cover focusing optics and processing points with protec-
tive covers, as far as possible. Protective covers have to be
designed so that laser light cannot escape.

Protective covers may be:

■ Housings in which focusing optics and processing point are
located.
■ Walk-in protective cabins.
All parts of protective covers that can be opened by the operat-
ing personnel during operation must be monitored. The moni-
toring has to stop the laser light emission immediately when a
protective cover is opened.
Protective covers that are only opened for repair have to be
monitored in the same way. If they are not monitored, tools must
be required for opening them.
TRUMPF laser devices have safety circuits that guarantee the
described safety function when they are appropriately wired.
More information can be found in the interface description of the
laser devices.
Walk-in protective cabins should be equipped with motion detec-
tors or similar equipment. Like this, it can be recognized that
persons are in the protective cabin even if the cabin door is
closed.

Protecting the endangered Protect the areas in which laser light can escape so that unau-
area thorized persons cannot access them; use code locks or suitable
signaling devices, for example.

6.3 Organizational measures

Laser safety officer If your company operates a class 3B, 3R or class 4 laser prod-
uct, appoint a laser safety officer. Make sure that this person is
skilled so that he or she can evaluate the dangers caused by the
laser and take appropriate measures. Put this laser safety officer
in charge of supervising the protective measures taken against
dangers caused by lasers.

Selecting and qualifying As the laser device operator, only use trained and instructed
personnel staff. Set out clearly the individual responsibilities of the persons
for operation, setup, maintenance and upkeep.

Registering the laser unit As the operator, you are obliged to report the operation of class
3B and class 4 laser products to the authorities responsible for
laser safety.
If you have any questions, please contact a local agency of
TRUMPF.

1‐24 Measures of the user 2016-01 20-06-12-A2-CR02

 Trained electrician According to the electrical engineering rules, any work on the
electrical system of a laser product may only be carried out:
■ by a trained electrician.
■ by instructed persons under the supervision and guidance of
a trained electrician.

6.4 Observing standards and regulations

Some important standards and regulations which you have to

observe when operating a laser product are listed in the follow-
ing table. This list is for information purposes only and probably
incomplete.
As the operator, you are responsible for ensuring that the stand-
ards and safety regulations in force in your region are observed
as far as they are mandatory.

International standards IEC 60825 Radiation safety of laser products

EN 60825 Safety of laser products
EN 207 Filter and safety goggles against laser radiation
(laser safety goggles)
EN 60204 Electrical equipment of machines
Tab. 1-3

6.5 Behavior in certain operating stages

Standard operation Operate the laser product only when all protective and safety rel-
evant devices, - e.g. Emergency Stop equipment, protective cov-
ers, safety contacts, exhausters - are in place and fully opera-
tive.
Open the safety circuit of the light path in question when an
error occurs. Have any defects eliminated immediately.

Upkeep Service work may be carried out by trained personnel only.

For maintenance and repair, open the safety circuits of all
affected light paths and make sure that they remain open for the
entire duration of the work.
Before working on the electrical system of the laser product, turn
the main switch OFF. Lock the main switch in this position using
a shackle padlock.
Carry out the adjustment, maintenance and service work stated
in these operating instructions in due time. Observe information
regarding the replacement of parts.
Check the correct functioning of the safety devices of the laser
product regularly.

20-06-12-A2-CR02 2016-01 Measures of the user 1‐25

 6.6 Behavior in case of emergency

Cases of emergency include

■ Laser light escapes unexpectedly
■ A part of the machine in which the laser product is operated
makes uncontrolled movements.
■ There is a fire or explosion.
■ Substances which might affect the health are leaking.
If you assume that these or similar events might injure persons
or damage material, take appropriate measures.
If the case of emergency is caused by the laser product, push
the E-stop pushbutton to stop laser light emission and move-
ments of the machine.
Further measures depend on the situation.
TRUMPF recommends you, as the operator of a laser product,
to identify the possible risks in a risk analysis and to define suit-
able measures for minimizing the risks or as first-aid measures
when people are injured.
Prepare directives describing the behaviors in case of emer-
gency. Attach the directive in the dangerous area so that every-
one can read it.

6.7 Selecting and qualifying personnel

Only use trained and instructed staff.

Define the responsibilities on the laser product for:

■ Setup
■ Operation
■ Upkeep
Any work on the electrical equipment of a laser product must be
carried out by a trained electrician only.

Instructed personnel may work on the electrical equipment if

■ the rules for electrical safety are observed.
■ the work is carried out under the supervision and guidance of
a trained electrician.

1‐26 Measures of the user 2016-01 20-06-12-A2-CR02

 6.8 Instructing the personnel

Operator’s obligations As the operating company, make sure that all persons operating
the laser product have the knowledge and qualifications to do so.
In particular, the personnel needs the required awareness of
possible dangers that might be caused by the laser product.

Reading the operating Before starting the work, the personnel entrusted with work on
instructions the laser product must have read the operator’s manual and the
chapter "Safety" in particular. This applies especially to persons
working only occasionally on the laser product, e.g. during main-
tenance.

Training with TRUMPF If required, TRUMPF offers trainings for operators and personnel
responsible for upkeep. Please contact the TRUMPF service
department.

Directives Inform any person in the dangerous areas by means of direc-

tives. Attach the directives clearly visible and protected in the
dangerous areas.

Directives are short informative texts, mostly not longer than a

page, which present all essential information to
■ avoid dangers as far as possible
■ act correctly if accidents occur in spite of safety measures.

Signs Please observe the labels attached to the laser product. Ensure
that the labels are in a legible state. Any labels that are dam-
aged or not longer legible must be replaced.
For further information on the labels: see section "Labels"

6.9 Wearing personal protective

equipment

If your risk analysis for the laser product shows that technical
measures are not enough, persons can be protected in addition
by wearing a personal protective equipment.

Examples:
■ Laser safety goggles to protect the eyes against escaping
laser light.
■ Gloves to protect the hands against hot workpieces.
■ Respiratory equipment to protect the respiratory tract against
hazardous substances.
Please make sure that the provided personal protective equip-
ment is effective. In case of laser safety goggles, for example,

20-06-12-A2-CR02 2016-01 Measures of the user 1‐27

 the filtering glasses have to be suitable for the wavelengths of
the laser light emitted by the laser. The optical density of the fil-
tering glasses must be adapted to the beam intensity.
Clearly regulate wearing of personal protective equipment, e.g. in
a directive.
Make sure that this regulation is observed.
Punish any violation of this regulation.

1‐28 Measures of the user 2016-01 20-06-12-A2-CR02

 Chapter 2

Installation conditions,
transport

1 Scope of delivery 2‐4

1.1 Components of the laser device 2‐4
1.2 Further accessories 2‐5
1.3 Documents 2‐5

2 Dimensions 2‐7
2.1 Laser device 2‐7
Type D 2‐7
Type D+ 2‐8
2.2 Free spaces for service work 2‐9
2.3 Operating panel 2‐9
2.4 Laser light cable 2‐10
2.5 Focusing optics 2‐10

20-06-12-A2-CR02 2016-01 Installation conditions, transport 2‐1

 3 Weight, floor at the installation site 2‐13

4 Connections 2‐14
4.1 External connections 2‐14
4.2 Electrical interfaces 2‐14

5 Electrical connected loads 2‐18

5.1 Electrical connection 2‐19
5.2 Electromagnetic compatibility 2‐19
5.3 Insulation resistance 2‐19

6 Cooling unit 2‐21

6.1 External cooling circuit 2‐21
Cooling water requirement for the tube 2‐22
dimensioning
Cooling water connections 2‐24
6.2 Data for chillers 2‐24
6.3 Installation examples 2‐26
6.4 Laser cooling circuit 2‐26

7 Ambient conditions 2‐28

8 Emissions 2‐30

9 Position of the user 2‐31

9.1 Position for switching on and off 2‐31
9.2 Position for operating the laser device 2‐31
9.3 Position for setting the focusing optics 2‐32
9.4 Position for maintenance work 2‐33

10 First measures to be taken after receipt of 2‐34

the laser device
10.1 Delivery of the laser device 2‐34
10.2 Commissioning 2‐34
Protecting the laser device against rolling 2‐34
away

11 Transport 2‐35
11.1 Moving the laser device on casters 2‐35
11.2 Transport by forklift truck / Transport by 2‐36
means of pallet jack

2‐2 Installation conditions, transport 2016-01 20-06-12-A2-CR02

 11.3 Packing the laser device 2‐38

20-06-12-A2-CR02 2016-01 Installation conditions, transport 2‐3

 1. Scope of delivery

Laser devices from TRUMPF are configured, equipped with

accessories and delivered according to the user’s requirements.
Therefore, each delivery is specifically assembled.

The following pages give information on

■ the basic scope of delivery.
■ important optional components.
■ documents which are included in the delivery.
The total scope of delivery is listed on the delivery note. This
note contains additional information which can be important for
the identification of components, e.g. material numbers.
The components are described in the chapter "Description".

1.1 Components of the laser device

WS-79006

1 Operating panel 2 Laser device

Fig. 2-1

2‐4 Scope of delivery 2016-01 20-06-12-A2-CR02

 1.2 Further accessories

1 Laser light cable 2 Focusing optics

Fig. 2-2

Laser light cable Number and length of the laser light cables depend on the appli-
cation of the laser device.

Focusing optics Number and arrangement of the focusing optics depend on the
processing task the laser device has to carry out.

Also included in the delivery are:

■ documentation for laser device and accessories(see "Docu-
ments", pg. 2‐5).
■ further components for special purposes according to your
requirements (e.g. series transformer).

Pay attention to delivery Detailed specification to the supplied articles including material
note! numbers and number of pieces are to be found on the delivery
note.

1.3 Documents

The following documents are included in the delivery:

■ Operator's manual.
■ Software manual.
■ Interface descriptions.
■ Dimensional drawing, e.g. focusing optics.
■ Declaration of Incorporation or Declaration of Conformity
■ Acceptance certificate.
■ Circuit documents for the TRUMPF Service Department.

20-06-12-A2-CR02 2016-01 Scope of delivery 2‐5

 ■ Labels and warning signs which have to be attached to the
workstation.
■ Optional: Documentation of externally-bought components
for example:
− operating instructions for a CCD camera which is oper-
ated on a focusing optics.
− documentation of the chiller.

2‐6 Scope of delivery 2016-01 20-06-12-A2-CR02

 2. Dimensions

All dimensions in millimeters [mm].

2.1 Laser device

Type D

Fig. 2-3

20-06-12-A2-CR02 2016-01 Dimensions 2‐7

 Type D+

Fig. 2-4

2‐8 Dimensions 2016-01 20-06-12-A2-CR02

 2.2 Free spaces for service work

Type D: Y = 2730 / Z = 750 Type D+: Y = 2990 / Z = 1000

Fig. 2-5

The laser device must be accessible from all sides for service
work. Furthermore space for tools and measuring instruments is
required in most cases.
The indicated spaces show the minimum spaces that must be
free around the laser device.

2.3 Operating panel

155

WS-75001

270 292

Fig. 2-6

20-06-12-A2-CR02 2016-01 Dimensions 2‐9

 2.4 Laser light cable

Fig. 2-7

Length The length of the laser light cable depends on the distance
between laser device and focusing optics.
The documents for the laser device contain specifications on the
dimensions of the laser light cable.

Bending radius The bending radius of the laser cable must not be smaller
than 200 mm.

Installation Corresponding ways and surfaces must be prepared for the

installation of the laser light cable.
Laser light cables must be laid without traction, kinks and tor-
sion.

2.5 Focusing optics

Focusing optics are made up of modules as required by the

processing task.

Dimensions The dimensions are determined by the components used for pro-
ducing your focusing optics.

2‐10 Dimensions 2016-01 20-06-12-A2-CR02

 Free space Space has to be kept free around the focusing optics, especially
for:
■ unhindered emission of laser light.
■ adjustment work.
■ maintenance and service work.

Documents Information on dimensions, fastening and space to be kept free

can be found in the following documentation:
■ operating manual of your focusing optics.
■ dimensional drawing of your focusing optics.
■ installation directive.
These documents have been delivered together with your laser
device or with the separately delivered focusing optics.

Dimensional drawing and The dimensional drawing contains:

installation directive ■ all dimensions in millimeters [mm].
■ letters as a reference to the installation directive.
How to use the dimensional drawing and the installation instruc-
tions is illustrated on the next page.

WS-00044

Dimensional drawing of the focusing optics (example) Fig. 2-8

In addition to the dimensions, you will also find letters on the

drawing. The arrow points to the letter f.

20-06-12-A2-CR02 2016-01 Dimensions 2‐11

 Under "f" you will find in the installation directive the dimensional
drawing for the holes "Cube 90°".

Dimensional drawing for "Cube 90°" in the installation Fig. 2-9

instructions

2‐12 Dimensions 2016-01 20-06-12-A2-CR02

 3. Weight, floor at the installation site

Weight laser device Type D: 5 kN (500 kg)

Type D+: 5.5 kN (550 kg)
distributed on 4 adjustable legs Ø
36 mm
Height difference on the bottom Maximum 10 mm.
Tab. 2-1

Vibrating charge Maximum vibrating charge in vertical direction:

Vibrating acceleration 0,01 g ≙ 100 mm/s²
Vibration amplitude 0,6 mm/s
Tab. 2-2

If there is a higher vibrating charge at the installation site, vibra-

tion dampers must be used. For the dimensioning of the vibra-
tion dampers, a vibration measurement is required at the installa-
tion site.

20-06-12-A2-CR02 2016-01 Weight, floor at the installation site 2‐13

 4. Connections

4.1 External connections

WS-79111
1 2

1 Cable for external interfaces 3 Cooling water hoses

2 Mains cable
Fig. 2-10

Cooling water connections The cooling water hoses are mounted on a hose gland which is
fastened at the laser device by means of the knurled nut.
Further information on the connection of hose and thread dimen-
sions: (see "Cooling water connections", pg. 2‐24).

Electrical connection The mains cable is connected to the laser device.

Further information on the electrical connection: (see "Electrical
connected loads", pg. 2‐18).

Socket for service work There must be a 230 V socket for the connection of measuring
instruments nearby the laser device.

4.2 Electrical interfaces

This chapter describes the electrical interfaces that can be used

to connect the laser device to other equipment. Further informa-
tion can be found in the interface description.

2‐14 Connections 2016-01 20-06-12-A2-CR02

 5 6 7 8 9 10

4
3

6 2
11
1
12

13 14 15

1 Modem interface 6 USB interfaces 11 Safety circuit interface

2 Space for fieldbus interfaces 7 Parallel and realtime interface 12 Focusing optics interface
3 Interface for operating panel 8 Analog output 13 E-Stop interface
4 Ethernet interfaces 9 Analog input 14 Switch-on interface
5 Peripheral bus interface 10 Interface for external laser warn- 15 CPX/control panel interface
ing lamp
Control and part of the mains distribution Fig. 2-11

Parallel interface or fieldbus The laser device can be controlled by an external control unit
interface (e.g. PLC) via parallel or fieldbus interfaces.
The external control unit can be connected to the parallel or real-
time interface. Further information on this topic is given in chap-
ter "Operation" and in the interface description for the laser
device.

20-06-12-A2-CR02 2016-01 Connections 2‐15

 You can control the laser device as well via one of the following
fieldbuses:
■ Profibus-DP
■ DeviceNet
In this case, the board of the selected fieldbus system is instal-
led in one of the free spaces for the fieldbus modules. Informa-
tion on pin assignment and data format is given in the interface
description of the selected fieldbus system.

Analog input The optional interface "Analog input" enables the definition of the
laser power, pulse duration and frequency as analog quantity
externally by voltage or current.

Safety circuit interface The safety circuit interface of the laser device allows:
■ external safety devices to be integrated into the safety circuit
of the laser device
■ status signals to be displayed externally.
A shutter switch releases the respective light path when the
safety circuit of the shutter switch is closed.
Further information is to be found in the interface description of
the ASV.

Interface for the control The control panel for switching the control on and off can be
panel connected optionally to interface X3.

start-up interface The contacts which are necessary to activate the function ”Con-
trol ON", ”Control OFF" from an external device (for example a
PLC ) are provided on the interface X2. In addition to that, the
interface has contacts for connecting an external laser warning
lamp and an external monitoring lamp.

E-Stop interface Via the E-Stop interface you can:

■ connect further E-Stop push-buttons to the laser device.
or
■ integrate the laser device into a higher-ranking E-Stop circuit.
The higher-ranking E-Stop circuit can belong to a plant of which
the laser device is a part.

Note
Lay the cables to the external E-Stop devices in such a way that
they are not exposed to any danger, e.g. by crushing or being
run over.

Peripheral bus interface The TRUMPF Peripheral Bus is a fieldbus system based on real-
time Ethernet. The TRUMPF Peripheral Bus components are
designed for mounting on DIN mounting rails (35 mm) according
to EN 50022.

2‐16 Connections 2016-01 20-06-12-A2-CR02

 For connection of the TRUMPF Peripheral Bus stations commer-
cial Ethernet cables can be used.
More information can be found in the interface description
"TRUMPF Peripheral Bus interfaces".

Analog output The front plate of the DLC board is provided with 2 analog out-
puts. For each output, the user can select via software which
signal is to be scanned at a connector for measuring purposes.
Measuring instruments (such as an oscillograph) can be con-
nected directly to the output signals.
More information can be found in the interface description "Ana-
log output of the DLC board".

20-06-12-A2-CR02 2016-01 Connections 2‐17

 5. Electrical connected loads

Mains 380 V (-10 %) ... 460 V (+10 %), 3AC + PE,

50 Hz (-3 Hz) ... 60 Hz (+3 Hz)
Further data according to EN 60204-1, TN net
according to IEC 60364-1
cos φ (DPF) at 0,98
nominal power
λ at nominal 0,84
power (total power
factor)
Insulation resist- 180 kOhm
ance
Back-up fuse 50 A
gL / gG or comparable characteristics
Tab. 2-3

Power Power Current with Use

[kW] [kVA] 400 V [A]
Electric power at nominal laser 16.5 20.0 28.5 Consumption data
power at the workpiece
Maximum power consumption (in 22.5 22.5 32.5 Mains dimensioning!!
case of service)
Tab. 2-4

Residual current device If required use an all current suitable fault current circuit breaker
(RCD type B).

Electric check Check the laser device regularly, at least each 4 years, regard-
ing its electric safety.
Further information on this subject is contained in chapter
"Safety" of the operator’s manual, section „Electric energy“.

If you would like to operate the laser device with mains voltages
other than mentioned above, you must use a series transformer.
Contact TRUMPF, if you need further information on this subject.

2‐18 Electrical connected loads 2016-01 20-06-12-A2-CR02

 5.1 Electrical connection

The laser device is supplied with electrical energy via a mains

cable. The mains cable is firmly connected to the laser device.

Length 5 m usable length

Cable cross section 4 x 10 mm²
connection clamps 0,5 … 16 mm² (solid)
0,5 ... 10 mm² (flex)
Tab. 2-5

5.2 Electromagnetic compatibility

An incorrect connection of the laser device to the supply system

or to other electric devices can change the characteristics of the
laser device with regard to electromagnetic compatibility. Specifi-
cations for the connection of the lines are to be found in the
interface description „Interfaces of the laser devices“.
The laser device is only suited for connection to the electric
mains in an industrial environment.

5.3 Insulation resistance

The insulation resistance is the resistance which is measured at

an electric equipment between a phase connection (L1, L2 or
L3) and the protective earth conductor (PE). TRUMPF laser devi-
ces can have an insulation resistance < 1 MΩ when they are
delivered. However it is ensured for these laser devices that the
admissible touch voltage is not exceeded in any case. Different
types of laser devices are listed in the table (see "Tab. 2-6",
pg. 2‐20). Among them there are several ones that can have
an insulation resistance < 1 MΩ due to their type of construction.
The table indicates the minimum measuring value which is
admissible for these types. A laser device can be registered with
the mark "All right", if this value is not undershot.

Conditions
■ The equipment is disconnected from the mains during trans-
port.
■ The main switch is in ON position.
■ According to EN 60204, the insulation resistance must be
≥ 1 MΩ.
If you find out during the regular check of the electrical equip-
ment that a TRUMPF laser device has an insulation resistance
< 1 MΩ, proceed as follows:

20-06-12-A2-CR02 2016-01 Electrical connected loads 2‐19

 Regular check 1. Look for the minimal insulation resistance admissible for the
laser device in table (see "Tab. 2-6", pg. 2‐20).
2. If the measured value is higher than the table value, register
and mark the laser device with "All right".
3. If the measured value is lower than the table value, eliminate
the cause for the lower value and repeat the measurement.
One reason might be that a technical modification that influ-
ences the insulation resistance was carried out at the laser
device after delivery.
or
Ø If you cannot find the cause or cannot elimnate it, contact
the TRUMPF service department to agree upon the fur-
ther proceeding.
The contact data (phone No. etc) of the service are to be
found in the operator's manual of the laser device.

Laser device Minimum admissible insulation resistance

Profiweld 310 kΩ
HL 54 250 kΩ
HL 101P 260 kΩ
HL 204 260 kΩ
HL 304P, HL 506P 260 kΩ
HLD 1001.5 1 MΩ
TruDisk 1000 180 kΩ
TruDisk 2002 1 MΩ
TruDisk 3002 1 MΩ
TruDisk 4002 1 MΩ
TruDisk 5001 1 MΩ
TruDisk 6001 1 MΩ
TruDisk 6002 1 MΩ
TruDisk 8002 1 MΩ
TruDisk 10003 1 MΩ
TruMicro 3040 1 MΩ
TruMicro 3140 1 MΩ
TruPulse 21 400 kΩ
TruPulse 33 400 kΩ
TruPulse 44 400 kΩ
TruPulse 62 210 kΩ
TruPulse 74 210 kΩ
TruPulse 103 210 kΩ
TruPulse 106 210 kΩ
TruPulse 156 210 kΩ
TruPulse 203 180 kΩ
TruPulse 304 180 kΩ
TruPulse 506 180 kΩ
Tab. 2-6

2‐20 Electrical connected loads 2016-01 20-06-12-A2-CR02

 6. Cooling unit

6.1 External cooling circuit

Temperature supply +6 °C .. +28 °C

Pressure ≤ 6 bar
Differential pressure Δp 0,6 bar ≤ Δp ≤ 6 bar
between supply and return
(see "Fig. 2-13", pg. 2‐22)
at the laser device
Minimum water requirement (see "Fig. 2-12", pg. 2‐22)
Water quality Cooling tower water according to VDI
3803, appendix B, table B3.
In case of strongly soiled water a prefil-
ter ≤ 115 µm is recommended (Filter
stage in the device 250 µm).
Water additives Operation with water additives (e.g. frost
protection, algae protection ...) is possi-
ble if it is ensured that the materials
used in the cooling unit are not affected.
Water additives reduce the cooling
capacity.

Operation with water additives on possi-

ble:
■ at lower supply temperature
■ with reduced laser power or
■ at increased flow.
Connections of supply and (see "Fig. 2-15", pg. 2‐24) and
return
(see "Tab. 2-8", pg. 2‐24)
Material V2A, V4A, brass/red brass, PVC-U,
EPDM, redbrass, NBR, copper
Tab. 2-7

Note
Note that the differential pressure refers directly to the connec-
tions of the laser device. Connected hoses cause further pres-
sure loss. This one depends on the length and the diameter of
the hoses.

20-06-12-A2-CR02 2016-01 Cooling unit 2‐21

 Cooling water requirement for the tube
dimensioning

minimum water requirement [m³/h]

6

2
1

0
5 10 15 20 25 30 35
supply temperature [°C]

Minimum water requirement characteristic curve Fig. 2-12

Characteristic curve of pressure loss Fig. 2-13

Here the flow quantity versus the minimum pressure difference of

the laser cooler (in case of opened internal valves) is shown.
Note that the pressure difference lies at the connections of the
laser device.

2‐22 Cooling unit 2016-01 20-06-12-A2-CR02

 Determining dimensioning
data

Example Fig. 2-14

Note
Dimension the tube system for the external cooling water so
that the required differential pressure is applied directly at the
device connections.
1. Determine the maximum possible supply temperature of the
external cooling water.
2. Read off the minimum water requirement at the correspond-
ing characteristic curve of water requirement (Fig. "Example"
left).
- In the example: water requirement of 1 m³/h with maximum
power consumption at 22°C supply temperature.
3. Read off the pressure difference applicable for this flow
quantity between supply and return of the cooler at its char-
acteristic curve (Fig. "Example" right).
- In the example: 0,6 bar.
4. For the determination of hose cross sections and hose
lengths TRUMPF recommends to consider a factor of safety
of 0.5 bar in order to compensate a slight soiling of the filter
and measuring inaccuracies on site.
- In the example: 1,1 bar.
In order to ensure the function of the internal solenoid
vales, a minimum pressure difference of > 0,6 bar must be
reached!
The determined values for the water requirement and the pres-
sure loss are dimensioned in such a way that the laser device
works reliably. If you operate the laser device with smaller val-
ues, you reduce the control reserve of the cooler. The conse-
quence may be that monitoring and fault messages are often
displayed due to overtemperature. The operation of the laser
device is interrupted by the messages.

20-06-12-A2-CR02 2016-01 Cooling unit 2‐23

 Cooling water connections

1 2 3 4 5

WS-79017
1 Housing connection for supply 4 Hose connection gland
2 Housing connection for return 5 Hose
3 Union nut
Fig. 2-15

Pos. Wrench/ thread

in dimensions
Fig.
Casing connection external thread 1 / 2 G 1"
Union nut internal thread 3 1"
Hose connection outer diameter 4 3/4" flat sealing
gland
Hose 5 3/4"
Tab. 2-8

The connecting lines of supply and return must be provided with

stop valves.

Note
Store the covers of the cooling water connections for transport.
If the laser is not used, shut off the domestic water connections
in the supply and return of the external cooling circuit.

6.2 Data for chillers

If the operate the laser device together with a chiller, the chiller
must meet at least the requirements indicated in the following
table.

2‐24 Cooling unit 2016-01 20-06-12-A2-CR02

 Cooling power ≥ 22.3 kW
(Cooling power on request of the maxi-
mum system reserve)
Minimum water circulation (see "Fig. 2-12", pg. 2‐22)
quantity
Pressure difference (see "Fig. 2-13", pg. 2‐22)*
supply-return
Overflow valve required
Tab. 2-9

*) Recommendation: Value from the pressure drop curve + pres-

sure drop for connecting piping or hosing.
The tube and hose system of the connections is to be dimen-
sioned in such a way that a pressure loss of 1 bar is not
exceeded for the required water quantity. If this is the case any-
way, the delivery height of the pump must be adapted corre-
spondingly.

px + py = pz

X in the laser device Z required delivery pressure of

Y connection lines the pump in the chiller

Fig. 2-16

The chiller pump must be designed for the total pressure drop
(pressure drop in the laser device + pressure drop of the con-
necting lines).

Example Pressure drop in the Pressure drop of Required feed pressure

laser device at 1000 l/h the connecting of the pump in the chiller
(see "Fig. 2-13", lines
pg. 2‐22)
0.6 bar + 1 bar = 1.6 bar
Tab. 2-10

20-06-12-A2-CR02 2016-01 Cooling unit 2‐25

 6.3 Installation examples

A Laser device connected to an 1 House water circuit

in-house cooling system or a 2 Standard chiller
cooling tower
B Laser device connected to a
standard chiller with cooling
against air.
The standard chiller can be
ordered from TRUMPF.
Fig. 2-17

6.4 Laser cooling circuit

Cooling means Deionized water

Quantity ca. 25 l
Conductivity max. 15 µS, recommended: ≤ 5 µS
Specifications on the laser cooling circuit Tab. 2-11

Conductivity A monitoring message is displayed when the conductivity of the

cooling water in the laser cooling circuit exceeds 15 μS. Then
you can still operate the laser device. A fault message is dis-
played when the conductivity rises to 25 μS.
You can only continue to operate the laser device, if you have
replaced the cooling water and the deionizing filter of the laser
cooling circuit.

The replacement of the deionizing filter and the cooling water is

described in chapter "Maintenance".

Cooling of externally-bought DI water from the cooling circuit of the laser can result in
components corrosion in components containing materials not resistant

2‐26 Cooling unit 2016-01 20-06-12-A2-CR02

 to DI water. Corrosion products that enter the laser device
via the cooling circuit can cause damage in the laser.
TRUMPF shall only be liable in accordance with legal regula-
tions for damage caused by defects in devices or compo-
nents delivered by TRUMPF. TRUMPF cannot be held liable
for damage caused by foreign products.

20-06-12-A2-CR02 2016-01 Cooling unit 2‐27

 7. Ambient conditions

Temperature Operation +10 °C .. +40 °C

Storage +5 °C .. +40 °C
Relative humidity Operation max. 100 % at 24 °C
Storage
Protection class Laser IP 54 in case of closed front doors
device
Operating IP 54
panel
Tab. 2-12

IP 54 The international protection IP 54 is only fulfilled when all hoods,

doors and covers are closed. If the environment is heavily
loaded with dust and aerosols, TRUMPF recommends to sur-
round the laser device by a structural containment which protects
the laser against influences of the environment also when it is
opened.

Dew point If warm and humid air reaches cold surfaces, condensation water
is formed at certain temperatures. This condensation water can
lead to faults of the electrical and optical components or even to
their failure.
Therefore, for avoiding condensation water, it is required that the
ambient conditions at the laser device are within certain limits.

Dew point diagram Fig. 2-18

In order to determine the ambient conditions, the ambient tem-

perature and the air humidity in the environment of the laser
device must be measured. When operating the laser device,
there measuring values must be within the grey are in the dew-
point diagram.

2‐28 Ambient conditions 2016-01 20-06-12-A2-CR02

 If the required ambient conditions are not kept, a corresponding
environment must be created for the laser device artificially
(cabin, air conditioning).

20-06-12-A2-CR02 2016-01 Ambient conditions 2‐29

 8. Emissions

Sound level Laser device ≤ 54 dB(A) according to EN ISO

3744
Processing spot Depending on the application
Tab. 2-13

2‐30 Emissions 2016-01 20-06-12-A2-CR02

 9. Position of the user

The following sections describe where persons stay in different

situations when handling the laser device. The situations are:
■ Switching the laser device on and off.
■ Operating the laser device
■ Maintenance of the laser device.

9.1 Position for switching on and off

Fig. 2-19

Note
Position the laser device in such a way the main switch can be
reached easily.

9.2 Position for operating the laser

device

Fig. 2-20

20-06-12-A2-CR02 2016-01 Position of the user 2‐31

 If the laser device is switched on, all operating processes can be
carried out from the operating panel.

9.3 Position for setting the focusing

optics

Fig. 2-21

The position or the setting work at the focusing optics is at the

processing stations.

2‐32 Position of the user 2016-01 20-06-12-A2-CR02

 9.4 Position for maintenance work

1 Focusing optics 5 Electric fuses

2 Laser light cable 6 Lamp power supply
3 Fan at the control 7 Flash lamp
4 Connections 8 Laser cooler
Fig. 2-22

20-06-12-A2-CR02 2016-01 Position of the user 2‐33

 10. First measures to be taken after
receipt of the laser device

10.1 Delivery of the laser device

Check all parts of the laser device and the accessories for trans-
port damages immediately after delivery.

Report transport damages immediately to the following authori-

ties:
■ The shipping agent.
■ The insurance agency which insured the transport.
■ The dispatch department of TRUMPF.

10.2 Commissioning

Only staff from TRUMPF or specially instructed persons are

allowed to put the laser device into operation.

DI-water Keep ready a sufficient quantity of deionized water for the com-
missioning (see "Laser cooling circuit", pg. 2‐26).

Protecting the laser device against rolling

away

Fig. 2-23

1. Loosen counter nut (1).

2. Lower each adjustable leg (2) until it rests on the floor and
the laser device can no longer roll away.
3. Tighten the counter nut (1).

2‐34 First measures to be taken after receipt of the laser 2016-01 20-06-12-A2-CR02
device
 11. Transport

Appropriate transport means for the movement of the laser

device within in a building or on the premises are:
■ The fitted casters
■ Forklift truck / Pallet jack
Appropriate packaging is required for the long-distance transport
with vehicles (see "Packing the laser device", pg. 2‐38).

11.1 Moving the laser device on casters

On an even floor it is possible to move the laser device with the

fitted casters.

Conditions
■ To move the laser device at the installation site:
− The laser device must be switched off.
− Laser light cables and supply lines must be laid in such a
way that sufficient motion reserve is available.
− It must be ensured that laser light cables and supply
lines are not damaged.
■ To change the installation site of the laser device:
− All lines which lead from other devices to the laser device
(e. g. from external controls) must be disconnected.
− All laser light cables must be separated from the laser
device.
− The cooling unit must be emptied completely, if during
transport or during the storage of the laser device there
can be temperatures below 0 °C.
A detailed description for the emptying of the laser
cooler is to be found in chapter "Maintenance".

Means, Tools, Materials

■ Fork wrench 13 mm, 17 mm

Before moving the laser device, all 4 adjustable legs must be

lifted so that the laser device stands on the casters.

Preparation 1. Disconnect the laser device from the electric mains.

20-06-12-A2-CR02 2016-01 Transport 2‐35

 Lifting the adjustable legs

Fig. 2-24

2. Turn counter nut (1) downwards.

3. Lift the adjustable leg by turning the adjustment nut(2) in
anticlockwise direction.
If all adjustment legs are lifted, the laser device stands on
the guide rollers and can be moved.

Moving the laser device

Risk of injury because of a large mass that moves!

WARNING
Cornering or stopping the device can cause a large inertial
force.
Ø Only move on horizontal planes.
Ø Move slowly.
Ø Warn persons, in the route of transport.

4. Move laser device.

5. Lower and adjust legs.

11.2 Transport by forklift truck / Transport

by means of pallet jack

Condition
■ Before transport:
− All lines which lead from other devices to the laser device
(e. g. from external controls) must be disconnected.
− All laser light cables must be separated from the laser
device.
− The cooling unit must be emptied completely, if during
transport or during the storage of the laser device there
can be temperatures below 0 °C.

2‐36 Transport 2016-01 20-06-12-A2-CR02

 For emptying the cooling unit a compressed air connec-
tion is required.
A detailed description for the emptying of the laser cooler
is to be found in chapter "Maintenance".

Minimum loading capacity of the forklift truck

Type D 5 kN (500 kg)
Type D+ 5,5 kN ( 550 kg)
Tab. 2-14

Preparation 1. Disconnect laser device from the electric mains.

Lift the laser device

600

Fig. 2-25

Parts of the body may get between forklift truck and the
CAUTION item to be transported.
Parts of the body can be broken or crushed.
Ø There must not be any persons in the danger zone of the
forklift truck.
Ø The laser device may only be transported by instructed per-
sons.
Ø Observe the safety regulation of the transport means.

2. Adjust distance between forks to 600 mm.

Notes
■ Lift the laser device only from the front.
■ The laser device may not be inclined more than about
10°.

20-06-12-A2-CR02 2016-01 Transport 2‐37

 3. Lift the laser device carefully by means of the forklift truck.
4. Secure the laser device by means of a belt against sliding.
5. When moving, avoid:
− Abrupt start and stop.
− Quick cornering.
6. Place the laser device carefully.

11.3 Packing the laser device

Preparation 1. Turn the laser device off (see chapter "Operation").

2. Emptying the cooling unit of the laser device (see chapter
"Maintenance").
3. Disconnect all electric connections from the laser device.
4. Disconnect the laser light cable (see chapter "Maintenance").

Fig. 2-26
5. Disconnect operating panel from the cable and pack it sepa-
rately.

2‐38 Transport 2016-01 20-06-12-A2-CR02

 Inner packing 1
2

3
4

Fig. 2-27
6. Place the laser device on a pallet.

Pos. Designation Additional information

1 Crossbeam 80 mm x 100 mm x 900 mm
2 Plywood panel 1140 mm x 900 mm
Thickness: 15 mm - 18 mm
3 Hard foam panel 1140 mm x 900 mm
Nopaplank R65,
Thickness: 50 mm, 65 kg/m³
4 Pallet 1650 mm x 1100 mm
with 3 bottom runners, 80 mm x 100 mm x
900 mm
Tab. 2-15

20-06-12-A2-CR02 2016-01 Transport 2‐39

 1

1 Plastic foil vapor coated with 3 Hard foam panel 4 Stretch film
aluminum
2 Crossbeam
Inner packing Fig. 2-28
7. Place hood of aluminium-vaporized plastic foil over the laser
device.
8. Enwrapping the laser device with stretch film.

Pos. Designation Additional information

1 Crossbeam 80 mm x 100 mm x 900 mm
2 Hard foam panel 1350 mm x 700 mm
Nopaplank R65,
Thickness: 50 mm, 65 kg/m³
Tab. 2-16

9. Place hardfoam panel on the lid of the laser device.

10. Place the crossbeam on the hard foam plate.

2‐40 Transport 2016-01 20-06-12-A2-CR02

 Outer packing

3 4
1 2 5 6

Fig. 2-29

11. Fill out all spaces in between with hard foam panels.

Pos. Designation Additional information

1 Plywood panel- 1110 mm x 1550 mm
lateral panels Thickness: 15 mm - 18 mm
2 Hard foam panel 1140 mm x 900 mm
- Nopaplank R65,
lateral panels Thickness: 50 mm, 65 kg/m³
3 Plywood panel- 1650 mm x 1550 mm
front and rear Thickness: 15 mm - 18 mm
panel
4 Hard foam panel 1500 mm x 1140 mm
- Nopaplank R65,
front and rear Thickness: 50 mm, 65 kg/m³
panel
5 Tightening Width: ca. 25 mm
straps Tensile strength : ca. 9,3 kN (950 kp)
number: 2
6 Plywood panel - 1650 mm x 1100 mm
Lid Thickness: 15 mm - 18 mm
Tab. 2-17

12. Attach the wooden walls.

13. Attach tightening straps.
14. Label the packaging:
"Transport in upright position only!".

20-06-12-A2-CR02 2016-01 Transport 2‐41

2‐42 Transport 2016-01 20-06-12-A2-CR02
 Chapter 3

Description

1 Overview 3‐3

2 Laser 3‐4
2.1 Design 3‐4
2.2 Specifications 3‐4

3 Optical arrangement 3‐8

3.1 Components of the optical arrangement 3‐10
Central shutter (VZ) 3‐10
Shutter (V1, V2, ...) 3‐11
Switch (W1, W2, ...) 3‐11
Shutter switch (VW1, VW2, ...) 3‐13
Shutter switch with pilot laser 3‐14
Physical splitter with adjustable splitter 3‐15
ratio
Deflection (U1, U2, ...) 3‐16
Central pilot laser 3‐16
Incoupling optics 3‐17

20-06-12-A2-CR02 2016-01 Description 3‐1

 4 Laser light cable 3‐18

5 Focusing optics 3‐20

6 Control 3‐22

7 Operating panel 3‐24

8 Control panel (Option) 3‐25

9 Mains distribution 3‐26

10 Laser cooler 3‐28

11 Lamp power supply 3‐30

12 Telepresence 3‐31
12.1 Connection via VPN TRUMPF to the laser 3‐31
device
12.2 Connection via VPN laser device to TRUMPF 3‐32
12.3 Connection via SSH 3‐32
12.4 Direct connection over an analog modem 3‐33

3‐2 Description 2016-01 20-06-12-A2-CR02

 1. Overview

10

3
2

8 5
7
6

1 Incoupling optics 5 Control 8 Laser cooler

2 Laser 6 Mains distribution 9 Operating panel
3 Laser light cable 7 Lamp power supply 10 Optical arrangement
4 Focusing optics
Fig. 3-1

20-06-12-A2-CR02 2016-01 Overview 3‐3

 2. Laser

2.1 Design

1 2 3 4

1 Output coupling mirror 3 Beam guard

2 Cavity 4 Rear mirrors
Fig. 3-2

The main components of the laser are:

■ Cavity
■ Rear mirrors
■ Output coupling mirror
The output coupling mirror is partially transmitting for laser
light.
The cavity is cooled with deionized water.

2.2 Specifications

The following values of laser power and beam parameter product

are available at the working station.

Laser types TruPulse 556 (6) TruPulse 556 (9)

Wavelength of the laser light 1064 nm 1064 nm
Maximum average power 530 W 530 W
Minimum pulse power 500 W 500 W
Maximum pulse power 10 kW 10 kW
Minimum Pulse duration 0.3 ms 0.3 ms
Maximum Pulse duration 50 ms 50 ms
Maximum pulse energy 60 J 100 J
Maximum pulse repetition fre- 833 Hz (Power 833 Hz (Power
quency regulated burst) regulated burst)
beam quality 25 mm·mrad 25 mm·mrad
Tab. 3-1

The characteristic lines on the following pages show the typical

courses of the laser. The course may in individual cases differ
from the ones indicated here.

3‐4 Laser 2016-01 20-06-12-A2-CR02

 TruPulse 556 (6)

Fig. 3-3

Fig. 3-4

20-06-12-A2-CR02 2016-01 Laser 3‐5

 Fig. 3-5

TruPulse 556 (9)

Fig. 3-6

3‐6 Laser 2016-01 20-06-12-A2-CR02

 Fig. 3-7

Fig. 3-8

20-06-12-A2-CR02 2016-01 Laser 3‐7

 3. Optical arrangement

WS-79035
Fig. 3-9

The optical arrangement contains all components for guidance of

the laser light within the laser device until the beam enters the
incoupling optics. The laser light cable is connected to the incou-
pling optics.
The components of the optical arrangement are grouped and
arranged according to the respective machining task.
The following picture shows an example of an optical arrange-
ment. The picture shows the main components available for opti-
cal arrangements. The meaning and function of the components
are explained below.
A representation of your optical arrangement is to be found in
the documentation delivered together with your laser device. To
understand the functions of your optical arrangement, please see
the explanations in section "Components of the optical arrange-
ment".

3‐8 Optical arrangement 2016-01 20-06-12-A2-CR02

 1

4
5

5 7

WS-79036
9 9 9 9 8 9 8

1 Laser light cable 4 Physical splitter with adjustable 7 Central shutter (VZ)
2 Incoupling optics splitter ratio 8 Deflection 90°
3 Beam guard 5 Absorber 9 Shutter switches
6 LEM*
Optical arrangement (Example) Fig. 3-10

*LEM: Power and energy measuring sensor

The laser light is fed in at the point to which the arrow desig-
nated “LASER” is pointing.
The central shutter VZ can block or enable the laser light for all
light paths.
The positions of the shutter switches VW determine to which
light path the laser light is guided.
Further information on the functions of the optical arrangement
components is written below.

20-06-12-A2-CR02 2016-01 Optical arrangement 3‐9

 3.1 Components of the optical
arrangement

Central shutter (VZ)

1 Laser beam blocked 3 Absorber 5 Mirror moved out of beam

2 Mirror in beam guideway 4 Laser beam enabled guideway

Fig. 3-11

The central shutter allows the laser beam emission to be blocked

(picture A) or enabled (picture B) for all light paths.
If the laser beam is enabled, it passes through the central shut-
ter as shown in partial picture B. If the laser beam is locked, the
central shutter guides the laser beam into the absorber (3),
where it is transformed into heat.
At zero current, the central shutter blocks the light path.
The central shutter has two functions:

Operating function In the operating function the central shutter is controlled by oper-
ator-originated commands or laser programs as long as the
safety circuit is closed.

Safety function When the safety circuit is interrupted, the central shutter is
immediately closed. This also happens when the signal to open
comes from the operator or from the running laser program.
Information about functioning and wiring of the safety circuit is to
be found in the interface description safety circuit ASV.

3‐10 Optical arrangement 2016-01 20-06-12-A2-CR02

 Shutter (V1, V2, ...)

The shutter can enable or block an individual light path. When

the shutter enables the light path, the laser beam passes
through it as shown in picture B (see "Fig. 3-11", pg. 3‐10).
When the shutter closes the light path, the laser beam will be
guided into an absorber (picture A).
The light path controls the shutter. The light path can be
adjusted by manual mode or by laser program.
When the shutter is controlled by an ASV board, it can be inte-
grated into a safety circuit. In this case it has not only an oper-
ating function, but also a safety function. What has been said
regarding the safety function for the central shutter will then also
apply analogously to the light path in which the shutter is
located.

Switch (W1, W2, ...)

1 Mirror moved out of beam 3 Mirror in beam guideway 4 Laser beam is deflected by 90°
guideway
2 Laser beam passes through in a
straight line
Fig. 3-12

The laser beam can be guided into one of two directions by

means of a beam switch.
If the mirror is in the beam guideway, the laser beam is
deflected by 90° (picture B). If the beam is swiveled out of the
beam guideway, the laser beam passes through the beam switch
in a straight line (picture A).

20-06-12-A2-CR02 2016-01 Optical arrangement 3‐11

 The beam switch can be controlled by user commands or by
laser programs.

3‐12 Optical arrangement 2016-01 20-06-12-A2-CR02

 Shutter switch (VW1, VW2, ...)

A VW1 and VW2 closed B VW1 open C VW2 open

Fig. 3-13

A shutter switch is a switch with a safety function. Its design

does not differ from that of a usual switch. The difference lies in
the activation of the shutter switch by an ASV or ASV2 board.

20-06-12-A2-CR02 2016-01 Optical arrangement 3‐13

 The shutter switch is integrated into a safety circuit via the ASV
or ASV2 board.
Thus, the shutter switch has two functions:

Operating function In the operating function the shutter switch is controlled by oper-
ator-originated commands or laser programs as long as the
safety circuit is closed.

Safety function When the safety circuit is interrupted, the shutter switch is set
immediately to direct the laser beam into an absorber (see "Fig.
3-13", pg. 3‐13) (picture A) . This also happens when a different
command comes from the operator or from the running laser
program.
Information about functioning and wiring of the safety circuit is to
be found in the interface description safety circuit ASV.
The number of shutter switches in an optical arrangement is usu-
ally identical to the number of light paths. The shutter switches
are arranged in series. They are activated in such a way that at
most one shutter switch is open (mirror in the beam guideway,
(see "Shutter switch (VW1, VW2, ...)", pg. 3‐13) (pictures B and
C)). This ensures that when the safety circuit is interrupted the
laser beam is always directed into the absorber which is the last
in the series.

Shutter switch with pilot laser

1 pilot laser 3 Pilot laser beam

2 Shutter switch mirror
Fig. 3-14

The casing of the shutter switch with pilot laser houses a semi-
conductor laser is (1). The semiconductor laser works as pilot

3‐14 Optical arrangement 2016-01 20-06-12-A2-CR02

 laser of the light path to which shutter switch is assigned. In con-
trast, the central pilot laser can be used in all light paths.

Advantage The pilot laser in the shutter switch can be used while the work-
ing laser light is being guided to a different light path. This
makes it possible to use the pilot laser at processing point, while
workpieces are being machined at a different point.

Shutter switch functions The basic shutter switch functions (work and safety function) are
identical, as are those of the shutter switch without pilot laser
(see "Fig. 3-13", pg. 3‐13).

Switching the pilot laser on The pilot laser can be switched on as soon as the shutter switch
mirror has been swiveled out of the beam guideway (shutter
closed (see "Fig. 3-14", pg. 3‐14)).
Switching on the workstation with the user interface is described
in chapter "Operation" .

Laser classes The pilot laser has been classified as a class 3R component.
This must be taken into account when it is operated, for example
by the service, after removal from the unit.
In standard operation, the pilot laser light emitted from the
focusing optics outlet corresponds to class 2.

Physical splitter with adjustable splitter

ratio

Fig. 3-15

The physical splitter with adjustable splitter ratio contains a semi-

transparent mirror with variable transparency over the angle of
rotation. Accordingly, the splitter ratio depends on the angular
position of the mirror.

20-06-12-A2-CR02 2016-01 Optical arrangement 3‐15

 The proportion a of the deflected beam can be set to a value in
the range from 20% to 80% on an actuator (arrow).

Deflection (U1, U2, ...)

Fig. 3-16

The deflection deflects the laser beam by 90° to the right or left.

Central pilot laser

Fig. 3-17

The central pilot laser is a semiconductor laser having a power <

5 mW, which emits red laser light (wavelength 635 nm).

3‐16 Optical arrangement 2016-01 20-06-12-A2-CR02

 The pilot laser can be used:
■ to check a light path.
■ to visibly mark the workpiece location where the beam of the
YAG laser has impacted during the welding or cutting proc-
ess.
The pilot laser is located in the optical arrangement behind the
central shutter. As a result the pilot laser can be operated even
when the central shutter is closed.
Switching on and off the workstation with the TruControl 1000
program is described in chapter "Description".
The incoupling of the pilot laser can take place into any light
path of the laser device. To do so, the light path must have been
selected..
Alternatively, your laser device can also be equipped with shutter
switches that contain a pilot laser. Each pilot laser in a shutter
switch can only be used for one light path.

Laser Class The central pilot laser has been classified as a Class 3R com-
ponent. This must be taken into account when it is operated, for
example by the service, after removal from the unit.
In standard operation, the pilot laser light emitted from the
processing optics outlet corresponds to class 2.

Incoupling optics

WS-75014

Fig. 3-18

The incoupling optics contains a lens which focuses the laser

beam to the beginning of the light guide in the laser light cable.

20-06-12-A2-CR02 2016-01 Optical arrangement 3‐17

 4. Laser light cable

WS-79051
Fig. 3-19

Purpose The laser light cable is a flexible transmission medium for laser
beams. It allows spatial separation between laser and machining
station.

Design In the interior of the laser light cable there is light guide, which
guides the laser beam from the laser device to the focusing
optics. The light guide is surrounded by a plastic tube and a
steel casing. The steel casing protects the light guide from
mechanical stress. It limits the bending radius of the laser light
cable.
The steel casing is surrounded by an external plastic tube which
protects the laser light cable against environmental effects.
A safety device integrated into the laser light cable switches the
laser automatically off, when the optical wave guide is damaged
or the laser light cable at the laser or at the focusing optics is
pulled out.

Technical data Standard lengths 10 m, 15 m, 20 m, 30 m, 100

m
Min. permissible bending radius 200 mm
Cable core diameter 12.5 mm
Fiber core diameter 600 µm
Tab. 3-2

3‐18 Laser light cable 2016-01 20-06-12-A2-CR02

 WS-00029
1 Optical plug, laser side 4 Cables
2 Protective glass 5 Optical plug, machining side
3 Electrical plug, Monitoring 6 Protective glass
Laser light cable, components Fig. 3-20

Monitoring The laser light cable is monitored on the whole length. The laser
device switches off immediately and no more laser light may be
emitted if a fault occurs in the laser light cable.
The fit of the two optical plugs is monitored as well. If an optical
plug is loosened, the laser device immediately switches off.
The integrated monitoring of the laser light cable is connected
with the safety circuit of the laser device by means of the electri-
cal plug.

Laying the LLK Outside the laser cabin, laser light cables must be installed
permanently.

To do so, use:
■ Cable clamps
■ Cable ducts
■ Other appropriate auxiliaries for fastening cables.
Inside laser cabins which are monitored by a safety circuit,
laser light cables can be laid freely and loosely.

20-06-12-A2-CR02 2016-01 Laser light cable 3‐19

 5. Focusing optics

WS-79053
Fig. 3-21

The focusing optics focuses the laser light onto the processing
point. The high power density required for the material process-
ing is generated thereby.
Focusing optics are composed of modules according to the
requirements of the respective task.
Further information is to be found in the operating manual of
your focusing optics.

3‐20 Focusing optics 2016-01 20-06-12-A2-CR02

 1

WS-00113
6

1 Receptacle for LLK plug 5 Splitter and deflection

2 Collimation 6 Lens with lens protection
3 Set ring for defocusing 7 Observation optics
4 Counterring 8 Eyepiece
Focusing optics (Example for welding) Fig. 3-22

20-06-12-A2-CR02 2016-01 Focusing optics 3‐21

 6. Control

Fig. 3-23

The control unit controls all functions of the laser device. Apart
from this, it monitors numerous operational values and reports
when a value is outside the permitted range.
The control unit contains interfaces to higher-ranking control
units. They allow an external control of the laser device. Further
information about this is to be found in chapter 2 of this manual
and in the interface descriptions.

Controlling The most important functions are:

■ Switching the laser on and off
■ Controlling the optical arrangement
■ Controlling the laser power
■ Communication with external units (e.g. PLC).

Monitoring The control unit also monitors the following operational values:
■ Laser power
■ Temperature of the coolants
■ Temperatures within the area of the laser and of the optical
arrangement
■ Condition of the laser light cable
■ Safety contacts at the processing points.

Message If an operational value is outside the admissible range, the con-

trol will generate a monitoring message or a fault message.
This message is displayed on the screen. In case of a fault the
control prevents further operation of the laser until the cause for
the fault is eliminated.

3‐22 Control 2016-01 20-06-12-A2-CR02

 Configuration

1 2 3 4 5 6 7

11

11

10 9 8 9 8 9 8

1 Host processor (CPX) 5 ASV3 board for central shutter 9 ASV3 board for shutter switches
2 Power board 6 Monitoring LLK and TKO or shutter
3 DLC board 7 STC board 10 Parallel IO and realtime inter-
face
4 Analog input board 8 Interface Intelligent Optics (IIO)
11 Slots for fieldbus boards
Control unit of the laser device Fig. 3-24

The control system is composed of individual electronic compo-

nents. The component parts of the control unit can differ from
the figure.

20-06-12-A2-CR02 2016-01 Control 3‐23

 7. Operating panel

1 Touch screen 3 CONTROL ON button 5 Turn-and-push button

2 EMERGENCY STOP pushbutton 4 CONTROL OFF button
Fig. 3-25

Your laser device is normally operated via an operating panel

that is connected to laser device by means of a cable.
By means of the User interface with touch screen (1), and the
turn-and-push button (5), the software TruControl 1000 is oper-
ated for controlling the laser device.
In case of emergency, the emergency-stop pushbutton (2) ena-
bles a quick deactivation of the laser device.
The buttons CONTROL ON (3) and CONTROL OFF (4) allow
you to switch the control unit of the laser device on and off.

3‐24 Operating panel 2016-01 20-06-12-A2-CR02

 8. Control panel (Option)

Instead of an operating panel it is also possible to connect a

control panel to the laser device. The control unit of the laser
device can be activated and deactivated on the control panel.
Furthermore, it is possible to quickly switch off the beam source
in case of emergency by pressing an EMERGENCY STOP push-
button.

20-06-12-A2-CR02 2016-01 Control panel (Option) 3‐25

 9. Mains distribution

Fig. 3-26

The mains distribution distributes the electrical energy to the indi-

vidual consuming devices.

3‐26 Mains distribution 2016-01 20-06-12-A2-CR02

 1 2 3 4 5 6

10

11

12

15 14 13

1 Contactor for lamp power supply 6 Power supply unit -24V (option) 11 Start-up interface
2 Electric fuses 7 CMD board 12 E-Stop interface
3 EMERGENCY STOP relays 8 Pump button 13 Cover
4 Power supply unit 24 V 9 Pushbotton for solenoid valves 14 Electric fuses
5 Power supply unit 24 V (option) 10 CPX/control panel interface 15 PSB1 board
Fig. 3-27

Detailed information about the mains distribution can be found in

the circuit documents.

20-06-12-A2-CR02 2016-01 Mains distribution 3‐27

 10. Laser cooler

Fig. 3-28

The laser cooler dissipates the heat arising in the laser through
a heat exchanger to an external cooling circuit. The temperature
of the laser circuit is regulated to a constant value.
If the supply temperature in the external cooling circuit exceeds
a certain value, an external chiller must be used in addition. You
will find the corresponding technical information in the chapter
"Installation conditions, transport".

3‐28 Laser cooler 2016-01 20-06-12-A2-CR02

 6

4 5

1 Tank 4 Pump 6 Cabinet cooler

2 Stop valve in the return 5 Heat exchanger 7 Contamination filter
3 Deionizing filter
Fig. 3-29

The laser is cooled with deionized water. The pump delivers the
water from the tank via the supply distributor to the cooled com-
ponents:
■ Cavity and other cooled components of the laser
■ Absorber in the optical arrangement.
■ Focusing optics.
■ Lamp power supply.
The water absorbs the heat in the components and flows
through the return collectors into the heat changer where the
heat is dissipated to the external cooling circuit. From the heat
exchanger the water flows back to the tank.

20-06-12-A2-CR02 2016-01 Laser cooler 3‐29

 11. Lamp power supply

Fig. 3-30

The Lamp power supply provides the excitation lamp of the laser
with electric energy.

In detail the lamp power supply carries out the following func-
tions:
■ Igniting the excitation lamp when the user or the laser pro-
gram gives the command "Laser on“.
■ Storing electric energy so that the desired pulse power is
reached when releasing a laser pulse.
■ Providing the lamp current when releasing a laser pulse so
that the desired pulse power can be given for the set pulse
duration.
The control monitors the lamp power supply. The operating val-
ues of the lamp power supply can be displayed on the operating
(Main activity> Diagnostics).

3‐30 Lamp power supply 2016-01 20-06-12-A2-CR02

 12. Telepresence

What does telepresence Telepresence is an optional TRUMPF service.

mean?
The TRUMPF staff can access the laser device via telephone
line or internet (VPN connection) and do the following actions:
■ Remote operation of the laser device.
■ Displaying operational values.
■ Troubleshooting.
■ Read-out of operational data and transferring them to
TRUMPF.
■ Changing the parameters.
■ Updating the software.

Support provided by With the telepresence option TRUMPF can assist you in
TRUMPF ■ using the laser device most efficiently for your application.
■ recognizing the necessity of preventive maintenance.
■ locating faults quickly and taking the appropriate steps for
eliminating them.
■ operating the laser device always with the most up-to-date
software.

Safety certificate The TRUMPF staff use the "TRUMPF Telepresence Portal" for
the telepresence.
The "TRUMPF Telepresence Portal" corresponds to the severe
safety requirements of the international certification standard for
the information security of management systems (ISO 27001,
certified to BSI - Germany's National Information Security Author-
ity).

12.1 Connection via VPN TRUMPF to the

laser device

The VPN link setup is initiated by TRUMPF subsidiary.

For further information regarding the connection via VPN, refer to
the technical information "VPN connection".

The access via a Virtual Private Network (VPN) can be carried

out in the following ways:
■ VPN via internet
■ Special connection as defined by the customer

20-06-12-A2-CR02 2016-01 Telepresence 3‐31

 Required information TRUMPF requires the following information to ensure connection
via VPN:
■ IP address of the VPN connection.
■ user name and password.

The following information concerning the server used are

required:
■ VPN software used.
■ VPN connection information.
■ IP address of the operating unit of the laser device.
■ device number of the laser devices from TRUMPF.
■ IP address of the laser device from TRUMPF
■ name of the contact person for the laser device.
■ telephone number for questions.

12.2 Connection via VPN laser device to

TRUMPF

The VPN link setup is initiated by the laser device. The software
tool Request service is an extension of the TRUMPF TelePre-
sence Portal. This tool can be used to establish a connection to
the TRUMPF TelePresence Portal in order to allow a service
technician of TRUMPF a remote access to the laser device. The
Request service function is safe and protected by a firewall. In
the software manual "TruControl 1000" (10-06-80-A1-CR01),
chapter "Service", you will find further information on the Request
service function.

12.3 Connection via SSH

Secure Shell (SSH) allows a safe, authenticated and encoded

data connection between the TRUMPF service department and
the laser devices of TRUMPF in the user's plant via an insecure
network (internet). For more information, please refer to the tech-
nical information "Telediagnosis via Internet using SSH".
For reasons of safety, the user should only allow the use of the
IP address 217.6.238.162 of the sender TRUMPF and lock all
other IP addresses.

3‐32 Telepresence 2016-01 20-06-12-A2-CR02

 In order to establish a safe connection to the laser device, the
TRUMPF service department requires the following data from the
user:
■ public IP address of the firewall.
■ public port addresses and the 10-digit device numbers
assigned to the laser devices (see field "ser.-no." on the rat-
ing plate).

12.4 Direct connection over an analog

modem

A telephone connection with one of the following is needed:

■ Signal shape: analog
■ Connection: RJ 12
An international modem is already included in the control unit of
the laser device.

Required information TRUMPF requires the following information to ensure a direct

connection:
■ telephone number of the modem-connection.
■ serial number of the laser device from TRUMPF.
■ name of the contact person for the laser device.
■ telephone number for questions.

20-06-12-A2-CR02 2016-01 Telepresence 3‐33

3‐34 Telepresence 2016-01 20-06-12-A2-CR02
 Chapter 4

Operation

1 Operating elements and indicators 4‐3

1.1 Case 4‐3
1.2 Operating panel 4‐5

2 Switching the laser device on and off 4‐7

2.1 Switching on 4‐7
2.2 Switching off in case of malfunction and 4‐7
emergencies
2.3 Switching on after EMERGENCY STOP 4‐7
2.4 Switching off after work 4‐8

3 Operating the laser device using TruCon- 4‐9

trol 1000
3.1 Selecting light path 4‐9
Select the light path in the parameter set 4‐9
Change the light path name 4‐11
3.2 Activating and deactivating the laser 4‐12
Switching the laser on and off 4‐12

20-06-12-A2-CR02 2016-01 Operation 4‐1

 Open or close the central shutter (VZ) in 4‐13
the parameter set
3.3 Responding to messages 4‐13
Resetting the message 4‐14
3.4 Generating pulse shapes 4‐15
3.5 Creating laser programs 4‐16
3.6 Programming light paths 4‐17
3.7 Pilot laser (option) 4‐17
Switching the switching functions of pilot 4‐18
laser on and off
Setting the pilot laser mode 4‐18
Switching the pilot laser in the light path 4‐20
on and off

4 Controlling the laser device from outside 4‐23

4.1 TRUMPF LaserNetwork (option) 4‐23

4‐2 Operation 2016-01 20-06-12-A2-CR02

 1. Operating elements and indicators

1.1 Case

1 EMERGENCY STOP pushbut- 5 Key-operated switch

ton 6 Main switch
2 Signal lamp "Mains On" 7 Operating panel
3 Signal lamp "Monitoring"
4 Laser warning lamp
Fig. 4-1

EMERGENCY STOP The laser and the cooling unit are immediately switched off when
pushbutton the pushbutton EMERGENCY STOP is pressed. In particular, no
more laser light is emitted.
The EMERGENCY STOP pushbutton can be integrated in the
Emergency Stop circuit of a system. With this pushbutton, the
entire system can be cut off. More information can be found in
the interface description EMERGENCY STOP.

Signal lamp "Mains On" The signal lamp "Mains on" lights up:
■ when the laser device is connected to the power supply
and
■ the main switch is in ON position.

Signal lamp "Monitoring" The signal lamp "Monitoring" is lit when:

■ an operating value has exceeded the monitoring limit.
■ a malfunction has occurred.
■ the interlock unit has been interrupted.
If the signal lamp "Monitoring" is lit, a message is displayed. The
message contains information about cause and measures to
eliminate the problem.

Laser warning lamp The laser warning lamp is lit when:

■ laser light is emitted at the processing point.
■ the laser is ready for emitting laser light, even if no laser light
is emitted at the processing point yet ("laser on" status).

20-06-12-A2-CR02 2016-01 Operating elements and indicators 4‐3

 Key-operated switch

Fig. 4-2

Activation of the laser by an unauthorized person can be pre-

vented by means of the key-operated switch. To do so, turn the
key to the position 0 (chart A) and be withdrawn.
The key has to be inserted for operation. The key-operated
switch has to be turned to the right. The key-operated switch
must be turned to position I (chart B).

Main switch The main switch has 2 positions: ON and OFF.

For connecting the laser device to the mains, position the main
switch to ON.
For disconnecting the laser device from the mains, position the
main switch to OFF.

In OFF position:
■ the main switch disconnects the laser device from the mains.
■ the main switch can be protected against unauthorized
switching-on by means of shackle type locks.
Always protect the main switch against unauthorized switching-
on during maintenance and repair work.

Exceptions are allowed only:

■ if work is done by trained personnel or skilled electricians
and
■ if the work cannot be carried out with the laser device
switched off.

4‐4 Operating elements and indicators 2016-01 20-06-12-A2-CR02

 1.2 Operating panel

1 Touch screen 3 CONTROL ON button 5 Turn-and-push button

2 EMERGENCY STOP pushbutton 4 CONTROL OFF button
Fig. 4-3

Touch screen Touch screen means more or less: "a screen that you can
touch". The screen of the operating panel reacts to finger pres-
sure. Software functions, buttons and fields are selected by
touching the respective point on the user interface with the fin-
ger.

If the Operating panel is not connected, the EMERGENCY

WARNING STOP functions of the operating panel are inactive!
Ø Remove the unconnected Operating panel from the working
area or cover it.

EMERGENCY STOP The laser and the cooling unit are immediately switched off when
pushbutton the pushbutton EMERGENCY STOP is pressed. In particular, no
more laser light is emitted.
The EMERGENCY STOP pushbutton can be integrated in the
Emergency Stop circuit of a system. With this pushbutton, the
entire system can be cut off. More information can be found in
the interface description EMERGENCY STOP.

CONTROL ON button With the CONTROL ON button, the laser is switched on.

CONTROL OFF button With the CONTROL OFF button, the laser is switched off.

Turn-and-push button It is possible to operate the device using the turn-and-push-but-

ton or the touch screen.

20-06-12-A2-CR02 2016-01 Operating elements and indicators 4‐5

 Turning to the right or to the left causes depending on the situa-
tion:
■ the marking of positions in lists or tables.
■ the setting of numerical values in input fields.

Pressing the turn-and-push button causes:

■ the selection or activation of the marked element on the user
interface.

Alternatively, a panel PC is available. In this case, the CON-

TROL ON and the CONTROL OFF button and the EMER-
GENCY STOP push button are located on the control panel. Fur-
ther information can be obtained from TRUMPF upon request.

4‐6 Operating elements and indicators 2016-01 20-06-12-A2-CR02

 2. Switching the laser device on and off

2.1 Switching on

Condition
■ The following lines and cables are connected:
− Electric mains connection.
− External cooling circuit (only in case of water cooling).
− Laser light cable.
− Control lines between operating panel and laser device.
− Control lines to the plant environment, where applicable.

1. To activate the external cooler (if existing): Open the valves

in the supply and return line of the external cooling circuit.
2. If a chiller is used: Switch on the chiller.
3. Turn the key-operated switch into position I.
4. Turn the main switch of the laser device to position ON.
5. Press key CONTROL ON at the operating panel.
The indicator "Mains on" is illuminated and the operating
panel is switched on.
The laser device is switched on now.

2.2 Switching off in case of malfunction

and emergencies

Ø Press EMERGENCY STOP pushbutton at the operating

panel or at the front of the laser device.
Laser and cooling unit of the laser device is switched off. No
laser light in particular can be emitted after the EMER-
GENCY STOP button has been operated.
The control unit of the laser device remains switched on.

2.3 Switching on after EMERGENCY

STOP

1. Turn depressed EMERGENCY STOP pushbutton in the

direction of the arrow.
The pushbutton is unlocked. Disabled functions of the laser
device are rendered ready for service.
2. Observe the monitoring and fault messages.

20-06-12-A2-CR02 2016-01 Switching the laser device on and off 4‐7

 3. Eliminate the cause of faults (see chapter "Conduct in case
of service interruptions").
4. In TruControl 1000 select manual mode and press the Reset
button.
The control unit is reset to original condition.
The laser device is again ready for operation.

2.4 Switching off after work

Note
You must proceed in the indicated order as otherwise software
and hardware damage may occur in the control unit of the laser
device.

RP-00102

Switching off the operating panel Fig. 4-4

1. Press the button CONTROL OFF on the operating panel.

The operating panel and the control unit are switched off.
2. Turn the main switch of the laser device to the OFF position.
3. If a cooling unit is used: Switch off the chiller
The laser device is switched off.

4‐8 Switching the laser device on and off 2016-01 20-06-12-A2-CR02

 3. Operating the laser device using
TruControl 1000

This section informs you on the most important functions of the

program TruControl 1000 for the control of the laser device.
The software manual TruControl 1000 contains further informa-
tion.

3.1 Selecting light path

The optical arrangement of the laser device mostly permits

selection between several laser light cables through which the
laser light can be conducted to the machining point. The light
path which the laser beam is to take can be selected in TruCon-
trol 1000.
The light path can be selected for each parameter set. The light
path and the pulse shapes are determined during the program-
ming stage.

Select the light path in the parameter set

1. Select main activity Man. operation.

2. Select the Pulse data tab.
3. Open the parameter set with .

20-06-12-A2-CR02 2016-01 Operating the laser device using TruControl 1000 4‐9
 RP-00322
Fig. 4-5
4. Selecting light path.
The selection list is closed. The selection field shows the name
of the chosen light path.
The laser beam is transmitted through the chosen light path
when the laser is activated next time.

4‐10 Operating the laser device using TruControl 1000 2016-01 20-06-12-A2-CR02
 Change the light path name

Condition
■ User level ≥ 60

1
2

5 7

RP-00264
Fig. 4-6

1. Select main activity Technology. (1-2)

The Light path tab is opened.
2. Mark the light path. (3)
3. Select Change.(4)
The Edit light path dialog appears.
4. Select the Change name button.(5)
The screen keyboard is displayed.
5. Enter name and select the button Finish. (6)
6. Select Save.(7)
The name of the light path has been changed.

20-06-12-A2-CR02 2016-01 Operating the laser device using TruControl 1000 4‐11
 3.2 Activating and deactivating the laser

Switching the laser on and off

Conditions
■ The laser device has been turned on.
■ The Laser button on the touch screen of the operating panel
is active.
■ There is no active fault message.
■ The parameter set or the laser program has been selected.

1. Select main activity Man. operation.

2. Select the Laser program tab.
or
Ø Select the Pulse data tab.
3. Select the parameter set or laser program with .
4. Select Laser.
The pump diode in the supply unit sends pump light to the
laser head through the pump light cable.

Eyes and skin may be exposed to laser radiation, if the

WARNING laser light is not placed under a protective cover!
Laser light can burn the skin. Direct or scattered laser light
can permanently damage the eyes.
Ø Do not reach between focusing optics and workpiece.
Ø Wear safety goggles suitable for the wavelength of the laser
light (see notice signs).

5. Select Release.
The Trigger button changes its color from gray to yellow.
With the Trigger button, a laser program or parameter set is
started. With the central shutter closed, the laser beam is
guided into the absorber. With the central shutter open, laser
light is emitted at the processing point.
The central shutter in a laser program is controlled by the
laser program. In a parameter set, the central shutter must
be closed using the Shutter button. The Trigger button
causes the generation of laser light or the start of a laser
program.
6. Select Stop.
The Stop button changes its color from yellow to grey.

4‐12 Operating the laser device using TruControl 1000 2016-01 20-06-12-A2-CR02
 An operating mode without defined end (e.g. continuous
pulse, pulse train or endless loop in the laser program) is
correctly completed.
An operating mode with defined end (laser program or pulse
train) is interrupted. In this case, the monitoring message
"Program interrupted with Stop" appears. It can be deleted
with Reset .

Open or close the central shutter (VZ) in

the parameter set

The central shutter is opened or closed:

■ by means of corresponding commands in the laser programs.
■ with the Shutter button.

Note
The central shutter in the laser program is controlled by the laser
program.

Eyes and skin may be exposed to laser radiation, if the

WARNING laser light is not placed under a protective cover!
Laser light can burn the skin. Direct or scattered laser light
can permanently damage the eyes.
Ø Do not reach between focusing optics and workpiece.
Ø Wear safety goggles suitable for the wavelength of the laser
light (see notice signs).

1. Select main activity Man. operation.

2. Select the Pulse data tab.
3. Select Shutter.
The Shutter button changes its color from grey to yellow.
With the central shutter (VZ) open, laser light can be trans-
mitted to the optical components via the selected light path.
4. Select Shutter.
The Shutter button changes its color from yellow to grey. No
laser light can be emitted from the laser device.

3.3 Responding to messages

The control unit monitors numerous operational values of your

laser device.

20-06-12-A2-CR02 2016-01 Operating the laser device using TruControl 1000 4‐13
 If an operational value reaches the monitoring or fault limit, the
icon for monitoring or fault message is displayed in the status
line of the user interface.

Symbol Meaning
Symbol for fault message

Symbol for monitoring message

Tab. 4-1

The message line displays the message code and the short text
of the message.

1 Symbol of the message 3 Message code and short text

2 Message line
Fig. 4-7

A fault message is displayed as soon as a monitored opera-

tional value leaves the permissible range and thus causes a crit-
ical condition.
The laser is deactivated if a fault message is displayed. It cannot
be switched on again until the cause for the critical condition has
been eliminated.
For further information about messages, please refer to chapter
"Conduct in case of service interruptions" and the software man-
ual TruControl 1000.

Resetting the message

Fault and monitoring messages can be reset with the Reset but-
ton. In case of a fault message, the fault must be eliminated
before resetting the message. If fault messages are active, the
reset starts an initialization of the control. This means: Switch-on
and test sequences are carried out until the laser device is ready
again.
Ø Either
Ø Select the main activity Diagnostics.
Ø Select the message history with .
Ø Select Reset.

4‐14 Operating the laser device using TruControl 1000 2016-01 20-06-12-A2-CR02
 or
Ø Select title bar.
Ø Select the >Message tab.
Ø Press Reset to reset the fault message.
The message is reset.

3.4 Generating pulse shapes

The laser device can create any pulse shapes. A pulse shape
editor is integrated in TruControl 1000. Pulse shapes are cre-
ated, modified and managed with it.

1 Title bar 3 Option to change the time differ- 5 Diagram pulse shape
2 Table pulse data ence
4 Context bar
Pulsform-Editor Fig. 4-8

The power points of the pulse shape can be entered graphically

or via a table.

20-06-12-A2-CR02 2016-01 Operating the laser device using TruControl 1000 4‐15
 Pulse shapes can:
■ be integrated in parameter sets and in laser programs.
■ be statical or scalable.
■ be taken over as reference in a parameter set.
■ taken over as reference or as copy into a laser program.
■ be saved as templates
Information on pulse shapes and on the operation of the pulse
shape editor is to be found in the software manual TruCon-
trol 1000.

3.5 Creating laser programs

A laser program is a sequence of commands and settings which

are carried out automatically after starting.
A laser program editor is integrated in TruControl 1000. Laser
programs are created, modified and managed with it.

Laser programs can be called up:

■ by manual operation.
■ externally via a interface of the laser device.

Fig. 4-9

Laser programs consist of program lines.

Information on the operation of the laser program editor is con-
tained in the software manual TruControl 1000.

4‐16 Operating the laser device using TruControl 1000 2016-01 20-06-12-A2-CR02
 3.6 Programming light paths

In connection with light paths, the following actions are possible

under TruControl 1000:
■ Programming light paths
■ Editing light path names (see software manual TruCon-
trol 1000)
■ Selecting light paths (see software manual TruControl 1000).
■ Managing light paths (see software manual TruControl 1000).

Definitions Programming a light path means:

■ Defining the position of switch mirrors and shutter mirrors in
the optical arrangement.
■ Storing the information on mirror positions in a data record
for the light path.
TRUMPF has already programmed all possible light paths for the
optical arrangement of your laser device. Each light path leads
through a laser light cable to a processing point. Two or more
laser light cables may belong to one light path when optical split-
ters are used.

Editing light path names Every light path can be given a user name.
Please refer to the software manual TruControl 1000 for further
information on authorization and processing.

Programming light paths Programming light paths should be done exclusively by the
TRUMPF service technicians (from user level 70). This is only
necessary if the optical arrangement of the laser device was
changed in such a way that other light paths become possible or
previous light paths are no longer possible.

3.7 Pilot laser (option)

A pilot laser is optionally provided in the laser device and sends

visible, red light with low power through the beam guideway.
This allows you to observe the light path and operations at the
processing point. When the pilot laser is switched on, the symbol
for the pilot laser is displayed in the message line.

Fig. 4-10

20-06-12-A2-CR02 2016-01 Operating the laser device using TruControl 1000 4‐17
 Switching on pilot laser When the pilot laser is switched on, is determined:
■ by the pilot laser mode set in the system settings.
■ by the shutter switch state (shutter switch closed or open).
■ by the state of the safety circuit (safety circuit interrupted or
closed).

Switching the switching functions of pilot

laser on and off

If the switching functions of the pilot laser are switched on or off

by TruControl 1000, the pilot laser are switched on or off for all
existing light paths. The pilot laser can be switched on or off for
individual light paths in the light path overview .

1. Select main activity Set-up.

2. Use to select Switching functions.
3. Checkmark the box for switching the pilot laser.
The pilot laser is active. Remove the checkmark to switch the
pilot laser off.

Setting the pilot laser mode

Condition
■ User level ≥ 10

Note
The pilot laser is switched off irrespective of the set pilot laser
mode if the single channel safety circuit (ASV3, connector X24)
is used for internal functions (for ex. protection of the laser light
cables in the user's compartment) AND if the single channel
safety circuit is interrupted.

4‐18 Operating the laser device using TruControl 1000 2016-01 20-06-12-A2-CR02
 Fig. 4-11

1. Select main activity Set-up. (1-2)

2. Open the system settings with . (3-4)
3. Mark the signal "PilotLaserMode". (5)
4. Select Change.(6)
5. Select the mode. (7)
The following table describes the modes in the system set-
tings.

Mode Meaning
0 Pilot laser constantly off.
1 Pilot laser is switched on if the shutter switch is closed.
2 The pilot laser is switched on if the safety circuit is interrupted.
3 The pilot laser is active, when
■ its switching functions are activated (see "Switching func-
tions of the pilot laser are switched on and off")
OR
■ External signal PILOT_LASER_ON is set.
■ AND
shutter switch is closed.

20-06-12-A2-CR02 2016-01 Operating the laser device using TruControl 1000 4‐19
 Mode Meaning
4 The pilot laser is active, when
■ its switching functions are activated (see "Switching func-
tions of the pilot laser are switched on and off")
OR
■ External signal PILOT_LASER_ON is set.
■ AND
the safety circuit is interrupted.
5 The pilot laser is active, when
■ its switching functions are activated (see "Switching func-
tions of the pilot laser are switched on and off")
OR
■ External signal PILOT_LASER_ON is set.
Boun- The pilot laser is switched off irrespective of the set pilot laser
dary mode:
condi- ■ if the single channel safety circuit (ASV3, connector X24) is
tion
used for internal functions (for ex. protection of the laser
light cables in the user's compartment)
AND
if the single channel safety circuit is interrupted.
Tab. 4-2

6. Select Apply.
The pilot laser mode has been set.

Switching the pilot laser in the light path

on and off

In the light path overview, the user can switch the pilot laser for
the individual light paths on and off.

Note
If the connector at the X24 of the ASV board is used for internal
functions (for ex. protection of the laser light cables in the user's
compartment), the pilot laser is switched off as soon as the one-
channel safety circuit is interrupted irrespective of the adjusted
pilot mode.

4‐20 Operating the laser device using TruControl 1000 2016-01 20-06-12-A2-CR02
 1

Fig. 4-12

1. Select main activity Production. (1-2)

2. Open the light path overview with . (3-4)
3. Select the button for the pilot laser in the Pilot column of the
desired light path. (5)
The Overview - pilot laser dialog is displayed.

Dialog overview - Pilot laser Fig. 4-13

4. Switch on the pilot laser in the respective light path with .

20-06-12-A2-CR02 2016-01 Operating the laser device using TruControl 1000 4‐21
 or
Ø Switch off the pilot laser in the respective light path with
.

4‐22 Operating the laser device using TruControl 1000 2016-01 20-06-12-A2-CR02
 4. Controlling the laser device from
outside

4.1 TRUMPF LaserNetwork (option)

Optionally, the laser device can be equipped with TRUMPF

LaserNetwork (TLN) components.

Components of the TRUMPF LaserNetwork (TLN) are:

■ Multi-PLC Interface (MPI)
■ Interface LaserNetwork (ILN)
■ Ethernet

MPI The Multi PLC Interface is a software interface of the laser

device for exchanging control signals with a maximum of 32
external control units. The external control units are connected
with the laser device through field bus components.
MPI can be used efficiently if the laser power of a laser device
has to be requested by various control units.

ILN The interface LaserNetwork contains signal lines for:

■ light path coding.
■ two-channel safety circuits.

Ethernet The laser device can be connected to other devices in a local

network (LAN) via Ethernet.
Detailed information can be found in the Technical Information
TRUMPF LaserNetwork and other documents available from
TRUMPF.

20-06-12-A2-CR02 2016-01 Controlling the laser device from outside 4‐23

4‐24 Controlling the laser device from outside 2016-01 20-06-12-A2-CR02
 Chapter 5

Maintenance

1 Installation guideline 5‐4

2 Material 5‐5
2.1 Wearing parts 5‐5
2.2 Tools and auxiliaries 5‐5
2.3 Consumables 5‐6
2.4 Disposal 5‐7

3 Opening and closing the laser device 5‐8

3.1 Opening and closing doors 5‐8
3.2 Remove covers 5‐8
3.3 Open and close hood 5‐9

4 Hose connections 5‐10

4.1 Connecting the hose 5‐10
4.2 Disconnecting the hose 5‐10

20-06-12-A2-CR02 2016-01 Maintenance 5‐1

 5 Flash lamp 5‐11
5.1 Replacing the flash lamp 5‐11

6 Optical arrangement and laser light cable 5‐18

6.1 Check mirror and lenses 5‐18
6.2 Removing and mounting the laser light cable 5‐19
Dismount laser light cable 5‐19
Fitting a laser light cable 5‐23
6.3 Maintaining laser light cable 5‐28
Cleaning the protective sleeve with cover 5‐28
slide
Replacing the protective sleeve along with 5‐29
the cover slide

7 Fan at the control 5‐31

7.1 Check the function of the fan on the control 5‐31
unit
7.2 Clean the grids on top of the fans 5‐32

8 Lamp power supply 5‐34

8.1 Replacing the lamp power supply, TruPulse 5‐34
203 ... TruPulse 556

9 Laser cooler 5‐40

9.1 Topping up cooling water 5‐41
9.2 Replacing the water in the tank 5‐42
9.3 Cleaning the tank, cleaning or changing the 5‐44
filter of the tank
9.4 Replacing the deionizing filter 5‐47
9.5 Cleaning the particle filter 5‐50
9.6 Cleaning the contamination filter 5‐52
9.7 Checking the cooling unit for tightness 5‐54
9.8 Checking the solenoid valve 5‐55
9.9 Emptying and filling the cooling unit 5‐56
Emptying the cooling unit of the laser 5‐56
device
Filling the cooling unit 5‐62

10 Electrical system 5‐67

10.1 Identifying blown electrical fuses 5‐67
10.2 Replacing a microfuse 5‐69

5‐2 Maintenance 2016-01 20-06-12-A2-CR02

 10.3 Activating an automatic circuit breaker 5‐70

11 Operating panel 5‐71

11.1 Clean the screen of the operating panel 5‐71

20-06-12-A2-CR02 2016-01 Maintenance 5‐3

 1. Installation guideline

The correct maintenance is an important condition for a faultless

operation of the laser device and for the quality of the working
result.
The laser device requires little maintenance. All important func-
tions are electronically monitored. A monitoring message, which
is indicated by the laser device, can call for maintenance work.
Check regularly the condition of your laser device. Carry out
maintenance work as a precautionary measure when you detect
signs of wear or dirt.
Check regularly the laser light cable for damaged sheath. The
laser light cable must be replaced in case of a damaged sheath.

While carrying out maintenance work on the laser device

DANGER you can come into contact with parts which are dangerous
to persons or property.
Improper or incautious procedures can cause injuries or
damage to property.
Ø Maintenance work may be carried out only by instructed per-
sons.
Ø Any work on the electrical equipment must be carried out
only by a trained electrician.
Ø You must observe the warning instructions of these mainte-
nance instructions.
Ø Before starting maintenance work, switch off the laser
device.

Note
The laser device must be switched on during maintenance work
only if it is necessary for maintenance or control purposes. You
will be informed about this in the corresponding passages of this
manual.

Assistance in case of Contact the TRUMPF service department, if there are any prob-
problems lems you cannot resolve. The service address can be found at
the beginning of the operating instructions.

5‐4 Installation guideline 2016-01 20-06-12-A2-CR02

 2. Material

2.1 Wearing parts

Subas- Designation Material Recommended

sembly no. stock
Laser Flash lamp 773787 2
Cooling Filter in the tank 359880 1
unit
Deionizing filter 1354262 1
Sieve tube in the parti- 765481 1
cle filter
Spare sieve for con- 1445470 1
tamination filter.
Electrics Fuse set 1366362 1
Tab. 5-1

2.2 Tools and auxiliaries

Symbol Designation Dimensions, further specifications

Double-bit key for opening the doors and the hoods

Slotted screw driver 2 mm, 3 mm

Crosstip screw driver 2 mm

Hexagon screwdriver 3 mm, 4 mm

Torque screwdriver 3 mm, 2 Nm

(Laser device accessory)

Fork wrench 30 mm

Pan for cooling water

Cloth to wipe up drained water

Safety gloves rubber, to be worn when handling

deionized water

20-06-12-A2-CR02 2016-01 Material 5‐5

 Symbol Designation Dimensions, further specifications
Protective goggles protection against glass splinters

Cleaning brush soft bristles

clean water jug from plastic for filling the tank of the laser cooler

Blow-out gun for cleaning the filter cartridge in the

entry filter

Vacuum cleaner

Cleaning set for optical compo- tools and material for cleaning work
nents on optical components
Material no.: 0779603

Tools and auxiliaries for maintenance work Tab. 5-2

2.3 Consumables

For maintenance work on your laser device you need the follow-
ing extras:
■ Lens cleaning paper (obtainable from photo shops) or cotton
wool for cleaning optical glasses.
■ Deionized water (DI water) as cooling water for the internal
laser cooler circuit. The required quantity is indicated. For the
extraction of DI water, water of drinking water quality must
be used.
■ Tap water as cleaning agent for filter inserts.
■ Use compressed-air only for blowing out the filter inserts.
■ Methanol as cleaning agent for optical glasses.

5‐6 Material 2016-01 20-06-12-A2-CR02

 Methanol is inflammable and toxic when you inhale or
CAUTION swallow it.
Ø Keep methanol away from fire and other ignition sources.
Ø Do not smoke.
Ø Ensure sufficient fresh air supply.
Ø Do not inhale methanol vapor.

2.4 Disposal

Some maintenance work will produce waste material that must

be disposed of. Instructions for an appropriate disposal are given
in the corresponding passages.

Note
The instructions for disposal of waste material are recommenda-
tions, derived from regulations applied at place and time when
these operating instructions have been prepared. As operator of
the laser device, however, you are obliged to inform yourself
about the regulations concerning waste disposal and to observe
these regulations.

Unless the regulations applicable do no stipulate otherwise, the

waste material is to be disposed of as follows:

Seals, O-Rings Refuse.

Lens cleaning paper Refuse.
Cooling water Sewerage system
Deionizing filter Refuse.
Filter material Refuse.
Electric fuses Refuse.
Tab. 5-3

20-06-12-A2-CR02 2016-01 Material 5‐7

 3. Opening and closing the laser device

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

3.1 Opening and closing doors

Fig. 5-1

3.2 Remove covers

2.

1.

Fig. 5-2

5‐8 Opening and closing the laser device 2016-01 20-06-12-A2-CR02

 Note
Side walls and back walls are connected with the laser device
through a grounding cable. When removing or inserting side wall
and back walls please pay attention to grounding cable.

3.3 Open and close hood

Pinch points at edges of hood and device frame, especially

WARNING on left and right side of the laser device.
Hand bones may be broken.
Ø Do not close the hood until you are sure that no other per-
son has his/her hands on the squeezing point.

Note
Before opening the hood, you must remove operating panel from
support at the hood of the laser device.

Fig. 5-3

20-06-12-A2-CR02 2016-01 Opening and closing the laser device 5‐9

 4. Hose connections

4.1 Connecting the hose

Fig. 5-4

1. Push the hose into the hose coupling.

2. After the first resistance continue to forcefully push in the
hose until it reaches the stop.
Now the hose is firmly connected to the hose coupling.

4.2 Disconnecting the hose

1.

2.

1.

Fig. 5-5

1. Press the hose coupling ring in direction of the hose cou-

pling.
The hose coupling lock is unlocked.
2. Pull the hose out of the hose coupling.

5‐10 Hose connections 2016-01 20-06-12-A2-CR02

 5. Flash lamp

Control reserve limit The flash lamp in the cavity of your laser device ages during the
operation. Laser performance control compensates aging of the
flash lamp. When control reserve limit is reached flash lamp
must be replaced.

Control reserve limit is reached, when:

■ a monitoring message shows that average control interven-
tion exceeds a certain limit value.
or
■ a monitoring message shows that measured energy differs
too much from nominal energy.
That this monitoring message is shown, energy control in
laser program must be activated. (refer toSoftware man-
ual TruControl 1000).

Flash lamp failure Note

You can set a limit value for flash lamp in main activity "Mainte-
nance". Limit value indicates a number of pulses. If "lamp pulse
counter" reaches limit value, a monitoring message is displayed.
You can set the limit value according to your experience regard-
ing life time of flash lamp (refer to Software manual TruCon-
trol 1000).

Replace:
■ both flash lamps, when a flash lamp with long period of oper-
ation failed.
■ only failed flash lamp, when it failed after a short period of
operation.

5.1 Replacing the flash lamp

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Double-bit key
■ Torque screwdriver 3 mm, 2 Nm
■ (Laser device accessory)
■ Cloth to wipe up drained off cooling water
■ Protective goggles
■ Blitzlampe (Material no.773787)

20-06-12-A2-CR02 2016-01 Flash lamp 5‐11

 ■ upon demand:
■ Lens cleaning paper and methanol from the optics cleaning
set .

Note
Use only flash lamps and O-rings that you bought from
TRUMPF .

While changing the flash lamp you can come into contact
DANGER with dangerous live parts.
Touching live electric parts can be extremely dangerous.
Ø The flash lamp must be replaced only while the laser device
is switched off and by instructed persons only.

1. After switching off the laser device, wait until the flash lamp
has gone off.
2. Open the hood of the laser device.

Remove flash lamp

Fig. 5-6

3. Unscrew screws at lid of the cavity and remove lid.

Wait 90 seconds before work is continued.

5‐12 Flash lamp 2016-01 20-06-12-A2-CR02

 90 sec

Fig. 5-7
4. Unscrew screws at cavity top and take out cavity top part
horizontally.

Fig. 5-8
5. Let residual water flow out of the cavity top part.

The inside of the lamp is under pressure.

WARNING
If a lamp breaks into pieces, splinters of glass can injure
eyes and skin.
Ø Do not touch the bulb of the lamp.
Ø Wear safety goggles.
Ø Wear clean rubber or nylon gloves.

20-06-12-A2-CR02 2016-01 Flash lamp 5‐13

 Fig. 5-9
6. Remove covers at connections and pull out flash lamp.
If flash lamp cannot be pulled out immediately:

Ø Flash lamp may be released by turning it. Therefore hold

flash lamp at both ends. Turn flash lamp in cavity.

In case of broken glass Note

Remove glass splinters very carefully.
• It is strictly prohibited to open the cavity!
• Do not blow out the cavity with compressed air.
• Do not extract splinters in cavity by suction.
7. If the flash lamp failed because of broken glass, there will be
splinters of glass in the cavity. The glass splinters must be
removed:
− Repeatedly push non-fuzzing cloth through lamp channel
of the cavity with a thin stick.
− Pay attention that cloth does not establish a ball. It
should be possible to push cloth slightly through the lamp
channel. Otherwise the laser device may become dam-
aged.
This way glass splinters are pushed out of the cavity.
8. Completely remove pushed out and scattered glass splinters.
9. Remove glass splinters from the particle filter (refer to sec-
tion "Cleaning the particle filter").
10. Put old flash lamp aside until the new flash lamp has been
inserted.

Insert new flash lamp Note

Do not touch the bulb with your fingers.
11. Take new flash lamp out of packaging.
12. Check if bulb of the new flash lamp is clean.
13. Clean flash lamp, if you detect finger prints or other contami-
nation on it. Use lens cleaning paper and Methanol for clean-
ing.

5‐14 Flash lamp 2016-01 20-06-12-A2-CR02

 Note
Make sure that the red end of the flash lamp is at the same
side than the red point on the cavity (see arrows).

Fig. 5-10
14. Push the new flash lamp with the correct side (red end of the
flash lamp to red point) into the cavity and center the flash
lamp.
15. Replace O-rings on both sides of the cavity.
4 O-rings are delivered with spare flash lamp.

Fig. 5-11
16. Mount covers at connections.
17. Replace residual 2nd flash lamp as described before, when it
has been operated for a longer period.

20-06-12-A2-CR02 2016-01 Flash lamp 5‐15

 OK
OK

Fig. 5-12
18. Insert cavity top part into cavity.
− Flash lamp connections must be placed centrally on ter-
minal blocks.
− Cavity top part must be placed centrally in cavity.

Fig. 5-13
19. Mount cavity top part and lid of the cavity (tightening torque
2 Nm).
Dispose old flash lamp 20. Put the old flash lamp in the package of the new one. Break
the used flash lamp in the closed package against an edge.
21. Used flash lamps must be disposed of as residual waste.
Dichtheit der Kavität prüfen 22. Switch on the laser device.

PUMP

Y_L AS

Y_CA B

?
Fig. 5-14

5‐16 Flash lamp 2016-01 20-06-12-A2-CR02

 23. Briefly press the pump button in the optical arrangement sev-
eral times, then for a longer period.
The pump of the cooling unit runs as long as the button
remains pressed, thus supplying the cavities with cooling
water.
24. Observe environment of lamp connections at the cavity for
several minutes.
25. If cooling water escapes, seal the leaky points. Wipe off
escaped cooling water.
Working with the laser 26. Close the cover of the laser device.
device 27. Working with the laser device. Check the working results
(welding or cuttings).

20-06-12-A2-CR02 2016-01 Flash lamp 5‐17

 6. Optical arrangement and laser light
cable

6.1 Check mirror and lenses

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Double-bit key

1. Open the hood of the laser device.

Fig. 5-15
2. Check all visible mirrors and lenses (visual check).
3. Inform the TRUMPF Laser Service Department if a mirror or
a lens is soiled or damaged.
If a damage or contamination is detected,

Ø use the device only if the Service Department of

TRUMPF Laser explicitly agreed to it.

4. Close the cover of the laser device.

5‐18 Optical arrangement and laser light cable 2016-01 20-06-12-A2-CR02

 6.2 Removing and mounting the laser
light cable

A laser light cable must be removed and fitted:

■ if you want to transport the laser device.
■ if you want to replace a laser light cable by another one, e.g.
with different length.

Note
Laser light cables are optical precision parts, which are produced
with maximum accuracy and with observance of the utmost
cleanliness. During the use of the laser light cables, avoid con-
tamination and mechanical stress (shocks, impacts) of the optical
plugs.

Laser light cables must be removed or mounted by instructed

persons only.

Dismount laser light cable

Work steps
■ Preparation
■ Dismount laser light cable at laser device
■ Detach the LLK from the processing optics
■ Remove laser light cable and coil
■ Final procedures.

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ When replacing laser light cables, obtain information from
TRUMPF Laser on the adequate number of new laser light
cables (material no. depending on length).
■ Two protective caps per removed laser light cable, Material
no. 774616
■ Connectors for each coupling optical unit from which a laser
light cable is removed, Material-Nr. 773140
■ Plugs for all openings at the focusing optics from which the
laser light cables are removed, Material-Nr. 760816.
■ Hexagon screwdriver 3 mm, 4 mm.
■ Slotted screw driver 2 mm.

20-06-12-A2-CR02 2016-01 Optical arrangement and laser light cable 5‐19

 Preparation 1. Open the hood of the laser device.

Fig. 5-16
2. Remove the cover of bushing.

1 2 3

1 LLK coding cable(Option) 4 Lead-through for further LLK

2 LLK-D 5 Holder
3 IFO-cable(Option) 6 Slotted grommet
Fig. 5-17
3. Remove the support on the bushing from the LLK to be
replaced.
4. Remove laser light cable from slotted sleeves (6).
Now laser light cable may be dismounted from laser device.

5‐20 Optical arrangement and laser light cable 2016-01 20-06-12-A2-CR02

Dismount laser light cable at
laser device

1 Monitoring plug 2 Locking screw

Fig. 5-18

5. Detach monitoring plug.

6. Release clamp screw at coupling optical unit.

Notes
■ Never rotate the ring at the incoupling optics. Otherwise
the incoupling optics may be misaligned.
■ Do not tilt or turn the optical plug.
■ Never touch the light guide end or the glass body of the
protective sleeve with fingers.
■ Avoid dirt on the plug or the light guide.

Fig. 5-19
7. Pull out optical plug of Incoupling opticsIncoupling optics.
WS-00030

Fig. 5-20
8. Put protective cap on the optical plug and tighten the
threaded pin.
9. Insert connector into opening of coupling optical unit.

20-06-12-A2-CR02 2016-01 Optical arrangement and laser light cable 5‐21

 Note
Do not knock the plug against anything. The light guide
might break.
10. Remove the laser light cable from the device.
The LLC is disconnected from the laser side.

Detach the LLK from the

processing optics

4 mm

2 3

2 mm
4

Fig. 5-21

Note
If the focusing optics is fitted on a swivelable mount, it
should be brought to a possibly horizontal position for the fol-
lowing activities. So it is prevented that dirt gets to optical
components which are temporarily exposed when detaching
the connections.
11. Release clamp screw (1) at focusing optical unit.
12. Pull out optical plug without canting or turning it.
13. Put protective cap (2) on optical plug and tighten setscrew
(3).
14. Put connector (4) into opening of focusing optical unit.
The LLK is disconnected from the focusing optics.

5‐22 Optical arrangement and laser light cable 2016-01 20-06-12-A2-CR02

 Remove laser light cable 15. Release the laser light cable across the entire length of
and coil tracks, fastening clamps, clamping pieces etc.

Note
Please note that optical plugs do not attach anywhere during
coiling. Else the optical fiber may be damaged.
16. Coil the laser light cable to a ring with a diameter of approx.
80 cm.
Laser light cable is removed.
Final procedures 17. Check, if protective caps or connectors are attached on all
occurring openings.
18. Attach support of bushing at laser device again.
19. Close the cover of the laser device.
Demounting the laser light cable is completed.

Fitting a laser light cable

Work steps
■ Pass laser light cable.
■ Preparing the laser device
■ Connect laser light cable with laser device
■ Connecting the laser light cable to the focusing optics
■ Final procedures

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Double-bit key
■ Hexagon screwdriver, 3 mm, 4 mm
■ Slotted screw driver, 2 mm

Pass laser light cable 1. The plugs of the LLK are packed in protective shells. Do not
remove these protective shells, until you have laid the LLK.

20-06-12-A2-CR02 2016-01 Optical arrangement and laser light cable 5‐23

 Packaging Connector Use
Large Protective Incoupling connector Connection between the
shell laser light cable and the
laser device
Small Protective Outcoupling connec- Connection between the
shell tor laser light cable and the
focusing optics
Tab. 5-4

2. Outside the laser safety cabins, the laser light cables must
be installed permanently and protected.
To do so, use:
− Cable clamps
− Cable ducts
− Other appropriate auxiliaries for fastening cables.
3. Inside laser cabins , which are monitored by a safety cir-
cuit, laser light cables can be laid freely and loosely.
Preparing the laser device 4. Open the hood of the laser device.

Fig. 5-22
5. Remove the cover of bushing.

Fig. 5-23
6. Remove the desired support from the bushing.

5‐24 Optical arrangement and laser light cable 2016-01 20-06-12-A2-CR02

 2

WS-00035
1 Protective shell 3 Protection foil
2 Seal
Fig. 5-24
7. Remove protective shell from the optical plug, break the seal
and remove the protection foil.
Connect laser light cable 8. Insert the laser light cable into the laser device.
with laser device 9. Remove protective cap from coupling optics opening.

Notes
■ Ensure that the openings from which the caps were
removed do not become soiled.
■ Never touch ending of light conductor with your fingers.

WS-00031
Fig. 5-25
10. Release setscrew andPull the protective cap from the incou-
pling connector

1 Monitoring plug 2 Locking screw

Fig. 5-26

20-06-12-A2-CR02 2016-01 Optical arrangement and laser light cable 5‐25

 11. Adjust the monitoring plug to the top and insert the optical
plug into the coupling optics as far as it will go.

Note
Optical plug must necessarily be inserted into coupling optics
as far as it will go when tightening clamping screw.
12. Tighten clamp screw at coupling optical unit. Thereby press
optical plug against coupling optical unit.
13. Connect monitoring plug to according plug connector.

2 3 4

1 Hose connection gland 5 Bushings for further LLKs

2 LLK coding cable(Option) 6 Holder
3 Laser light cable 7 Bushing cover
4 IFO cable (Option)
Fig. 5-27

14. Apply grommets (1) around inserted LLKs and cables.

15. Mount support (6).
16. Mount bushing cover (7).
LLK is connected with incoupling optics and monitoring elec-
tronics.

Pass LLKs Note

Bending radius of laser light cable must not be smaller than
200 mm. Do not bend or pass LLK along sharp edges.

5‐26 Optical arrangement and laser light cable 2016-01 20-06-12-A2-CR02

 17. Pass LLK to focusing optical unit.

Connecting the laser light Note

cable to the focusing optics
If the focusing optics is fitted on a swivelable mount, it
should be brought to a possibly horizontal position for the fol-
lowing activities. So it is prevented that dirt gets to optical
components which are temporarily exposed when detaching
the connections.
18. Seal rip open at optical plug and remove the protective film.

1 2
2 mm

4
5

4 mm
6
Fig. 5-28

Notes
■ Ensure that the openings from which the caps were
removed do not become soiled.
■ Never touch ending of light conductor with your fingers.
19. Release setscrew (2) land remove protective cap (1) from
optical plug.
20. Pull out connector (3) from opening of focusing optical unit.
21. Adjust the optical plug in a way that the pin at the optical
plug (5) gets into the fitting notch of focusing optics (4).

20-06-12-A2-CR02 2016-01 Optical arrangement and laser light cable 5‐27

 22. Plug optical plug into focusing optics.
23. Fasten locking screw (6) at the focusing optics. Thereby
press optical plug against focusing optics.
The LLK is now connected to the focusing optics.
Final procedures 24. Position the hood.
The laser light cable is inserted.

6.3 Maintaining laser light cable

Cleaning the protective sleeve with cover

slide

Means, Tools, Materials

■ Lens cleaning paper and methanol from the optics cleaning
set (material no. 779603).

Methanol is inflammable and toxic when you inhale or

CAUTION swallow it.
Ø Keep methanol away from fire and other ignition sources.
Ø Do not smoke.
Ø Ensure sufficient fresh air supply.
Ø Do not inhale methanol vapor.

Fig. 5-29

Notes
■ Never touch the protective glass (2) with the fingers.

5‐28 Optical arrangement and laser light cable 2016-01 20-06-12-A2-CR02

 ■ Ensure that the protective glass is not scratched.
■ If scratches or burnt-in particles are on the protective
glass, the protective sleeve with protective glass must be
changed.(see "Replacing the protective sleeve along with
the cover slide", pg. 5‐29).
1. Moisten the lens cleaning paper with methanol.
2. Slowly wipe across the protective glass (pos. 2) until it is
clean.
3. Used lens cleaning paper must be disposed of as refuse.

Replacing the protective sleeve along with

the cover slide

Means, Tools, Materials

■ Protective sleeve with protective glass (Material no. 568077)
■ Mounting key for protective sleeve (Material no. 566618)

Fig. 5-30

Notes
■ Never touch the optical wave guide (2).
■ Ensure that the optical wave guide is neither soiled nor
damaged.
■ With the protective sleeve (3) removed, hold the opening
of the optical-plug downward so that no dirt particles can
fall on the end of the wave guide (2).

20-06-12-A2-CR02 2016-01 Optical arrangement and laser light cable 5‐29

 ■ Do not touch the protective glass of the new protective
sleeve.
■ Make sure that no dirt particles enter the new protective
sleeve.
1. Screw off the protective sleeve (3) using the mounting key
(4).
2. Remove the protective sleeve cautiously in direction of the
beam from the optical plug.
If you remove the protective sleeve laterally, there is a risk
that wave guide becomes damaged.
3. Hold new protective sleeve by the inner protective cap (6)
and remove outer protective cap (5).
4. Hold the new protective sleeve by the inner protective cap,
slide it cautiously onto the optical plug (1) in the direction of
beam and twist it onto the screw.
5. Pull off the inner protective cap and fasten the protective
sleeve using the mounting key (4).
6. Check new protective glass for soiling and clean it, if neces-
sary
7. Dispose of the wrapping material and the old protective
sleeve as residual waste.

5‐30 Optical arrangement and laser light cable 2016-01 20-06-12-A2-CR02

 7. Fan at the control

7.1 Check the function of the fan on the

control unit

Means, Tools, Materials

■ Double-bit key

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

1. Open the right front door of the laser device.

Fig. 5-31
2. Lead one hand into free space above control unit.
Here the air flow leaves that is caused by the 2 ventilators.
If both ventilators operate properly, the air flow can be
noticed on the left and the right side. If on one side no air
flow is noticed, ventilator is stopped.
3. Inform the TRUMPF service department in case one ventila-
tor has failed.

20-06-12-A2-CR02 2016-01 Fan at the control 5‐31

 7.2 Clean the grids on top of the fans

After long-term operation, there may be dust deposits on the

grids above the fans. In this case the fan unit must be removed
and the grids must be cleaned.

Conditions
■ Laser device has been switched off and protected against
restart.
■ A clearance of 1 m must be accessible on the right side of
the laser device.

Means, Tools, Materials

■ Double-bit key
■ Slotted screw driver 3 mm
■ Hexagon screwdriver 4 mm
■ Cloth
■ Vacuum cleaner

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

Fig. 5-32

1. Remove the right side panel of the laser device.

2. Loosen the screws of the plug and remove the cable.

5‐32 Fan at the control 2016-01 20-06-12-A2-CR02

 3. Unscrew the fastening screws (2x) of the fan unit.
4. Remove the fan unit from the laser device.

WS-76097
Fig. 5-33
5. Clean the grids above the fans with a moist cloth or a vac-
uum cleaner.
6. Check the condition of the fan wheels.
− If soiled:
Clean the fan wheels with a vacuum cleaner.
− If damaged:
Informing the TRUMPF service department.
7. Replace the fan unit and screw in the fastening screws.
8. Connect the cables.
9. Mount the right side panel of the laser device.
10. Switch on the laser device.
11. Check the function of the fans (see "Check the function of
the fan on the control unit", pg. 5‐31).
The laser device is ready for use

20-06-12-A2-CR02 2016-01 Fan at the control 5‐33

 8. Lamp power supply

There are 6 different LPS for the TruPulse and they can be
ordered by indicating the following material numbers.

■ Spare parts package LPS1: 1377649

■ Spare parts package LPS2: 1377652
■ Spare parts package LPS3: 1377653
■ Spare parts package LPS4: 1377654
■ Spare parts package LPS5: 1402215
■ Spare parts package LPS6: 1402216

8.1 Replacing the lamp power supply,

TruPulse 203 ... TruPulse 556

According to the laser power, the laser device is equipped with a

lamp power supply of type LPS5 or LPS6. The type name is
marked on the rating plate at the front of the lamp power supply.

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Double-bit key
■ Hexagon screwdriver 4 mm
■ Crosstip screw driver PH1, PH 2
■ Cloth
or
■ Drip pan for cooling water
■ Replacement lamp power supply:
■ LPS5: (Material no. 1327909)
■ LPS6: (Material no. 1327916)

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

5‐34 Lamp power supply 2016-01 20-06-12-A2-CR02

 Preparation 1. Open the right front door of the laser device.

Removing the lamp power

supply

Fig. 5-34

2. Plug off the connectors at the front of the lamp power supply.
− CAN bus connector (2x).
− Mains supply.
− Connector top left.
3. Unscrew the fastening screws (4x).

Note
Make sure that no cables or hoses under the lamp power
supply are damaged when removing the lamp power supply.
WS-75016

Fig. 5-35

20-06-12-A2-CR02 2016-01 Lamp power supply 5‐35

 4. Pull out the lamp power supply by about 5 cm.
5. Put the drip pan underneath.

Note
The two cooling water connectors must be removed simulta-
neously in order to avoid a larger amount of water running
out of the connections.

Deionized water (DI water) is used to fill the tank!

CAUTION
Cooling water can be aggressive against skin and textiles.
Ø Do not bring the cooling water in eyes, nose or mouth.
Ø Avoid that cooling water comes into contact with your cloth-
ing.
Ø You can wash off the cooling water with tap water.
Ø Wear protective gloves, protective clothing and safety gog-
gles.

6. Simultaneously remove the two cooling water connectors.

A small quantity of cooling water flows out.
7. Collect the draining cooling water with a cloth.

Dangerous electric voltage inside the lamp power supply!

DANGER
Touching live electric parts can be life-threatening.
Ø Do not touch any parts inside the lamp power supply
Ø Only remove the lamp power supply if the LEDs at the lamp
power supply are off.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.

5‐36 Lamp power supply 2016-01 20-06-12-A2-CR02

 1 Charge indicator of the basic 2 Charge indicator of the addi-
electrolytic capacitor for LPS5 tional electrolytic capacitor for
and LPS6 LPS6
Fig. 5-36
8. Pull out the lamp power supply to the front until the charging
state indicators (LEDs) are visible as shown in the figure.
9. If the LEDs are lit, dangerous voltage still exists inside the
lamp power supply.
Wait until the LEDs have gone out. This may take up to one
hour if the internal discharge circuit is defective.

Danger of injury by falling subassembly

WARNING
Legs or feet may be hit or crushed. Backache can be
caused or increased.
Ø Lift the subassembly with 2 persons.
Ø Place the subassembly on a stable support surface with an
appropriate height.

10. If no LED is lit any longer:

Remove the lamp power supply from the laser device.
Installing the lamp power 11. Insert the replacement lamp power supply into the laser
supply device, leaving a free space of 5 cm.
12. Simultaneously connect the cooling water hoses.
13. Completely insert the lamp power supply into the housing
and fasten it with screws.
14. Plug the connectors.
Make sure not to confuse the CAN bus connectors.

20-06-12-A2-CR02 2016-01 Lamp power supply 5‐37

Replacing the line contactor

1 Connection for control voltage 2 Connection for switching volt-

age
Fig. 5-37

15. Loosen the locking screws for the switching voltage connec-
tions and pull out the connecting wires (6x).
16. Loosen the locking screws for the control voltage connections
and pull out the connecting wires (2x).

A Diode assembly
Fig. 5-38
17. Remove line contactor from the top-hat rail.
18. Then remove the diode assembly from the line contactor.

5‐38 Lamp power supply 2016-01 20-06-12-A2-CR02

 1 Marking picture
Fig. 5-39
19. Insert the diode assembly into the line contactor from the
replacement kit according to the figure above.
Observe polarity!
20. Put the label of the removed line contactor on the new line
contactor.
21. Place new line contactor on the top-hat rail.
22. Insert the connecting wires for control voltage according to
the labeling into the connections and use the locking screws
to secure them.
Ensure correct assignment of the connecting wires!
23. Insert the connecting wires for switching voltage according to
the labeling into the connections and use the locking screws
to secure them.
Ensure correct assignment of the connecting wires!
24. Close the right front door of the laser device.
The laser device is ready for use.

20-06-12-A2-CR02 2016-01 Lamp power supply 5‐39

 9. Laser cooler

The following service work on the laser cooler can be necessary:

■ Topping up cooling water
■ Changing the cooling water
■ Cleaning the tank
■ Cleaning the particle filter
■ Cleaning the contamination filter
■ Replacing the deionizing filter
■ Checking the cooling unit for tightness
■ Emptying and filling the cooling unit

2
1 3

1 Tank 3 Deionizing filter

2 Stop valve in the return 4 Contamination filter
Fig. 5-40

Bacteria and algae may accumulate in the laser circuit over time,
especially when the laser device is not used for an extended
period of time. To avoid this:
■ Check regularly the quality of the cooling water.
■ Keep the doors and the hood closed.
■ Keep the cover of the tank closed.
■ Empty the cooling unit before a long shutdown of the laser
device.
■ If algae or bacteria slime show up, change the cooling water,
replace the deionization filter and clean the tank.
■ Avoid any contact with contaminated water.

5‐40 Laser cooler 2016-01 20-06-12-A2-CR02

 9.1 Topping up cooling water

Cooling water must be topped up if:

■ a message is indicated on the monitor of the operation panel
stating that the water level in the tank is too low.

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Double-bit key.
■ Water jug.
■ Deionized water.
■ Conductivity < 5 µS.
■ Protective gloves for protection against DI water.

1. Open the left front door of the laser device.

Deionized water (DI water) is used to fill the tank!

CAUTION
Cooling water can be aggressive against skin and textiles.
Ø Do not bring the cooling water in eyes, nose or mouth.
Ø Avoid that cooling water comes into contact with your cloth-
ing.
Ø You can wash off the cooling water with tap water.
Ø Wear protective gloves, protective clothing and safety gog-
gles.

2. Loosen the knurled nut on the tank cover and remove the
cover.

Note
The 100 % mark is placed at the front of the tank. A level
indicator at the back side of the cooling unit shows the water
level in the tank.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐41

 100

Min

Fig. 5-41
3. Top up with DI water until the water level reaches the 100 %
mark.
4. Close the tank cover
5. Close the left front door of the laser device.
The laser device is ready for use

9.2 Replacing the water in the tank

A prolonged exposure of the cooling water to light may cause an

algae growth in the tank, if, for example, the front door of the
laser device remains open for a longer period and the tank cover
is removed. Therefore keep the doors and the tank closed if no
work is to be carried out inside the laser device.
Only replace the cooling water, if it is no longer clear but dim.

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Deionized waterapprox. 25 l
■ Conductivity < 5 µS
■ Protective gloves for protection against DI water
■ Water jug
■ Pan
or
■ Drain in the floor

5‐42 Laser cooler 2016-01 20-06-12-A2-CR02

 ■ upon demand: Filter element in the tank (Material no.
359880)

Preparing the laser device 1. Open the left front door of the laser device.

Emptying the tank

Fig. 5-42

2. Place the collecting pan on the floor in front of the laser

device.

Deionized water (DI water) is used to fill the tank!

CAUTION
Cooling water can be aggressive against skin and textiles.
Ø Do not bring the cooling water in eyes, nose or mouth.
Ø Avoid that cooling water comes into contact with your cloth-
ing.
Ø You can wash off the cooling water with tap water.
Ø Wear protective gloves, protective clothing and safety gog-
gles.

3. Place the hoses with the numbers 1, 2 and 3 in the collect-

ing pan and remove the sealing caps.
The DI water in the tank, the piping, the pumps and the heat
exchanger drains off.
4. Wipe off leaked cooling water with a clean cloth.
5. Clean the tank, if necessary (see "Cleaning the tank, clean-
ing or changing the filter of the tank", pg. 5‐44).
Disposal 6. The water can be disposed of in the sewerage system.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐43

 Filling with cooling water 7. Fill with fresh DI water until the water level reaches the
100 % mark (see "Topping up cooling water", pg. 5‐41).
Ventilating the pump 8. Loosen the vent screw on the pump head. When water
leaks, close the vent screw.
or
If no water emerges, press pump button until water emerges.
Ventilation of the pump is complete.
9. Close the left front door of the laser device.
The laser device is ready for use.

9.3 Cleaning the tank, cleaning or

changing the filter of the tank

If deposits are visible, it may be necessary to clean the tank of

the laser cooler.

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Double-bit key.
■ Tap water as a cleaning agent.
■ Deionized water approx. 25 l.
■ Conductivity < 5 µS.
■ Protective gloves for protection against DI water.
■ clean cloth.
■ upon demand: Filter element in the tank (Material no.
359880)
■ Pan having a capacity of about 25 l.
or
■ Drain in the floor.

Preparation 1. Open the left front door of the laser device.

2. Place the collecting pan on the floor in front of the laser
device.

5‐44 Laser cooler 2016-01 20-06-12-A2-CR02

 Deionized water (DI water) is used to fill the tank!
CAUTION
Cooling water can be aggressive against skin and textiles.
Ø Do not bring the cooling water in eyes, nose or mouth.
Ø Avoid that cooling water comes into contact with your cloth-
ing.
Ø You can wash off the cooling water with tap water.
Ø Wear protective gloves, protective clothing and safety gog-
gles.

Fig. 5-43
3. Place the hoses with the numbers 1, 2 and 3 in the collect-
ing pan and remove the sealing caps.
The DI water in the tank, the piping, the pumps and the heat
exchanger drains off.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐45

 Cleaning the tank

1 Water guiding plate 2 Filter

Fig. 5-44

4. Loosen the knurled nut on the tank cover and remove the
cover.
5. Remove the water guiding plate.
6. Clean the inside of the tank with clean tap water and a cloth.
Do not use cleaning additives.
7. Dry the inside of the tank.
8. Remove the filter of the tank and check if it is soiled.
9. Clean the filter, if necessary.
or
Ø Change the filter if it is damaged.
10. Re-install the water guiding plate.
Filling the tank 11. Fill the tank with water up to the 100 % mark (see "Topping
up cooling water", pg. 5‐41).
Ventilating the pump 12. Loosen the vent screw on the pump head. When water
leaks, close the vent screw.
or
If no water emerges, press pump button until water emerges.
Ventilation of the pump is complete.
Final procedures 13. Switch on the laser device.

5‐46 Laser cooler 2016-01 20-06-12-A2-CR02

 Dangerous electric voltage in the interior of the laser
DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

14. Open the right front door of the laser device.

PUMP

Y_LAS

Y_CAB

Fig. 5-45
15. Press the push-button PUMP several times for 5 seconds.
16. Check the loosenend hose connections for tightness.
17. If necessary:
Top up with DI water until the water level reaches the 100 %
mark.
18. Close the tank cover.
19. Close the front doors of the laser device.
Disposal 20. The water can be disposed of in the sewerage system.
The laser device is ready for use.

9.4 Replacing the deionizing filter

If electrical conductivity exceeds 15 µS, a monitoring message is

displayed. In this case replace deionization filter once the laser
device is stopped next time.
If conductivity of cooling water reaches 25 µS, the laser device
shuts down. You cannot operate the laser device if the conduc-
tivity is higher than 25 µS.
After one year, the deionization filter must be replaced.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐47

 Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Absorbent cloth.
■ Bucket or deep washbasin.
■ Deionized water approx. 0.5 l
■ Conductivity < 5 µS
■ Protective gloves for protection against DI water.
■ Deionizing filter (Material no.1354262)

Note
If the cooling water is cloudy instead of clear, the cooling water
has to be changed as well (see "Replacing the water in the
tank", pg. 5‐42).

Preparing the laser device 1. Open the left front door of the laser device.

Removing the deionizing

filter

1 Hose coupling for the return 2 Hose coupling for the supply
hose hose
Fig. 5-46

5‐48 Laser cooler 2016-01 20-06-12-A2-CR02

 Deionized water (DI water) is used to fill the tank!
CAUTION
Cooling water can be aggressive against skin and textiles.
Ø Do not bring the cooling water in eyes, nose or mouth.
Ø Avoid that cooling water comes into contact with your cloth-
ing.
Ø You can wash off the cooling water with tap water.
Ø Wear protective gloves, protective clothing and safety gog-
gles.

2. Loosen Velcro strap at deionization filter and take the deioni-

zation filter out of the support.

Note
Until the new deionization filter has been installed, the hose
connections to the deionization filter must always stay above
the 100 % mark of the tank, otherwise cooling water drains
out of the hoses.
3. Disconnect the hose in the return (1).
Air gets into the cooling circuit. Water from deionization filter
flows back into the tank.

Note
Hold the deionization filter as horizontally as possible during
the next step, to prevent the DI water from draining out of
the deionization filter.
4. Disconnect the hose in the supply (2).
5. Put the deionization filter into a bucket until the DI water is
completely drained off.
6. Dispose of the deionization filter in the residual waste.
Mounting a new deionizing 7. Connect the hoses for supply (blue) and return (black)
filter according to the label at the new deionization filter.
8. Insert the deionization filter and fasten it with velcro fastener.
9. Switch on the laser device.

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

10. Open the right front door of the laser device.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐49

 PUMP

Y_LAS

Y_CAB

Fig. 5-47
11. Press the push-button PUMP several times for 5 seconds.
12. Check the loosenend hose connections for tightness.
13. Top up with DI water until the water level reaches the 100 %
mark. (see "Topping up cooling water", pg. 5‐41)
14. Close doors.
The laser device is ready for use.

9.5 Cleaning the particle filter

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Double-bit key.
■ Blow-out gunfor compressed air.
■ Cleaning cloth for wiping leaked cooling water.
■ upon demand: (Ersatz-Siebrohr im Partikelfilter (Material no.
765481).

Preparation 1. Open the left front door of the laser device.

5‐50 Laser cooler 2016-01 20-06-12-A2-CR02

 Fig. 5-48
2. Release cap nut of the particle filter with some turns, so that
it cannot be removed yet.
Air gets into the cooling circuits. The DI water flows into the
tank of the laser cooler.

Clean sieve tube

1 Cap nut 3 Sieve tube

2 Sieve cage 4 Supporting ring
Fig. 5-49

3. Unscrew particle filter.

4. Take sieve tube out of sieve cage.
5. Clean sieve tube with compressed air.
6. Clean sieve tube under running water.
7. Re-insert sieve tube into sieve cage.
8. Close sieve cage with supporting ring.
9. Insert particle filter. Tighten cap nut manually.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐51

 Checking the cooling unit
for tightness

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

10. Open the right front door of the laser device.

PUMP

Y_LAS

Y_CAB

Fig. 5-50
11. Press the push-button PUMP several times for 5 seconds.
12. Check cap nut of particle filter regarding impermeability.
Final procedures 13. Close doors.
The laser device is ready for use.

9.6 Cleaning the contamination filter

Condition
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Double-bit key.
■ Fork wrench 30 mm.
■ Cleaning brush
■ Blow-out gun for compressed air.
■ Cleaning cloth for wiping leaked cooling water.
■ upon demand:
Spare sieve for contamination filter. (Material no. 1445470).

5‐52 Laser cooler 2016-01 20-06-12-A2-CR02

 1. Shut off the in-house water connections in the supply and
return of the external cooling circuit.
2. Reduce pressure in hoses to the domestic water connection.
3. Remove the left side panel of the laser device.

30 mm

Fig. 5-51
4. Slowly loosen the filter insert in the contamination filter.
If external circuit is still under pressure, now a small amount
of water may escape that may be absorbed with a floor cloth.

WS-00035
Fig. 5-52
5. Unscrew filter element.
6. Blow out filter element with compressed air.
7. Clean filter elements under flowing water and with a soft
brush.
8. Screw in and tighten filter element again.
9. Open domestic water connections at inlet and outlet of exter-
nal cooling circuit.
10. Check dirt arrester regarding impermeability. If leaky,
retighten filter element, replace filter element if necessary.
11. Attach the left side panel of the laser device.
The laser device is ready for use.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐53

 9.7 Checking the cooling unit for
tightness

Conditions
■ The laser device has been turned on.
■ The external cooling circuit is connected and supplied with
the working pressure of the cooling water.

Means, Tools, Materials

■ Double-bit key

1. Open the hood of the laser device.

2. Open the left front door of the laser device.

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

3. Open the right front door of the laser device.

PUMP

Y_LAS

Y_CAB

Fig. 5-53
4. Press the button PUMP for 1 minute.
The pump pumps DI water through the cooling circuit.
5. Observe all the components, hoses and tubes of the DI
water circuit while the pump is working.

5‐54 Laser cooler 2016-01 20-06-12-A2-CR02

 PUMP

Y_LAS

Y_CAB

Fig. 5-54
6. Press the pushbuttons to activate the solenoid valves
(arrows) one by one for approx. 1 minute.
7. If DI water leaks, even in a small quantity, find the leaky
point and seal it, for example:
− Seal the hose connections
− Fasten the sealing clamps
− Fasten the spigot nuts.
8. If a part that contains or supplies water is damaged:
Informing the TRUMPF service department.
9. Wipe off leaked cooling water with a clean cloth.
10. Close the cover of the laser device.
11. Close the left front door of the laser device.
12. Close the right front door of the laser device.
The laser device is ready for use.

9.8 Checking the solenoid valve

Condition
■ The laser device has been turned on.

Means, Tools, Materials

■ Double-bit key

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐55

 1. Open the right front door of the laser device.

PUMP

Y_LAS

Y_CAB

Fig. 5-55
2. Press push-buttons for the activation of the solenoid valves
(arrows) alternatingly.
When pressing a push-button, the switching sound of the sol-
enoid valve must be audible.
3. If no switching sounds are audible:
Informing the TRUMPF service department

9.9 Emptying and filling the cooling unit

Emptying the cooling unit of the laser

device

All tanks and hoses, filled with water while operating the laser
device, must be emptied completely in the following situations:
■ before transport or storage of the laser device at low temper-
atures (danger of frost)
■ in case of transport by aircraft
■ before a long shutdown of the laser device (several weeks).

Conditions
■ Laser device has been switched off and protected against
restart.
■ The laser device has to be connected to the power supply
system.

Means, Tools, Materials

■ Double-bit key.
■ Hexagon screwdriver, 4 mm.
■ Fork wrench, 30 mm.
■ Cloth to wipe up drained off cooling water.

5‐56 Laser cooler 2016-01 20-06-12-A2-CR02

 ■ Protective gloves for protection against DI water.
■ Pan for collecting the cooling water.

Note
It is advantageous to have a drain in the floor near the laser
device through which the water runs into the sewerage system. If
not, you will need a suitable collecting pan.

Preparation 1. Open the hood of the laser device.

2. Open the left front door of the laser device.
3. Open the right front door of the laser device.
4. Remove the cover from the left side of the laser device.
Emptying the external 5. Shut off the in-house water connections in the supply and
cooling circuit return of the external cooling circuit.
6. Place a pan or an absorbent cloth under the cooling water
connections.

Fig. 5-56
7. Removing the cooling water hoses
The cooling water drains off.

Fig. 5-57
8. Remove the sealing caps from hoses numbers 5 and 6.
Air enters the external cooling circuit. The remaining cooling
water drains out of the cooling water connections. The sole-
noid valves are open.
9. Blow air through the external cooling circuit.
10. If no more water comes out of the cooling water connections:

20-06-12-A2-CR02 2016-01 Laser cooler 5‐57

 Re-attach the sealing caps.

Cleaning the contamination

30 mm
filter

Fig. 5-58
11. Cleaning the contamination filter(see "Cleaning the contami-
nation filter", pg. 5‐52).

Emptying the laser circuit

Fig. 5-59
12. Pull out the sealing plug at the cooling water distributor to
the focusing optics (2x).
Air gets into the cooling circuits. The DI water flows into the
tank of the laser cooler.

5‐58 Laser cooler 2016-01 20-06-12-A2-CR02

 Fig. 5-60
13. Place the collecting pan on the floor in front of the laser
device.

Deionized water (DI water) is used to fill the tank!

CAUTION
Cooling water can be aggressive against skin and textiles.
Ø Do not bring the cooling water in eyes, nose or mouth.
Ø Avoid that cooling water comes into contact with your cloth-
ing.
Ø You can wash off the cooling water with tap water.
Ø Wear protective gloves, protective clothing and safety gog-
gles.

14. Place the hoses with the numbers 1 to 4 in the collecting

pan and remove the sealing cap.
The DI water in the tank, the piping, the pumps and the heat
exchanger drains off.
Note
Leave the hoses in the pan.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐59

 Removing the deionizing
filter

1 Hose coupling for the return 2 Hose coupling for the supply
hose hose
Fig. 5-61

15. Loosen Velcro strap at deionization filter and take the deioni-
zation filter out of the support.
16. Disconnect the hose in the return (1). Let the DI water that
drains from the hose flow into the collecting pan.
17. Disconnect the hose in the supply (2). Let the DI water that
drains from the hose flow into the collecting pan.
18. Put the deionization filter into a bucket until the DI water is
completely drained off.

5‐60 Laser cooler 2016-01 20-06-12-A2-CR02

 Cleaning the particle filter

Fig. 5-62
19. Clean the particle filter (see "Cleaning the particle filter",
pg. 5‐50).

Emptying the lamp cover

supply

Fig. 5-63

20-06-12-A2-CR02 2016-01 Laser cooler 5‐61

 Dangerous electric voltage in the interior of the laser
DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

20. Unscrew the fastening screws (4x) at the lamp power supply.
21. Pull out the lamp power supply by about 5 cm.
22. Remove both cooling water connections from the lamp power
supply.
23. Remove both cooling water connections from the hoses and
let the water drain out of the hoses.
24. Wipe off leaked cooling water with a clean cloth.
25. Blow air through the lamp power supply
26. When no DI water runs out any longer:
− Reattach both cooling water connections.
− Plug the cooling water connections again into the lamp
power supply.
− Re-install the lamp power supply.
The lamp power supply is dewatered.
Final procedures 27. Re-insert the deionization filter and connect it.
28. Attach the plug on the cooling water distributor to the focus-
ing optics.
29. Mount the side wall, close the hood and the doors.
30. Attach the sealing caps on the hoses with the numbers 1 to
5 and stow the hoses in the laser device.
31. The water can be disposed of in the sewerage system.
This completes the emptying of the laser device.

Filling the cooling unit

Conditions
■ The laser device has to be connected to the power supply
system.
■ External cooling water lines are connected.
■ Laser device has been switched off and protected against
restart.

Means, Tools, Materials

■ Deionized water, approx. 25 l
■ Conductivity < 5 µS.

5‐62 Laser cooler 2016-01 20-06-12-A2-CR02

 ■ Protective gloves for protection against DI water.
■ Fork wrench, 9 mm.

Preparation 1. Open the left front door of the laser device.

2. Remove the left side panel of the laser device.
3. Open the hood.

Checking connections 1

2
3
4
5
6

1 Plug on the cooling water dis- 4 Drain hoses (6x)

tributor to the focusing optics 5 Connections at the lamp power
2 Stop valve in the return supply
3 Connections on the deionization 6 Contamination filter
filter
Fig. 5-64

Note
When the laser device was emptied, connections were dis-
connected. This is why all connections that were discon-
nected must be checked before filling the cooling unit.
4. Check whether the following connections are complete and
connected or closed correctly:

20-06-12-A2-CR02 2016-01 Laser cooler 5‐63

 Filling the laser circuit

100

Min

Fig. 5-65

Deionized water (DI water) is used to fill the tank!

CAUTION
Cooling water can be aggressive against skin and textiles.
Ø Do not bring the cooling water in eyes, nose or mouth.
Ø Avoid that cooling water comes into contact with your cloth-
ing.
Ø You can wash off the cooling water with tap water.
Ø Wear protective gloves, protective clothing and safety gog-
gles.

5. Loosen the knurled nut on the tank cover and remove the
cover.

Note
The 100 % mark is placed at the front of the tank. A level
indicator at the back side of the cooling unit shows the water
level in the tank.
6. Top up with DI water until the water level reaches the 100 %
mark.
Ventilating the pump 7. Loosen the vent screw on the pump head. When water
leaks, close the vent screw.
or
If no water emerges, press pump button until water emerges.
Ventilation of the pump is complete.

5‐64 Laser cooler 2016-01 20-06-12-A2-CR02

 Check for impermeability

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

8. Turn the main switch of the laser device to position ON.

9. Turn on control unit on the control panel.

PUMP

Y_LAS

Y_CAB

Fig. 5-66
10. Press the push-button PUMP several times for 5 seconds.
DI water flows through the filters and through the pump units.
11. Check the connections for leaks.

Topping up DI water Note

The filling of the cooled components has caused the water
level in the tank to drop. If the water level has fallen below
the 100 % mark, DI water has to be topped up.
12. Top up with DI water until the water level reaches the 100 %
mark.
13. Close the tank cover.
14. Close the left front door of the laser device.
15. Close the cover of the laser device.
Filling the external circuit 16. Open the domestic water connections at the supply and
return of the external cooling circuit.
Water flows into the external circuit.

20-06-12-A2-CR02 2016-01 Laser cooler 5‐65

 30 mm

Fig. 5-67
17. Check contamination filter for leaks.
18. Attach the left side panel of the laser device.
The internal and external circuits are full.
The laser device is ready for use.

5‐66 Laser cooler 2016-01 20-06-12-A2-CR02

 10. Electrical system

Maintenance work of the electrical system confines itself to

changing fuses or switching on the automatic circuit breakers
when they are disconnected due to a malfunction.
A blown fuse has to be changed. A circuit breaker that has
become disconnected must be switched on again. This is indi-
cated by the failure of partial functions or through corresponding
messages on the operating panel.

10.1 Identifying blown electrical fuses

Conditions
■ The laser device has to be connected to the power supply
system.
■ The mains switch of the laser device must be in position ON.
■ The control of the laser device is switched on.

Means, Tools, Materials

■ Double-bit key

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Before touching electric parts, first check if they are de-ener-
gized.

Preparing the laser device 1. Open the right front door of the laser device.

20-06-12-A2-CR02 2016-01 Electrical system 5‐67

 You obtain access to the mains distribution.

1 Automatic circuit breakers 2 Microfuses

Fig. 5-68

Determining a burnt-out
microfuse

F1 F2

F3 F4

F5 F6

F7 F8

Fig. 5-69
2. Check the LEDs on the PSB board.

LED to fuse Function

F1 Control board mains distribution
F2 Modem/switch
F3 Laser control unit/central processor
F4 (only lit with optionally installed programmable focusing
optics)
F5 Fan slide-in control module
F6 Cabinet fan 1
F7 Lamp power supply
Diode power supply
F8 Cabinet fan 2
Tab. 5-5

LEDs of the intact fuses are lit when a consumer is con-

nected.

5‐68 Electrical system 2016-01 20-06-12-A2-CR02

 If one of the LEDs is not lit, the corresponding fuse is defec-
tive.
3. Turn the laser device off.
Identify the blown automatic 4. A blown automatic circuit breaker can be identified by the
circuit breaker green display above the black lever of the circuit breaker.

10.2 Replacing a microfuse

Conditions
■ The burnt-out microfuse has to be identified.(see "Identifying
blown electrical fuses ", pg. 5‐67)
■ Laser device has been switched off and protected against
restart.

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø The laser must be switched off when fuses are changed.

1. Pull out the burnt-out fuse.

2. Eliminate the cause of the microfuse blowing. Otherwise, it
may occur that the replaced microfuse will blow again when
the device is switched on again.

Note
The replacement fuse must have correct current and fusing
properties. A list with the values of the fuses is attached to
the cover sheet near the microfuses.
3. Replace the microfuse by a new microfuse of the same type
(current and fusing properties).
4. Switch on the laser device.
5. Check LEDs
6. If other LEDs are not lit, replace also the corresponding
microfuse.
7. Close the right front door of the laser device.
The laser device is ready for use.

20-06-12-A2-CR02 2016-01 Electrical system 5‐69

 10.3 Activating an automatic circuit
breaker

Conditions
■ The blown automatic circuit breaker must be identified (see
"Identifying blown electrical fuses ", pg. 5‐67).
■ Laser device has been switched off and protected against
restart.

Dangerous electric voltage in the interior of the laser

DANGER device!
Touching live electric parts can be extremely dangerous.
Ø Circuit breakers may be switched on only while the device is
turned off.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.

Fig. 5-70

1. Eliminate the cause of the automatic circuit breaker blowing.

Otherwise, it may occur that it will blow again as soon as the
device is switched on.
2. Move the black lever of the blown automatic circuit breaker
upwards.
The color of the display changes from green to red.
3. Close the right front door of the laser device.
The laser device is ready for use.

5‐70 Electrical system 2016-01 20-06-12-A2-CR02

 11. Operating panel

11.1 Clean the screen of the operating

panel

Means, Tools, Materials

■ Soft cloth
■ Neutral cleaning agent
or
■ alcohol

WS-76099
Fig. 5-71

Ø Clean the screen with a soft cloth.

or
Ø in case of heavy soiling, humidify the cloth with neutral
cleaning agent or alcohol.

20-06-12-A2-CR02 2016-01 Operating panel 5‐71

5‐72 Operating panel 2016-01 20-06-12-A2-CR02
 Chapter 6

Conduct in case of service

interruptions

1 Service interruptions 6‐2

1.1 Measures in case of service interruptions 6‐2

2 Identifying causes 6‐3

3 Monitoring and faults 6‐4

3.1 Monitoring 6‐4
3.2 Fault 6‐5

4 Dealing with messages 6‐7

4.1 Structure of a message 6‐7
4.2 Message history 6‐9
Displaying the history of messages 6‐9
Setting the message filter 6‐9
Searching for a message 6‐10
Type of message 6‐12

20-06-12-A2-CR02 2016-01 Conduct in case of service interruptions 6‐1

 1. Service interruptions

TRUMPF laser devices are equipped with extensive monitoring

functions that ensure reliable operation. In case of anomalies
from normal operation, messages are displayed which indicate
necessary measures, if possible.
However, during operation of the laser device, events may occur
which cause service interruptions. In this case, the causes of the
service interruption must be eliminated before operation can be
continued.

1.1 Measures in case of service

interruptions

Work on the laser device might bear risks for you or others.
DANGER
If such risks are not avoided, they can lead to death,
serious injuries or considerable damage to property.
Ø Causes for service interruptions may only be remedied by
persons who are sufficiently familiar with the laser device.
Ø Switch off laser device and secure it against being switched
on again, if it is not absolutely necessary to switch it on.
Ø Before touching parts which are live during operation, check
whether they are dead.
Ø Wear personal protective equipment if required for the corre-
sponding action (e.g. laser safety goggles, safety gloves).
Ø Observe the safety instructions and warnings of these oper-
ating instructions and of other documents.

1. Identify the cause of the service interruption.

2. Carry out recommended measures according to the instruc-
tions of the manual, if applicable.
Contact the TRUMPF service department if you cannot
find or eliminate the cause. Indicate the following:

Ø Number of the displayed message.

Ø The events which lead to the service interruption.

The TRUMPF service department will carry out all necessary

work in order to allow you to operate the laser device as soon
as possible.

6‐2 Service interruptions 2016-01 20-06-12-A2-CR02

 2. Identifying causes

Different factors outside and inside the laser device can be taken
into consideration as causes for service interruptions. Before tak-
ing measures, you should know as much as possible about the
cause of service interruption.

Causes of a service interruption may be the following, e.g.:

■ Unsatisfactory machining results due to:
− Defective workpieces
− Soiled protective glasses of the focusing optics.
■ Errors in programs:
− Pulse shapes..
− laser programs.
− Light paths..
− Sequential programs in the external controls (PLC etc.).
■ Error in wiring of interfaces in case of external control of the
laser device.
■ Operating error
■ Malfunctions in the laser device
Having identified the cause, take appropriate measures to elimi-
nate it. Please contact the customer service of TRUMPF if you
need assistance.

20-06-12-A2-CR02 2016-01 Identifying causes 6‐3

 3. Monitoring and faults

3.1 Monitoring

Numerous operational values of the laser device are monitored.

Examples:
■ Laser power.
■ Position of the switch mirrors and shutter mirrors
■ Temperature and flow of the cooling water
The operational values are constantly measured and compared
to nominal values or limit values. If an operational value is out-
side the permissible range, the control unit of the laser device
generates a monitoring message.

Monitoring message The yellow display "Monitoring" is illuminated in the main dialog
of TruControl 1000.

Fig. 6-1

1 “Monitoring” sign 3 Message code

2 Reporting subassembly 4 Short message text
Monitoring message is displayed Fig. 6-2

Reporting subassembly Subassembly (board) of the control unit that generates the mes-
sage.

"Monitoring" sign The symbol indicates a monitoring message in the tool bar.

6‐4 Monitoring and faults 2016-01 20-06-12-A2-CR02

 There is another symbol which belongs to the category of moni-
toring messages:

Symbol Category Meaning

Light path monitoring Work can continue.

Tab. 6-1

Message code Via the display of the message memory it is possible to call up
the message text:
⇒ Select the main activity Diagnostics.
The message stack is displayed.

Short message text The short text gives the operator one-line information on the
cause of the message.

Note
When a monitoring is displayed you can still operate the laser
device. You should eliminate the cause at the next opportunity. If
you do not remedy the cause, it may be possible that a moni-
tored operational value exceeds the fault limit in the near future
(see section Fault).
In case of a fault you can only continue to operate the laser
device, when the cause is eliminated..

3.2 Fault

When a monitored operational value is far outside the permissi-

ble range, a critical condition will probably have been reached
which does not allow the operation of the laser device to be con-
tinued. This is why fault limits are set which the operational val-
ues are compared to.

If an operational value exceeds a fault limit:

■ The laser is switched off automatically.
■ a fault message is displayed on the screen.

Fault message The red display "Fault" is illuminated in the main dialog of Tru-
Control 1000.

20-06-12-A2-CR02 2016-01 Monitoring and faults 6‐5

 Fig. 6-3

1 “Fault” sign 3 Message code

2 Reporting subassembly 4 Short message text
A fault message is displayed Fig. 6-4

There is another symbol which belongs to the category of fault

messages:

Symbol Category Meaning

Light path fault Light path is blocked.

Tab. 6-2

Note
In case of malfunction, the laser device cannot be operated until
the cause of the malfunction has been eliminated and the laser
device has been reset. For more information on this, please refer
to the section “How to respond to messages” in chapter "Opera-
tion".

6‐6 Monitoring and faults 2016-01 20-06-12-A2-CR02

 4. Dealing with messages

4.1 Structure of a message

In order to display a text message:

Displaying a message text 1. Select the main activity Diagnostics.

2. Call messages using .
Active messages are displayed.

Displaying a message text Fig. 6-5

3. Mark the message (1).
4. Select Show (2).
The following display appears on the monitor:

20-06-12-A2-CR02 2016-01 Dealing with messages 6‐7

1 Date, time, message code, 3 Message text 5 Scroll bar
board 4 Number of causes 6 Context bar
2 Short text of the message
Fig. 6-6

Display
Date and time when the message occurred is displayed (1).
Additionally, the message code and the name of the board
that has created the message are displayed.
Short text
The short text (2) is the same as in the main dialog of Tru-
Control 1000.
Text message
The text message (3) consists of cause, effect and measure.
The Effect describes the effect of the reported state on the
laser device. A specific Measure belongs to each Cause. An
effect may have several causes. One of these causes is indi-
cated in this area. With the Next cause button, all the causes
can be displayed in succession. The Details contain informa-
tion for the TRUMPF service department. Details can be
called with a user level ≥ 70.
Scroll bar
Use the scroll bar (5) to scroll the text message vertically if it
is too long to be displayed in the display window.
Display of the causes
Display of the number of possible causes for a message (4).

6‐8 Dealing with messages 2016-01 20-06-12-A2-CR02

 4.2 Message history

All messages are entered in a message history so that they can

still be read even after resetting the laser device. This function is
useful for diagnostic purposes.

Displaying the history of messages

1. Select the main activity Diagnostics.

2. Call messages using .

Fig. 6-7
3. Call message history using the Show history button.
The history of messages is displayed.

Setting the message filter

1. Select the main activity Diagnostics.

2. Call messages using .
Active messages are displayed.
3. Select Change filter.
The filter settings are displayed.

20-06-12-A2-CR02 2016-01 Dealing with messages 6‐9

 Message filter Fig. 6-8
4. Tick the check boxes for the message types to be displayed
in the message list.
5. Select Apply.
The filter settings are displayed.

Searching for a message

There are Expert dialogs in all secondary operations of the main

operation Diagnostics. Expert dialogs contain extended dialogs
for diagnostics purposes for the TRUMPF service or for trained
users of the laser devices.
In extended diagnostics dialogs, the buttons for laser operation
and function activation/deactivation are only active starting from
user level ≥ 70.
Expert dialogs are loaded by pressing the Expert dialogs button.

1. Select the main activity Diagnostics.

2. Call messages using .

6‐10 Dealing with messages 2016-01 20-06-12-A2-CR02

 RP-00183
Expert dialog button Fig. 6-9
3. Select Expert dialog.
The Search message text dialog box is opened.
4. Enter the message code and select Search.
The message is displayed.

20-06-12-A2-CR02 2016-01 Dealing with messages 6‐11

 Type of message

The categories are marked with symbols.

Symbol Category Meaning

Fault Laser is switched off.
Message must be acknowledged by
means of Reset.
Monitoring Work can continue.
Message must be acknowledged by
means of Reset.
Light path fault Light path is blocked.
Must be acknowledged by means of
Reset light path or Reset laser.
Light path monitoring Work can continue.
Must be acknowledged by means of
Reset light path or Reset laser.
Maintenance Maintenance work must be carried
out.

Information Information message (status in the

laser device changed.)

Logbook A change in configuration has been

made (for example, a laser program
has been transmitted).
Tab. 6-3

6‐12 Dealing with messages 2016-01 20-06-12-A2-CR02