EU Declaration of Conformity

in accordance with
EC Machinery Directive 2006/42/EC
Directive relating to electromagnetic compatibility 2014/30/EU

We hereby declare that the following machine complies with all the relevant requirements of the EU directives
listed above.

Machine type: TruBend XXXX (B23)

Machine designation: Hydraulic press brake

Machine No.: B15XXIXXXX

Applied harmonized EN ISO 12100:2010, EN 60204-1:2006/A1:2009,

standards, in particular: EN 50370-1:2005, EN 50370-2:2003, EN ISO 13849-1:2015

Notified body: TÜV AUSTRIA SERVICES GmbH

Deutschstrasse 10, A-1230 Wien / Austria
Identification No.: 0408

Certificate number:
TÜV-A/MHF/MG/14/02427

Party authorized to compile

the technical file: Armin Rau

This declaration shall lose its validity if any changes are made to the machine without our authorization.

Town / Date / Signature Pasching, 24.07.2018

Armin Rau
President

TRUMPF Maschinen Austria GmbH + Co. KG

Industriepark 24 Phone +43 (0) 7221 603-0 info@[Link] TAT483la
4061 Pasching, Austria Fax +43 (0) 7221 603-42050 [Link] V 2016 - 04

en
 Operator's manual

TruBend Series 5000 (B23)

Operator's manual

TruBend Series 5000 (B23)

Original operator's manual

Edition 2019-05-18
 Order Information Please specify when ordering this document:
Operator's manual
TruBend Series 5000 (B23)
Edition 2019-05-18
Document number B876en

TRUMPF Maschinen Austria GmbH + Co. KG

Address for orders Technische Redaktion
Industriepark 24
A-4061 Pasching
Fon: +43 7221 603 - 0
Fax: +43 7221 603 - 50
Internet: [Link]
E-Mail: tat@[Link]

For "partly completed machinery" in accordance with the EC

Machinery Directive, this document corresponds to the
assembly instructions.

© TRUMPF Maschinen Austria GmbH + Co. KG

 Table of contents

Chapter 1 Safety

1 For your safety 1‐3

2 Operational safety 1‐5

2.1 Intended use 1‐5
2.2 Authorized personnel 1‐6

3 Hazards 1‐7
3.1 Dangers due to the open electrical cabinet 1‐7
3.2 Hazards due to laser radiation 1‐7
3.3 Dangers handling workpieces 1‐8
Sharp-edged workpieces 1‐8
Upper and lower tool 1‐8
Side of the workpiece 1‐9
Position the workpiece 1‐10
Falling workpieces 1‐11
Improper handling of flat workpieces 1‐11
Improper handling when bending boxes 1‐12
3.4 Dangers due to unexpected movements 1‐12
3.5 Dangers when using the bending aid (option) 1‐13
3.6 Dangers when using a bending foil 1‐15
3.7 Dangers when operating a robot 1‐15
3.8 Noise hazards 1‐16
3.9 Risks due to remote support 1‐16

4 Measures to be taken by the manufacturer 1‐17

4.1 Danger zones and safeguarding device 1‐17
4.2 Warning signs at the machine 1‐23
Additional warning signs in the USA and 1‐26
Canada
Warning sign on the bending aid (optional) 1‐27

B876en 2019-05-18 Table of contents 0‐1

 5 Organizational measures to be taken by 1‐29
the user
5.1 Observe warnings and warning signs 1‐29
5.2 Training and instructing operators 1‐29
Measures applicable worldwide 1‐29
5.3 Adhering to the duty of care when handling 1‐29
the machine
5.4 Water protection 1‐31
5.5 Spare parts, accessories, software, operating 1‐32
materials
5.6 Safety data sheet on hazardous materials 1‐32

6 Overview of residual risks 1‐33

7 Disassembly and disposal 1‐35

Chapter 2 TruBend Series 5000 (B23)

installation conditions

Who does what? 2‐3

1 Planning aid 2‐4

2 Installation site 2‐6

2.1 Space requirements 2‐6
2.2 Floor requirements 2‐7
Surface 2‐7
Floor quality 2‐9
2.3 Weight load 2‐11
2.4 Stress due to vibration 2‐13
2.5 Ambient conditions 2‐13

3 Compressed air supply 2‐15

4 Electrics 2‐17
4.1 Power supply 2‐17
Connected loads 2‐17
Connecting cables 2‐19

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 4.2 Power supply 2‐20
Uninterruptible Power Supply (UPS) 2‐20
Residual current device (RCD) 2‐20
Power supply configurations 2‐22
Isolating transformer 2‐23
4.3 Remote support 2‐23
4.4 Cloud connection 2‐24
4.5 Network link 2‐24

5 Operating materials 2‐25

5.1 Hydraulic oil 2‐25

6 Transport 2‐26
6.1 Preparing transport 2‐26
Transport dimensions 2‐26
6.2 Permitted auxiliary tools 2‐27
ToolMaster (option): Permitted auxiliary 2‐28
tools
6.3 Checking, unloading and transporting the 2‐30
machine
On delivery: check the machine 2‐30
Unloading and transporting the machine 2‐30
ToolMaster (option): Unloading and trans- 2‐33
porting the machine

Chapter 3 Description

1 Machine concept 3‐4

2 Machine axes 3‐5

2.1 Bending aid axes (option) 3‐6
2.2 Press beam inclination 3‐7

3 The most important assemblies 3‐8

3.1 Machine Frame 3‐9
3.2 Side safety doors 3‐10
3.3 On-demand servo drive with 4-cylinder equip- 3‐11
ment

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 3.4 Crowning 3‐12
Manual wedge crowning 3‐13
CNC-controlled wedge crowning (option) 3‐13
3.5 Backgauge 3‐13
2-axis backgauge 3‐14
4-axes backgauge (option) 3‐15
5-axes backgauge (option) 3‐15
6-axes backgauge (option) 3‐16
Additional backgauge fingers (option) 3‐17
3.6 Tool clamping 3‐17
Manual upper tool clamp 3‐18
Hydraulic upper tool clamp (option) 3‐19
Hydraulic lower tool clamp 3‐19
3.7 BendGuard (option) 3‐20
Increased working speed at maximum 3‐21
press force (option)
Manual BendGuard (option) 3‐22
Automatic BendGuard (option) 3‐22
3.8 Control system 3‐23
Operation panel with touchscreen 3‐23
Additional screen (option) 3‐24
Graphical shop floor programming 3‐25
Shop floor programming TecZone Bend 3‐26
(option)
3.9 Lower tool displacement (I axis) 3‐27
Pneumatic I axis 3‐27
CNC controlled I axis (Option) 3‐28
3.10 MobileControl 3‐28
3.11 MobileControl Pro (option) 3‐29
3.12 Wireless foot switch (option) 3‐30
3.13 MagicShoe (option) 3‐31
Notes on use 3‐32
Notes on maintenance 3‐34
3.14 Work area illumination (option) 3‐34
3.15 ACB laser optical angle measuring system 3‐35
(option)
3.16 Tactile ACB Wireless angle measuring sys- 3‐37
tem (option)
3.17 Angle measuring system ACB (option) 3‐40
3.18 Sheet thickness detection TCB (option) 3‐42
3.19 Angle measuring system OCB (option) 3‐44

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 3.20 Optical set up and positioning aid Tool Indica- 3‐44
tor (option)
3.21 Part Indicator insertion aid (option) 3‐45
3.22 2D code scanner (option) 3‐46
3.23 Simple support bracket (only in the area of 3‐47
application of the EC Machinery Directive)
3.24 Support bracket (option) 3‐48
Parking position for bending aid/support 3‐49
bracket (option)
Table length and table width extension 3‐50
3.25 Bending aid (option) 3‐51
Bending aid (option) 3‐52
Parking position for bending aid/support 3‐53
bracket (option)
3.26 Network connection 3‐54
3.27 Interfaces for robot (optional) 3‐54
3.28 MyTRUMPF customer portal 3‐54
3.29 Tool changer ToolMaster (option) 3‐55

4 Industry 4.0 with TruConnect 3‐57

4.1 What is Industry 4.0 at TRUMPF? 3‐57
4.2 Production overview 3‐57
4.3 Production control 3‐58
4.4 Connectivity 3‐59
4.5 Remote support 3‐60
4.6 TRUMPF machine apps 3‐60

5 Tools from TRUMPF 3‐62

6 Technical data 3‐65

Chapter 4 Operation

1 Description of the operating elements 4‐5

1.1 Operating panel 4‐5
User interface layout 4‐6
General notes on operation 4‐6
Status displays at the user interface 4‐8

B876en 2019-05-18 Table of contents 0‐5

 Auxiliary systems at the user interface 4‐11
Operating elements on the additional 4‐11
screen (option)
1.2 MobileControl 4‐12
Use MobileControl 4‐12
1.3 MobileControl Pro (option) 4‐13
Use MobileControl Pro 4‐13
Select/adjust parameter 4‐14
1.4 Foot switch 4‐14
1.5 Wireless foot switch (option) 4‐16
Using wireless foot switch 4‐19
1.6 MagicShoe (option) 4‐19
Use MagicShoe 4‐23
1.7 Operating elements on the rear side of the 4‐26
machine
ROBOT-MODE (option) key switch 4‐26
1.8 Side safety doors 4‐27

2 Switching on the machine 4‐28

2.1 Unlock EMERGENCY STOP 4‐28
2.2 Switching on the machine 4‐28

3 Switching off the machine 4‐31

3.1 Switching off the machine in the case of mal- 4‐31
functions
3.2 Switching off the machine 4‐31

4 What to do in an emergency and in case 4‐32

of a malfunction
4.1 Rescuing trapped persons 4‐32

5 Operating modes of the machine 4‐33

6 BendGuard (option) 4‐34

6.1 Manual BendGuard (option) 4‐34
Setting the working height 4‐34
6.2 Automatic BendGuard (option) 4‐36
Setting the setup/work position 4‐36
Automatic BendGuard (option): Setting 4‐36
the working height
6.3 Running the Tool Align function 4‐37
6.4 Selecting protect mode 4‐40

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 6.5 Disabling BendGuard (option) 4‐41
6.6 Define the mute point with check plates 4‐42

7 Manual operation 4‐44

7.1 Programming individual bends 4‐44
7.2 Producing individual bendings 4‐53

8 Program special functions (Manual opera- 4‐54

tion/Program)
8.1 Programming an increased working speed 4‐54
(option)
8.2 Programming fast folding (for BendGuard, 4‐55
option)
8.3 Programming a bend with ACB (option) 4‐57
8.4 Programming a bend with ACB Wireless 4‐58
(option)
8.5 Programming a bend with ACB Laser (option) 4‐59
8.6 Sheet thickness detection TCB (option) 4‐59
Programming individual bend with TCB 4‐60
(Option) (Manual operation)
Programming bending program with TCB 4‐60
(option) (Programming)
Programming learned bending with TCB 4‐61
(option) (Programming)

9 Programming 4‐62
9.1 Creating programs numerically 4‐62
9.2 Creating programs graphically with 4‐63
BendGraph
Change to BendGraph 4‐65
Creating a program 4‐65
Creating profile 4‐66
Deleting profile 4‐68
Modifying profile 4‐68
Create unfolding 4‐69
Returning to the user interface 4‐70
9.3 Programming tool stations 4‐70

10 Production 4‐71
10.1 Loading program 4‐71
10.2 Displaying a setup plan 4‐71
10.3 Producing a part 4‐72
10.4 Producing a part with ACB Speed 4‐72

B876en 2019-05-18 Table of contents 0‐7

 10.5 Producing a bend with fast folding 4‐73
10.6 Use bending aid 4‐74
10.7 Entering local corrections in the bending step 4‐76
10.8 Entering global corrections in the program 4‐76
10.9 Using the Part Indicator insertion aid (option) 4‐77

11 Technology 4‐79
11.1 Configuring the ID card (RFID) 4‐79
11.2 Configuring the remote connection 4‐80

12 Angle measuring system OCB (option) 4‐81

12.1 Using the angle-measuring system OCB 4‐81

13 Online Update Manager 4‐83

13.1 Call up Online Update Manager (on 4‐83
machines with TOSh)
13.2 Switch off Online Update function 4‐84

14 Help in case of problems 4‐85

14.1 Automatically calculated press force too high 4‐85
Checking the calculated press force 4‐85
14.2 Activate remote support 4‐86
14.3 The date and time are lost 4‐87

15 ToolMaster (option) 4‐88

15.1 Checking the tool inventory in the ToolMaster 4‐88
15.2 Transferring the setup plan to ToolMaster 4‐88
15.3 Importing the tool inventory of the 4‐88
ToolMaster onto the press brake
15.4 Transferring the tool inventory of the 4‐89
ToolMaster to the press brake
15.5 Setting a tool inventory in the ToolMaster 4‐89

0‐8 Table of contents 2019-05-18 B876en

 Chapter 5 Setting work

1 Backgauge Finger 5‐2

1.1 4-axes backgauge (option): Positioning addi- 5‐2
tional backgauge fingers
1.2 With 2-axis backgauge: move backgauge fin- 5‐2
gers manually

2 Tooling 5‐4
2.1 For a manual tool clamp: set up upper tools 5‐4
2.2 Hydraulic tool clamp (option): Set up the 5‐5
upper tool
2.3 Hydraulic tool clamp (option): Set up lower 5‐6
tool

3 BendGuard (option) 5‐8

3.1 Checking and setting BendGuard 5‐8

4 Tactile ACB Wireless angle measuring 5‐17

system (option)
4.1 Calibrating the sensor tool 5‐17

Chapter 6 Maintenance

1 Information on maintenance 6‐7

1.1 Replace safety-relevant parts of the controls 6‐9

2 Maintenance Overview 6‐10

3 Lubrication 6‐16
3.1 Overview 6‐16
3.2 Press Beam 6‐21
Clean and lubricate guide rails (Y axis) 6‐21
Lubricate (Y axis) guide rollers 6‐22
3.3 Backgauge 6‐24

B876en 2019-05-18 Table of contents 0‐9

 For 2 axis backgauge: grease clamping 6‐24
plate on the backgauge finger
For 2, 4 and 5 axis backgauge: grease 6‐25
the rack (X axis)
Lubricate the ball screw (R axis) 6‐25
For 2, 4 and 5 axis backgauge: grease 6‐26
the guide carriage (R axis)
For 6-axis backgauge: lubricate the guide 6‐27
carriage (R axis)
For 4-axis and 5-axis backgauge: Clean 6‐29
guide rail (Z axis)/Lubricate guide car-
riage (Z axis)
For 2-, 4- and 5-axis backgauge: Clean- 6‐30
ing guide rail (X axis)/Lubricating guide
carriage (X axis)
3.4 6 axes backgauge (option): central lubrication 6‐31
Check filling level 6‐31
3.5 Table plate for press table 6‐32
Cleaning and lubricating the table plate of 6‐32
the press table
3.6 Pneumatic I axis 6‐33
Clean and oil the contact surfaces 6‐33
Clean and oil the contact surfaces for the 6‐34
spacers
3.7 CNC controlled I axis (Option) 6‐35
Clean and grease the ball screw 6‐35
3.8 Crowning 6‐36
Cleaning and lubricating the wedge plate 6‐36
3.9 Bending aid (option) 6‐36
Lubricating the lift axis (H axis) 6‐36
Lubricating the guide carriage/rack (H 6‐36
axis) and the curved guide
Lubricating the brake's eccentric (Z axis) 6‐39
3.10 ACB laser optical angle measuring system 6‐41
(option)
Clean the guide rails/grease the guide car- 6‐41
riage

4 Mechanical elements 6‐43

4.1 Machine 6‐43
Check the machine alignment 6‐43
Check the mounting screw and floor 6‐43
anchors
Perform safety equipment test 6‐43

0‐10 Table of contents 2019-05-18 B876en

 Check that covers are complete and 6‐44
firmly seated
Back up the data 6‐44
Machine data backup 6‐45
4.2 Tool clamping 6‐45
Cleaning the tool adapters 6‐45
Check tool clamping function 6‐46
4.3 Support bracket (option) 6‐46
Cleaning the guide rails 6‐46
4.4 BendGuard (option) 6‐47
Clean guide rails 6‐47
BendGuard check and adjust 6‐48
Cleaning the transmitter and receiver 6‐48
4.5 Manual BendGuard (option) 6‐49
Replacing the roller spring 6‐49
4.6 Automatic BendGuard (option) 6‐50
Replacing the roller spring 6‐50
4.7 BendGuard (optional): Overtravel of the 6‐50
press beam
Check overtravel of the press beam with 6‐50
measuring device
4.8 Work area illumination (option) 6‐50
Cleaning work area illumination 6‐50
4.9 ACB laser optical angle measuring system 6‐51
(option)
Cleaning the glass panes 6‐51
Checking the gap in the cable carrier 6‐53
4.10 Part Indicator insertion aid (option) 6‐53
Cleaning the glass panes 6‐53
4.11 Press Beam 6‐54
Check guide rollers (Y axis) for fixed seat- 6‐54
ing
Check suspension (Y axis) for damage 6‐55
Check guide rails (Y axis) for wear 6‐55
Check the (Y axis) reference position 6‐56
Check distance measurement system (Y 6‐57
axis) for damage
Check limit switch (Y axis) functionality 6‐57
4.12 Backgauges 6‐57
2, 4 and 5 axis backgauge: Clean guide 6‐57
rail (Z axis)
Check the backgauge for wear/damage 6‐58

B876en 2019-05-18 Table of contents 0‐11

 Checking the reference position (R, X 6‐58
and Z axis)
5 axis backgauge: Check the alignment 6‐59
of the backgauge finger (X5 axis)
Check the alignment of the backgauge fin- 6‐59
gers (Z-direction )
Checking the (X axis) backlash 6‐59
6 axis backgauge: check the alignment of 6‐59
the motion unit
4.13 6 axes backgauge (option): central lubrication 6‐60
Check hoses for damage 6‐60
Check the film of grease at the lubrication 6‐61
points
4.14 Operating panel 6‐61
Cleaning the screen 6‐61
4.15 Lower tool displacement (I axis) 6‐62
Verifying the setting 6‐62
Check the play of the spherical plain bear- 6‐62
ing
4.16 Crowning 6‐62
Checking the reference position 6‐62
4.17 CNC-controlled wedge crowning (option) 6‐63
Check power consumption 6‐63
4.18 Heat sink (Cold Plate) 6‐63
Check the heat exchanger and fan for dirt 6‐63
Check the collecting tray for dirt 6‐64
Check filling level 6‐65
Checking the coolant quality 6‐66
Replace the coolant 6‐66
4.19 Bending aid (option) 6‐68
Cleaning the guide rail / sliding surfaces 6‐68
Checking the covers for stress marks 6‐69
Checking the brake function (Z axis) 6‐70
Performing a visual inspection within the 6‐70
bending aid

5 Electrics 6‐73
5.1 Side safety doors 6‐73
Checking the operation of the safety 6‐73
switch
5.2 Rear roller gate 6‐73
Checking the operation of the safety 6‐73
switch

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 5.3 Tool cabinet (option) 6‐74
5.4 Pneumatic I axis 6‐74
Checking the operation of the safety 6‐74
switch
5.5 EMERGENCY STOP push-button/PRESS 6‐75
BEAM DOWN foot switch with stop function
Check EMERGENCY STOP function 6‐75
5.6 Pilot lamps 6‐76
Checking the functioning of pilot lamps 6‐76
5.7 Energy supply chains (press beam, back- 6‐77
gauge)
Checking lines for damage/deformation/ 6‐77
abrasion
5.8 Electrical supply lines 6‐79
Checking lines for damage/deformation/ 6‐79
abrasion
5.9 Encoder connector and proximity switch 6‐79
Check that the encoder connector and 6‐79
proximity switch are firmly seated
5.10 Electrical cabinet 6‐79
Cleaning the electrical cabinet 6‐79
5.11 Electrical cabinet (control cabinet) 6‐80
Check the voltage of the buffer battery in 6‐80
the IPC
Replace the buffer battery (BIOS battery) 6‐80
in the IPC
Check the function of the fan in the IPC 6‐80
5.12 Electrical cabinet (power cabinet) 6‐81
Clean the fan and the fan modules of the 6‐81
axis regulator
Check the input voltage/control voltage 6‐81
5.13 Air conditioning unit 6‐81
Check the air conditioning unit for dirt 6‐81
Cleaning the air conditioning unit 6‐83
5.14 MagicShoe (option)/Wireless foot switch 6‐83
(option)
Replace buffer battery 6‐83
5.15 Communications rail: 6‐83
Check the communications rail for dirt 6‐83

6 Hydraulics 6‐85
6.1 Hydraulic unit 6‐85
Refill oil 6‐85
Changing the oil filter 6‐86

B876en 2019-05-18 Table of contents 0‐13

 Replace oil filter (first replacement) 6‐87
Replace oil filter (second replacement) 6‐88
Replace air filter 6‐88
Checking the hydraulic unit for leaks/ 6‐89
noise/vibrations
Analyze hydraulic oil (TruBend Fluid) 6‐89
Analyze hydraulic oil (all except 6‐90
TruBend Fluid)
Changing the hydraulic oil 6‐91
Electrical cabinet air conditioning up to an 6‐91
ambient temperature of 45 °C (option):
Check the oil cooler for contamination
Check the main motors and fans of the 6‐92
servomotors for contamination
Check control block, valves, hoses and 6‐93
tube screw fittings for damage/tightness
6.2 Hydraulic hoses 6‐93
Check hoses for damage/tightness 6‐93
Replace the hoses 6‐94
6.3 Hydraulic cylinders 6‐95
Check hydraulic cylinder for damage/tight- 6‐95
ness
6.4 Diaphragm accumulator 6‐96
Determining initial pressure; refilling nitro- 6‐96
gen as needed
6.5 Press Beam 6‐98
Check the holding pressure (Y-axis) 6‐98

7 Pneumatic system 6‐99

7.1 Overview 6‐99
7.2 Maintenance unit 6‐99
Draining condensation water 6‐99
Check the system pressure 6‐100
Replace the filter cartridge 6‐100
7.3 6 axes backgauge (option): central lubrication 6‐101
Check the silencer on the pneumatic 6‐101
valve for dirt
7.4 Pneumatic I axis 6‐102
Check the hoses for deformation 6‐102
Check the silencer on the pneumatic 6‐103
valve for dirt

0‐14 Table of contents 2019-05-18 B876en

 Chapter 7 Angle measuring system ACB
(option)

1 Structure 7‐3

2 Measuring principle 7‐5

2.1 Automatic bending angle correction sequence 7‐7

3 Technical Data 7‐8

4 Sensor tools and sensor disks 7‐9

4.1 Select sensor tool and sensor disks 7‐9

5 Changing sensor disks 7‐12

5.1 Bending installation device 7‐12
5.2 Removing sensor disks 7‐13
5.3 Installing sensor disks 7‐15
5.4 Cleaning the sensor tool 7‐16

6 Programming 7‐18
6.1 ACB Methods 7‐18
6.2 Programming a bend with ACB (option) 7‐19

7 Calibration 7‐21
7.1 Calibrating the sensor tool 7‐21

8 Production 7‐23
8.1 Producing a part with ACB Speed 7‐23

Chapter 8 Tactile ACB Wireless angle

measuring system (option)

1 Measuring principle 8‐3

1.1 Automatic bending angle correction sequence 8‐5

B876en 2019-05-18 Table of contents 0‐15

 2 Technical Data 8‐6

3 Bending with the angle measuring system 8‐7

ACB Wireless (overview)
3.1 Procedure 8‐7

4 Sensor tools and sensor disks 8‐8

4.1 Select sensor tool and sensor disks 8‐8

5 Changing sensor disks 8‐11

5.1 Bending installation device 8‐11
5.2 Removing sensor disks 8‐12
5.3 Installing sensor disks 8‐14
5.4 Cleaning the sensor tool 8‐15

6 Programming 8‐17
6.1 ACB Methods 8‐17
6.2 Programming a bend with ACB Wireless 8‐18
(option)

7 Calibration 8‐20
7.1 Calibrating the sensor tool 8‐20

8 Production 8‐22
8.1 Producing a part with ACB Speed 8‐22

Chapter 9 2D code scanner (option)

1 Description 9‐2
1.1 Code syntax 9‐3

2 Installing the device 9‐5

2.1 Attaching the holder 9‐5
2.2 For version with cable: Connecting the device 9‐6

0‐16 Table of contents 2019-05-18 B876en

 3 Loading program 9‐7
3.1 Loading a program by using a code 9‐7

4 Possible errors when scanning codes 9‐8

B876en 2019-05-18 Table of contents 0‐17

0‐18 Table of contents 2019-05-18 B876en
 Chapter 1

Safety

1 For your safety 1‐3

2 Operational safety 1‐5

2.1 Intended use 1‐5
2.2 Authorized personnel 1‐6

3 Hazards 1‐7
3.1 Dangers due to the open electrical cabinet 1‐7
3.2 Hazards due to laser radiation 1‐7
3.3 Dangers handling workpieces 1‐8
Sharp-edged workpieces 1‐8
Upper and lower tool 1‐8
Side of the workpiece 1‐9
Position the workpiece 1‐10
Falling workpieces 1‐11
Improper handling of flat workpieces 1‐11
Improper handling when bending boxes 1‐12

B876en 2019-05-18 Safety 1‐1

 3.4 Dangers due to unexpected movements 1‐12
3.5 Dangers when using the bending aid (option) 1‐13
3.6 Dangers when using a bending foil 1‐15
3.7 Dangers when operating a robot 1‐15
3.8 Noise hazards 1‐16
3.9 Risks due to remote support 1‐16

4 Measures to be taken by the manufacturer 1‐17

4.1 Danger zones and safeguarding device 1‐17
4.2 Warning signs at the machine 1‐23
Additional warning signs in the USA and 1‐26
Canada
Warning sign on the bending aid (optional) 1‐27

5 Organizational measures to be taken by 1‐29

the user
5.1 Observe warnings and warning signs 1‐29
5.2 Training and instructing operators 1‐29
Measures applicable worldwide 1‐29
5.3 Adhering to the duty of care when handling 1‐29
the machine
5.4 Water protection 1‐31
5.5 Spare parts, accessories, software, operating 1‐32
materials
5.6 Safety data sheet on hazardous materials 1‐32

6 Overview of residual risks 1‐33

7 Disassembly and disposal 1‐35

1‐2 Safety 2019-05-18 B876en

 1. For your safety

Regulations and guidelines With the CE marking and the EU Declaration of Conformity,
TRUMPF confirms that the machine meets the basic health and
safety requirements of the EC Machinery Directive.
The CE marking is located on the nameplate of the machine.
The EU Declaration of Conformity is delivered along with the
machine.
The machine meets the requirements of safety standard ANSI
B11.3.

Chapter Safety This chapter describes the safety concept. The chapter
describes how potential dangers can be avoided. The overview
of residual risks contains measures to be taken by the operator
in order to reduce the residual risks.

Notes
■ The operator must adhere to the valid safety and accident
prevention regulations of the respective country and the
safety laws of the state and of the region!
■ USA and Canada: TRUMPF also recommends that the
safety regulations for ANSI press brakes be observed.

Warnings and warning signs Certain operations can be a source of danger during operation.
The documentation contains warnings before the instructions for
these activities. There are warning plates on the machine.

A warning contains signaling words that have been explained in

the following table:

Signaling word Description

DANGER ... refers to great dangers. If not avoided, it can result
in death and serious injuries.
WARNING Refers to a dangerous situation. It could lead to seri-
ous injuries, if it is not avoided.
CAUTION ... indicates a potentially dangerous situation. It could
lead to injuries, if it is not avoided.
NOTICE If such a situation is not observed, it can lead to dam-
age to property.
Signaling words Tab. 1-1

B876en 2019-05-18 For your safety 1‐3

 Example of a warning:

Suspended load!
DANGER
Falling loads could lead to severe bodily injury or even
death.
Ø Observe safety regulations for the handling of heavy loads.
Ø Never walk under a suspended load.
Ø Use tested and appropriately sized tackle and means of
transportation.
Ø Employ qualified technicians to transport the machine.
Ø Carry out transport in accordance with the transport regula-
tions.

1‐4 For your safety 2019-05-18 B876en

 2. Operational safety

The machine can result in the following dangers if it is used

inappropriately or for purposes other than those intended, or
else if it is not safe to operate:
■ Dangers to the safety of the operator.
■ Damage to the machine and to other property of the opera-
tor.
■ Negative effect on the effective functioning of the machine.

2.1 Intended use

The user may use the machine only in the industrial sector.
Installation, operating and transport conditions defined by
TRUMPF must be adhered to and maintenance work must be
carried out in accordance with the Operator's manual. The user
must observe the specifications of the country in which the
machine is being operated as well as national and regional
safety and accident prevention regulations.
The user may bend cold sheets using the machine.

The following is not allowed:

■ Unauthorized alteration or conversion of the machine by the
user or personnel.
■ Any working procedure that impairs the safety.
■ Processing of hot, splintering or brittle materials.
■ Use of tools from other manufacturers without release by
TRUMPF.
■ The storage of tools no longer required on the press beam.

Disclaimer Any use going beyond this is considered to be unauthorized

use. TRUMPF is not liable for any damage, especially personnel
injuries and production failures resulting from this. The risk is
borne solely by the operator. The warranty will be voided.

B876en 2019-05-18 Operational safety 1‐5

 2.2 Authorized personnel

■ Operation, setting and maintenance work may only be car-

ried out by authorized, trained and instructed personnel.
■ Qualified personnel may do the following:
− Transporting the machine to the installation site.
− Carry out work at the hydraulic, pneumatic and electrical
modules.
− Disassemble the machine and its components.

1‐6 Operational safety 2019-05-18 B876en

 3. Hazards

3.1 Dangers due to the open electrical

cabinet

The electrical cabinet may be opened only by an electrician.

Electrical voltage!
DANGER
Electric shock!
Ø Keep the electrical cabinet closed.
Ø Before opening the electrical cabinet: turn off the MAIN
SWITCH and secure it against being switched back on
again. Wait for the discharging time (at least 5 minutes).

Hot components!
CAUTION
Burns!
Ø Keep electrical cabinet closed.
Ø Before opening the electrical cabinet: switch off the main
switch and secure against being switched back on.
Ø Wait for the cooling phase (minimum 5 minutes).

3.2 Hazards due to laser radiation

Laser products are divided into laser classes as per the Euro-
pean standard EN 60825-1 (USA: ANSI Z136.1, ANSI B11.21).
The laser class corresponds to the hazard level of the laser light
emitted.

Assembly Laser class Description

BendGuard optoelectronic safety 1 The accessible laser radiation is not dangerous under
device (option) sensibly predictable conditions.
ACB laser optical angle measuring 2M The accessible laser radiation lies in the visible spec-
system (option) tral range of 400 nm to 700 nm. It is not dangerous
for eyes in the case of short exposure time (up to
0.25 s) as long as the beam is not observed through
optical instruments (magnifying glass, lens, telescope).
Additional radiation parts outside the wavelength spec-
trum of 400-700 nm fulfill the conditions of class 1M.
Eyes are normally protected from the laser light by
turning away and closing the eyelids.
Laser classes Tab. 1-2

B876en 2019-05-18 Hazards 1‐7

 Risk of eye injuries due to laser radiation!
WARNING
Laser radiation causes irreparable damage to the eyes.
Ø Do not look directly into the beam.

3.3 Dangers handling workpieces

Processing workpieces can be dangerous. These dangers and

measures are different for every workpiece.

Sharp-edged workpieces

Workpieces have sharp edges!

WARNING
Risk of injury!
Ø Wear personal safety equipment.

Upper and lower tool

Upper and lower tool Fig. 25903

Press beam moves downwards!

WARNING
Body parts can be severed off!
Ø Do not insert hand between upper and lower tools.

1‐8 Hazards 2019-05-18 B876en

 Side of the workpiece

Side swivels far out Fig. 55869

Hand gets caught Fig. 55828

Hold workpiece from the side Fig. 53449

B876en 2019-05-18 Hazards 1‐9

 The flanges of the workpiece swivel upwards or
WARNING downwards during bending!
Risk of crushing between workpiece and tool clamp as well
as between other machine parts in this area.
Ø Maintain sufficient distance to the workpiece.
Ø Hold the workpiece in such a way that hands and fingers
do not get trapped.
Ø In the case of support brackets (optional): hold the work-
piece at the side after bending.

Bend internal flanges Fig. 71123

When bending flanges on the inside the workpiece swivels

WARNING downwards!
Risk of injury, crushing!
Ø Maintain sufficient distance from the workpiece and from the
lower tool clamp.
Ø Position the workpiece such that hands and fingers do not
get clamped.

Position the workpiece

If the workpiece is incorrectly positioned, the workpiece and the

gauge finger can collide.

1‐10 Hazards 2019-05-18 B876en

 The backgauge can move unexpectedly and at high speeds!
WARNING
Risk of injury!
Ø Position the workpiece only after the backgauge has moved
to the next position.
Ø For ASV movement strategy (automatic safety velocity):
position the workpiece at least 50 mm in front of the center
of the workpiece.

Falling workpieces

Falling workpieces!
CAUTION
Risk of injury!
Ø Wear safety shoes.

Improper handling of flat workpieces

Correctly bending flat workpiece Fig. 77538

■ Hold onto the workpiece by the front corners:

− Thumbs lie on the workpiece.
− Palms of hand hold the workpiece from below.

B876en 2019-05-18 Hazards 1‐11

 Improper handling when bending boxes

Bending box correctly Fig. 77539

■ Hold the workpiece at the right and left between your thumb
and index finger.
■ When holding, do not reach into the box with your hands.
Due to the bending operation, fingers or your hand can be
crushed or caught between the workpiece and upper tool.

3.4 Dangers due to unexpected

movements

The backgauge can move unexpectedly and at high speeds!

WARNING
Risk of injury!
Ø Position the workpiece only after the backgauge has moved
to the next position.
Ø Do not reach over the bending line.

1‐12 Hazards 2019-05-18 B876en

 3.5 Dangers when using the bending aid
(option)

Impermissibly or incorrectly loaded tools!

WARNING
Risk of injury.
Ø Only use TRUMPF standard tools.
Ø Ensure that the tool and the bending aid are correctly pro-
grammed and set up for the work. Example: Offset tools are
inserted in the correct position.

Impermissible work in the bending line danger zone!

WARNING
Risk of injury.
Ø The tooling status of the bending aid may not be changed
while the program is running.

Fig. 81813

B876en 2019-05-18 Hazards 1‐13

 An unsecured support table can slide forwards during the
WARNING swivel movement of the bending aid!
Risk of injury between support table and tool.
Ø Ensure that the support table is engaged in the rear posi-
tion or moved completely in the direction of the tool clamp
and thus secured magnetically.

Risk of injury at exposed bore holes during the swivel

CAUTION movement of the bending aid!
Ø Only use bending aid with supports mounted.

Unexpected movements of the bending aid

WARNING
Risk of injury.
Ø Keep a sufficient distance to the bending aid.
Ø Keep away from the swiveling range of the bending aid.
Ø Keep away from the swiveling range of the table extension
(option) and the table width extension (option).
Ø Do not put anything under the table extension (option) or
table width extension (option).
Ø Deactivate the bending aid in the program and at the
MobileControl unit, when not needed.
Ø Push the bending aid out of the working area (e.g. to the
edge or into its parking position) when not needed.

■ When positioning the workpiece, ensure that its center of

gravity or its centroidal axis is on the bending aid. In case of
operator carelessness, this should ensure that the sheet will
not fall down and injure the operator.

■ If the tool station is positioned offset to the bending aid, the

swivel movement of the bending aid may cause the work-
piece to fall, even though the center of gravity of the work-
piece is on the bending aid.

■ When moving the press beam, note that this means the
sheet cannot be clamped between the workpieces and thus
can fall back on the bending aid.
■ In order to avoid injury to the operator and undesirable defor-
mation of the sheet, the quality of the working step and the
workpiece can be improved by the use of a second bending
aid.

1‐14 Hazards 2019-05-18 B876en

 Fig. 80923

■ Observe the max. carrying capacity of the bending aid/table

extension depending on the position of the workpiece centre
of gravity.

3.6 Dangers when using a bending foil

Bending foil can be placed over the lower tool to prevent impres-
sions on the workpiece.

Travel motion of the backgauge with automatic step

WARNING change!
Risk of getting caught between the bending tool and the
backgauge.
Ø Always press the EMERGENCY STOP push-button before
clamping a bending foil.

3.7 Dangers when operating a robot

A robot can be connected to the machine via the interface pro-

vided for this purpose.

B876en 2019-05-18 Hazards 1‐15

 The press beam moves at rapid speed and the robot
DANGER moves.
Severe injury or death.
Ø The user must secure the machine and the robot in such a
way as to prevent any persons from entering the danger
zone (e.g. using safety fencing). Observe the country-spe-
cific safety regulations.

3.8 Noise hazards

The A-weighted emission sound pressure at the work station of

the personnel is at ≤70 dB(A).

3.9 Risks due to remote support

Remote support is used to establish a connection between the

machine and Technical Service.
The service engineer can access the user interface to analyze
problems and in some cases to eliminate them directly.

Activated remote support!

WARNING
Injury and damage to property.
Ø Only persons trained by TRUMPF may take part in a
remote support session.
Ø If doubts arise regarding the qualifications of the persons
involved or if comprehension issues arise, TRUMPF can
refuse remote support or terminate the remote support ses-
sion.

1‐16 Hazards 2019-05-18 B876en

 4. Measures to be taken by the
manufacturer

The danger zone of the machine is safeguarded by safety equip-

ment. The machine may only be operated with these safety devi-
ces.

4.1 Danger zones and safeguarding

device

1 Electrical cabinet (control cabi- 5 Side safety doors 9 Main switch

net) 6 PRESS BEAM UP foot switch 10 Electrical cabinet (power cabi-
2 Key switch for DEACTIVATE 7 PRESS BEAM DOWN foot net)
DOOR LOCK switch with stop function 11 Rear roller gate
3 EMERGENCY STOP push-but- 8 Backgauge
ton
4 BendGuard optoelectronic
safety device (option)
Danger zones and safeguarding device Fig. 68986

Side safety doors These safety doors safeguard the area to the side of the ram
and machine bed. When the doors are closed, it is not possible
for persons to reach into the danger zone from the side.

B876en 2019-05-18 Measures to be taken by the manufacturer 1‐17

 The side safety doors are monitored.
If both of the side protection doors are opened during opera-
tion, the emergency stop triggers.

The following happens if one of the side safety doors is opened

during operation:
■ The press beam stops.
■ Stop all axis motions of the backgauge.
■ The safety door can remain open if this is confirmed using
the PRESS BEAM DOWN foot switch. All axes can then be
moved again. The ram travels at reduced speed.

Rear roller gate The roller gate secures the danger zone inside the machine.
The roller gate is monitored.
If the roller gate is opened during machining, the EMERGENCY
STOP is triggered.

BendGuard optoelectronic The optoelectronic safety device monitors the area in front of,
safety device (option) behind and below the upper tool during operation by means of a
light field.
The press beam moves at a maximum speed between the
upper dead point and the mute [Link] the BendGuard is
pushed up by an obstacle (e.g. trapped hand) or if the light field
is interrupted, then the press beam will stop.
The press beam moves at reduced speed between the mute
point and the lower dead point. The optoelectronic safety device
is not active.

Main switch The machine is switched on and off via the main switch. The
main switch can be secured against being switched on again
using a padlock.

The main switch has the following positions:

Position Description
0 The machine is switched off and the voltage supply of the
machine is interrupted.
I The machine is switched on.
Tab. 1-3

EMERGENCY STOP push- EMERGENCY STOP has the following effect:

button/EMERGENCY STOP ■ Control stops.
function
■ The press beam stops.
■ Stop all axis motions of the backgauge.
■ The PRESS BEAM UP foot switch is deactivated.
■ All drives are switched off electrically.

1‐18 Measures to be taken by the manufacturer 2019-05-18 B876en

 ■ The hydraulic unit is switched off.
■ For a 2-axis backgauge or 6-axis backgauge (option) and/or
pneumatic I axis (option) and/or BendMaster (option): Pneu-
matics are shut off.

PRESS BEAM DOWN foot The foot switch has the following positions:
switch with stop function
Position Description
The foot switch is not The press beam is stationary or remains sta-
pressed. tionary.
The foot switch is The press beam moves downwards.
pressed as far as the
first pressure point
(neutral position).
The foot switch is The stop function leads to the following:
pressed all the way ■ Control stops.
down.
■ The press beam stops.
■ Stop all axis motions of the backgauge.
■ The hydraulic unit is switched off.
Tab. 1-4

PRESS BEAM UP foot The press beam can be moved upwards using the PRESS
switch BEAM UP foot switch.

The foot switch has the following positions:

Position Description
The foot switch is not No effect on the press beam.
pressed.
The foot switch is The press beam moves upwards.
pressed.
Tab. 1-5

The PRESS BEAM UP foot switch is not active in the following

cases:
■ EMERGENCY STOP was triggered.
■ Both side protection doors were opened.
■ The rear roller gate was opened.

B876en 2019-05-18 Measures to be taken by the manufacturer 1‐19

Wireless foot switch (option)

1 EMERGENCY STOP push-but- 4 PRESS BEAM DOWN foot

ton (active: lights up red, inac- switch with stop function
tive: gray) 5 Compartment for Connector
2 Pilot lamp
3 PRESS BEAM UP foot switch
Wireless foot switch (option) Fig. 87847

The wireless foot switch replaces the foot switch with a connec-
tion cable.
The foot switch may only be used within a defined working
range. The foot switch is wirelessly connected to the machine.
Ultrasonic sensors in the lower part of the press table checks
whether the operator is within the working range.

Notes
■ The EMERGENCY STOP push-button is only active if it is
illuminated red, i.e. as long as the operator is within the
working range.
■ The operator may only use the foot switch if they see the
red colour of the EMERGENCY STOP push-button.

1‐20 Measures to be taken by the manufacturer 2019-05-18 B876en

 MagicShoe (option)

1 Transmitting unit 4 MagicShoe Connector (Service

2 Safety shoe (safety class S2) life: approx. 20 hours)
3 2x status LED 5 Heel clip (with integrated vibra-
tion motor)
MagicShoe (option) Fig. 69013

A MagicShoe replaces the PRESS BEAM DOWN and PRESS

BEAM UP buttons in the foot switch.
MagicShoe may only be used within a defined working
[Link] is wirelessly connected to the machine. Ultra-
sonic sensors in the lower part of the press table and a transmit-
ter on the MagicShoe checks whether the operator is within the
working area.
The operator can only move the press beam, by going through
a two-stage sequence of movements within a defined period of
time.

With MagicShoe, the following actions are possible:

Action Action by the operator

Trigger stroke. Two-stage sequence of movements:
■ Lift the front part of your right foot and then
lower it again onto the floor (your heel stays
on the floor).
■ Within 5 seconds, maintain the pressure in
the front part of your foot until the stroke is
triggered. Maintain the pressure for as long
as the press beam is to move. Try to
ensure that you do not move your foot here.
Stop downward move- Step firmly down with the front part of your foot.
ment of the press
beam (stop function).
Move the press beam Two-stage sequence of movements:
upward. ■ Lift the front part of your right foot and then
lower it again onto the floor (your heel stays
on the floor).
■ Within 5 seconds, lift the front part of your
foot and keep it up for as long as the press
beam is to move. Try to ensure that you do
not move your foot to the left or right.
Tab. 1-6

B876en 2019-05-18 Measures to be taken by the manufacturer 1‐21

 USA, Canada, Mexico, There is a key switch for the maintenance work.
South America: Key switch
The key switch is located on the rear side of the machine.
for DEACTIVATE DOOR
LOCK
The key switch has the following positions:

Position Description
0 The power supply to the machine will be interrupted when
the switching cabinet door is opened.
The key must be removed and kept safely.
I The power supply to the machine remains switched on
when the electrical cabinet door is opened.
Tab. 1-7

ROBOT-MODE (option) key The robot can be activated/deactivated using the key switch.
switch
The key switch is located on the rear side of the machine.

The key switch has the following positions:

Position Description
0 The robot is deactivated.
The key must be removed and kept safely.
I The robot is activated.
Tab. 1-8

Processing strategy of the The backgauge can move to the next programmed position at
backgauge different times.

Step change Setting in the user interface Description

automatic "Decompression point" The backgauge automatically moves to the next index
position at the end of the bending operation.
"Mute point" The backgauge automatically moves to the next stop
position when the press beam has moved upwards up
to the mute point.
"Upper dead point" Default setting.
The backgauge automatically moves to the next stop
position when the press beam has moved upwards up
to the upper dead point.
Manual "Upper dead point. Control the press beam moves to the upper dead point
stops" (UDT).The control stops.
The backgauge moves to the next index position when
START is pressed.
"Upper dead point (BEAM the press beam moves to the upper dead point (UDT).
DOWN foot switch)" The backgauge moves to the next index position when
the PRESS BEAM DOWN foot switch is pressed.
Step change Tab. 1-9

1‐22 Measures to be taken by the manufacturer 2019-05-18 B876en

 For an automatic step change, the backgauge can move with
three different strategies.

Movement strategy Description

"ASV (automatic safety veloc- The backgauge bypasses the danger zone with a programmed speed
ity)" (50 mm behind and over the tool). The backgauge will finally move for-
wards (X axis). The backgauge will move at reduced speed when the dis-
tance between the backgauge finger and the tool is less than 50 mm.
"ASW (automatic safety way)" The backgauge bypasses the danger zone (50 mm behind and over the
tool). The backgauge will finally move downwards (R axis). All axes move
Not possible on a 5-axis back- at the programmed speed.
gauge.

Prerequisites:
■ The press beam opening is so large that the distance between the
backgauge finger and the tool cannot become less than 50 mm.
■ The travel range of the axes is sufficient.
■ The backgauge fingers can be folded upwards.

Movement strategy Tab. 1-10

For 2-axis backgauge: The backgauge fingers can be shifted manually towards the
manual shifting outside the right and left (Z axis). For this, the backgauge fingers must be
danger zone moved into a secure position in front of the tool clamp. The
operator may only shift the backgauge fingers outside the dan-
ger zone.

4.2 Warning signs at the machine

Warning signs draw attention to dangers when operating the

machine.

B876en 2019-05-18 Measures to be taken by the manufacturer 1‐23

1 Upper side 4 BendGuard (option) 7 Main switch
2 Cover 5 Press Beam 8 ACB laser optical angle measur-
3 Electrical cabinet (control cabi- 6 Electrical cabinet (power cabi- ing system (option)
net) net) 9 Press table
Warning signs at the machine Fig. 68987

Pos. Warning sign Description

3, 6 Warning of hot surface.

4, 8 WARNING about laser beams.

5 Safety information for freeing trapped

persons.

5 ■ 1: Risk of crushing between upper

and lower tool.
■ 2: Risk of crushing between work-
piece that has moved up or down
and machine parts in this area.
■ 3: Risk of impact due to workpiece
that has moved up or down.
■ 4: Risk of crushing and impact due
to backgauge.

1‐24 Measures to be taken by the manufacturer 2019-05-18 B876en

 Pos. Warning sign Description
3, 6, 7 Warning of electrical voltage.

– Secure machine on the truck during

transport.

9 Jacking point for hydraulic hoisting jack.

– Move the machine carefully and deli-

cately and by hand only. Do not use a
forklift truck or other motorized tractors
as there is a risk of tilting due to
abrupt acceleration.
8 Laser radiation.
Do not look into the beam or view it
directly with optical instruments.
Laser class 2M
H ≤ 25 W/m² λ = 658 nm

Warning signs at the machine Tab. 1-11

B876en 2019-05-18 Measures to be taken by the manufacturer 1‐25

 Additional warning signs in the USA and
Canada

Additional warning signs in the USA and Canada:

Pos. Warning sign

5

1‐26 Measures to be taken by the manufacturer 2019-05-18 B876en

 Pos. Warning sign
7

Additional warning signs in the USA and Canada Tab. 1-12

Warning sign on the bending aid (optional)

Fig. 78606

B876en 2019-05-18 Measures to be taken by the manufacturer 1‐27

 Pos. Warning sign Description
1 ■ When positioning the workpiece, ensure that its
center of gravity or its centroidal axis is on the
bending aid. In case of operator carelessness, this
should ensure that the sheet will not fall down
and injure the operator.
■ If the tool station is positioned offset to the bend-
ing aid, the swivel movement of the bending aid
may cause the workpiece to fall, even though the
center of gravity of the workpiece is on the bend-
ing aid.
2 Observe the max. carrying capacity of the bending
aid/table extension depending on the position of the
workpiece centre of gravity.

Warning sign on the bending aid (optional) Tab. 1-13

1‐28 Measures to be taken by the manufacturer 2019-05-18 B876en

 5. Organizational measures to be taken
by the user

5.1 Observe warnings and warning signs

Certain operations can be a source of danger during operation.

The documentation contains warnings before the instructions for
these activities and warning signs are provided on the machine.

5.2 Training and instructing operators

Measures applicable worldwide

The user must take the following measures before the personnel
start working on the machine:
■ Train personnel appropriately.
■ Inform the personnel about the possible dangers and the
safety measures. Chapter 1 "Safety" forms the basis.
■ Keep personal safety equipment ready.
■ As far as possible, ensure personnel wear protective gear
(e.g. gloves, safety shoes, hearing protection, safety
glasses...).
■ Define responsibilities for safety, operation, maintenance, set-
ting work and service.
■ Demand that personnel read the technical documentation of
the machine. Recommendation: obtain written confirmation
from the personnel.
■ For fault diagnosis and error correction, a connection will be
made via remote support between the machine and
TRUMPF Technical Service. When the machine is commis-
sioned, the user will be informed about the procedure and
possible risks of remote support. The user must provide
safety instruction to operators who are involved in the
remote support.

5.3 Adhering to the duty of care when

handling the machine

Checking the danger zone Safety devices must not be acknowledged when persons are in
and safety devices the danger zone. The personnel must always make sure that
nobody is in the danger zone before acknowledging.

B876en 2019-05-18 Organizational measures to be taken by the user 1‐29

 Personnel may only operate the machine with functional safety
devices. Safety devices may not be removed or put out of oper-
ation.

Once per shift, preferably before starting the production:

■ Check the safety devices for proper function.

Ensuring the perfect User:

working order ■ The user must ensure that the machine is installed as per
the installation plan and installation conditions.
■ The user must ensure that only authorized personnel works
at the machine.
■ The user must ensure that damaged or missing warning
signs on the machine are replaced.
■ The user or the persons appointed by him/her must operate
the machine when it is in perfect working order.
■ The user must ensure that the work station is kept clean
and tidy by issuing appropriate instructions and conducting
inspections.
■ The user must ensure that the working areas are supplied
with sufficient fresh air.

Operator:
■ The operator must immediately report changes (including the
operating performance) occurring in the machine to the oper-
ator. The machine must be checked for externally visible
defects and damage at least once per shift.
■ The operator must ensure before every use that worn tools
are not used.
■ The operator must ensure that only those people who are
absolutely required for operation may be in the immediate
danger zone (up to one meter in front of the bending line
over the entire length of the press table).
■ The operator must ensure that tools and backgauges are
correctly programmed and set up for the work to be done.

Lock the machine to If the operator leaves the machine for a short time or at the end
prevent unauthorized use of the shift, he must sign out at the user interface.

Observing the shutdown The prescribed switch-off procedures must be adhered to during
procedure all work (e.g. setting and maintenance work).

Operating the machine with ■ In the area of application of the EC Machinery directive, the
a robot user or integrator must meet the provisions of the EC machi-
nery Directive. The following documents are required for the

1‐30 Organizational measures to be taken by the user 2019-05-18 B876en

 integration: Risk assessment, EU declaration of conformity
and Operator's manuals.
■ The user must observe the requirements for manufacturers
or integrators outside the area of application of the EC
Machinery Directive.
■ The control and the electrical installation of robot are the
responsibility of the user or integrator. Wiring of the safety-
related signals may only be carried out by qualified person-
nel.
■ The user must secure the machine and the robot in such a
way as to prevent any persons from entering the danger
zone (e.g. using safety fencing). Observe the country-spe-
cific safety regulations.

5.4 Water protection

Water-pollutant substances should not enter the ground or into

water bodies.
Cooling water may be disposed off together with waste water
only in agreement with the local waste disposal authority.

The Federal Republic of The principle of precaution is applicable for machines in the Fed-
Germany eral Republic of Germany: water should not become contami-
nated when using water-pollutant substances (Federal Water Act
WHG).
The plant decree and the administrative regulations of the Fed-
eral states explain how this principle of precaution should be
adhered to.

Water-pollutant materials ■ Hydraulic oil

■ Lubricants
Water Hazard Class 1 or 2
Volume of water-pollutant materi- ≤1000 l (≤264 gal)
als
Hazard level of the machine A
Water protection specifications Tab. 1-14

Outside the Federal Outside the Federal Republic of Germany, the respective
Republic of Germany national regulations as regards water protection must be
adhered to.

B876en 2019-05-18 Organizational measures to be taken by the user 1‐31

 5.5 Spare parts, accessories, software,
operating materials

Using spare parts, Spare parts and accessories that have not been released by
accessories and software TRUMPF (in the following: "External parts and accessories") are
not checked. Installing and using external parts and accessories
can change design-related properties of the machine and
weaken the safety.
Only software that has been approved for installation by
TRUMPF may be installed.

Liability disclaimer TRUMPF is not liable for damage if external parts and accesso-
ries are used or if spare parts and accessories approved by
TRUMPF are not installed or replaced properly.
TRUMPF cannot be held liable for damages resulting from the
installation or operation of software which is not approved by
TRUMPF.

Using permissible operating The permissible operating materials (especially lubricating and
materials as per the cleaning agents) must be used as per the regulations. If a
regulations safety data sheet has been prescribed for the manufacturer of
the operating material (European Directive 1907/2006 REACH),
the instructions/notes in it must be followed/taken into considera-
tion, such as:
■ Chemical properties
■ Physical and safety-related specifications
■ Transport.
■ Regulations
■ Safety measures, storage, and handling
■ Measures for in the event of accidents or fires
■ Specifications for toxicology and ecology
■ Waste code with prescribed disposal method for the operat-
ing material

Note
The safety data sheet can be obtained from the manufacturer of
the respective operating material.

5.6 Safety data sheet on hazardous

materials

The safety data sheets e.g. for lubricants, cleaners or gases can
be downloaded from the TRUMPF web page: http://
[Link]/s/msds.

1‐32 Organizational measures to be taken by the user 2019-05-18 B876en

 6. Overview of residual risks

The machine has residual risks in spite of its safety devices and
construction type.
The following overview of residual risks is a summary of the
main potential threats to life and limb posed by the machine.
Any additional precautions that can be taken by the machine
user to reduce residual risks are specified in the overview of
residual risks.
For detailed descriptions of the measures: (see "Hazards",
pg. 1‐7).

Residual risks Hazard area Type of danger Necessary action

Mechanical elements
Squeezing, shearing off ■ Entering into the dan- Risk of injury Operation by trained and
of body parts, cutting, ger zone (from the instructed personnel.
impacts side).
Wear personal safety
■ Vertical tool change. equipment.
■ Stopping and position-
If body parts are trapped,
ing of the workpieces.
press the PRESS BEAM
UP foot switch.
Gripping or retracting ■ Movement of the back- Risk of injury Operation by trained and
gauge and the work- instructed personnel.
Squeezing, shearing off
piece.
of body parts Select appropriate proc-
■ Collision between the essing strategy of the
gauge fingers and the backgauge.
tool.
Position the workpiece
only after the backgauge
has moved to the next
position.
Do not reach over the
bending line.
Crushing ■ Between the work- Risk of fatal injury Operation by trained and
piece and the press instructed personnel.
beam.
■ Between the bending Risk of injury Operation by trained and
aid (option) and press instructed personnel.
beam/operating panel.
Friction or abrasion ■ Movement of the Risk of injury Operation by trained and
press beam. instructed personnel.
Do not touch the press
beam as long as it is
moving.
Joint ■ Manually shift the Risk of injury Operation by trained and
bending aid (option) or instructed personnel.
the support bracket
(option) in the Z direc-
tion.
Slipping, falling ■ In case of a fault: Risk of injury Operation by trained and
larger oil leak from the instructed personnel.
hydraulics.

B876en 2019-05-18 Overview of residual risks 1‐33

 Residual risks Hazard area Type of danger Necessary action
Injection ■ In case of a fault: Risk of injury Specially trained person-
escape of high-pres- nel for maintenance, serv-
sure hydraulic oil. ice and repairs.
Observe the compulsory
maintenance work require-
ments.
Falling workpieces ■ Releasing the work- Risk of injury Operation by trained and
piece after bending. instructed personnel.
Wear personal safety
equipment.
Falling tools ■ Unintentional actuation Risk of injury Operation by trained and
of the Safety-Click. instructed personnel.
Wear personal safety
equipment.
Instability ■ Tipping over of the Risk of fatal injury Use the intended secur-
machine. ing points and permitted
additional equipment to
transport the machine.
Anchor the machine to
the floor.
Radiation
Laser BendGuard optoelectronic Risk of injury Operation by trained and
safety device (option) instructed personnel.
ACB laser optical angle Do not look directly into
measuring system (option) the beam.
Materials
Contact with or by inhal- Hydraulic oil or lubricants Health hazard Specially trained person-
ing dust, aerosols and nel for maintenance, serv-
gases ice and repairs.
Wear personal safety
equipment.
Note the safety data
sheets.
Electrics
Electric contact ■ Direct contact with nor- Risk of fatal injury Specially trained person-
mally live parts. nel for maintenance, serv-
ice and repairs.
■ Indirect contact with Risk of fatal injury Specially trained person-
parts that are live due nel for maintenance, serv-
to an error. ice and repairs.
Remote support
Example: Electric contact ■ Example: Electrical Risk of fatal injury Have remote support ses-
cabinet sion performed only by
persons who have been
trained by TRUMPF.
Residual risks Tab. 1-15

1‐34 Overview of residual risks 2019-05-18 B876en

 7. Disassembly and disposal

TRUMPF recommends that TRUMPF machine tools be disas-

sembled and disposed of by Technical Service or a specialist
disposal company. The following information is to be passed on
to the specialist disposal company performing the disposal work,
to guarantee fast, environmentally sound and safe disposal.

Preparing disassembly The following measures must be taken to avoid dangers during
disassembly:
■ Lower moving assemblies and suspended loads. Secure or
support defective moving assemblies and suspended loads.
■ Switch off the machine, component or system and wait at
least 1 hour until residual voltages have dissipated and hot
components have cooled down.
■ If available: shut off the compressed air and gas supply and
disconnect them from the customer's system.
■ Relieve the pressure in pressurized components.
■ Clean away contamination, especially dust.
■ Have the machine, component or system disconnected from
the power supply by a trained electrician.
■ Cordon off the areas in which removal and storage are tak-
ing place.

Hazardous materials Prior to disassembly, dispose of the following hazardous materi-

als in accordance with national regulations:

Hazardous substance Installed in assembly

Hydraulic oil Hydraulic unit, hydraulic cylinder, hydraulic
lines, hydraulic system hoses
Refrigerant Air conditioning unit (electrical cabinet)
Lubricant 6 axes backgauge (option): central lubrication
Batteries Electrical cabinet, operating panel, ...
Rechargeable battery MagicShoe (option): MagicShoe Connector
Wireless operating unit with foot switches
(option): Connector
ToolMaster (option): transport slides
Hazardous materials Tab. 1-16

Area of application: China In China, the declaration of substances applies in acc. with GB/
T 26572‑2011 (China RoHS 2). The corresponding conformity
label is located on the nameplate.

B876en 2019-05-18 Disassembly and disposal 1‐35

 Conformity label at the nameplate Fig. 82463

Lead Mercury Cadmium Hexavalent Polybromi- Polybromi-

chromium nated nated
biphenyls diphenyl
ethers
(Pb) (Hg) (Cd) (Cr+6) (PBB) (PBDE)
Basic X O O O O O
machine
Electrical cab- X O O O O O
inet
O:
Indicates that this hazardous substance is present in all homogeneous materials for the parts listed. In terms of
EIP-A, EIP-B and EIP‑C, the value is below the limit stipulated in GB/T 26572‑2011.
X:
Indicates that this hazardous substance in all homogeneous materials in terms of EIP-A, EIP-B and EIP-C is
above the limit value stipulated in GB/T 26572‑2011.
Comments: -
Substances that must be declared Tab. 1-17

Assemblies with particular The following assemblies will constitute a hazard if disassem-
risk potential bled:

Assembly Danger
Machine Can tilt forwards if the brace is released.
Press Beam Falls down if the hydraulic components are
removed first.
Assemblies with particular risk potential during disassembly Tab. 1-18

Remove ■ Poisonous vapors can result when thermally cutting painted

components or components made out of composite materials.
− Select a suitable cutting process.
or
− Wear a suitable protective mask and ensure there is a
sufficient supply of fresh air.
■ Secure top-heavy assemblies to prevent them from tipping
over and carefully put them in a good transport position
(center of gravity down).
■ Moving assemblies may be unbraked after being discon-
nected from the power supply.
− Fix movable assemblies prior to disassembly/transport,
so that the center of gravity cannot move in an uncontrol-
led manner.

1‐36 Disassembly and disposal 2019-05-18 B876en

 ■ Mechanical stresses can be released when undoing chains,
ropes and steel constructions!
− Wear suitable protective gear and close off the area over
a wide area.
■ On defective machines, parts of the hydraulic system and
the compressed air system may still be under pressure!

Transporting assemblies ■ Cordon off transport routes and storage positions extensively.
■ Use suitable lifting gear. See installation conditions.
■ Fasten assemblies above the center of gravity as far as pos-
sible.

B876en 2019-05-18 Disassembly and disposal 1‐37

1‐38 Disassembly and disposal 2019-05-18 B876en
 Chapter 2

TruBend Series 5000 (B23)

installation conditions
Who does what? 2‐3

1 Planning aid 2‐4

2 Installation site 2‐6

2.1 Space requirements 2‐6
2.2 Floor requirements 2‐7
Surface 2‐7
Floor quality 2‐9
2.3 Weight load 2‐11
2.4 Stress due to vibration 2‐13
2.5 Ambient conditions 2‐13

3 Compressed air supply 2‐15

B876en TruBend Series 5000 (B23) installation conditions - 2‐1

Version 12
 4 Electrics 2‐17
4.1 Power supply 2‐17
Connected loads 2‐17
Connecting cables 2‐19
4.2 Power supply 2‐20
Uninterruptible Power Supply (UPS) 2‐20
Residual current device (RCD) 2‐20
Power supply configurations 2‐22
Isolating transformer 2‐23
4.3 Remote support 2‐23
4.4 Cloud connection 2‐24
4.5 Network link 2‐24

5 Operating materials 2‐25

5.1 Hydraulic oil 2‐25

6 Transport 2‐26
6.1 Preparing transport 2‐26
Transport dimensions 2‐26
6.2 Permitted auxiliary tools 2‐27
ToolMaster (option): Permitted auxiliary 2‐28
tools
6.3 Checking, unloading and transporting the 2‐30
machine
On delivery: check the machine 2‐30
Unloading and transporting the machine 2‐30
ToolMaster (option): Unloading and trans- 2‐33
porting the machine

2‐2 TruBend Series 5000 (B23) installation conditions - B876en

Version 12
 Who does what?

Customer All the conditions described in this chapter must be fulfilled

before the machine is delivered.
If this is not the case, Technical Service will not be able to put
the machine into service.

Note
During start-up, the main switch on the machine may only be
switched on by Technical Service.

Technical Service The machine is put into service by Technical Service.

Start-up includes:
■ Installing, aligning, leveling and securing the machine.
■ If required: fill oil.
■ Connecting the machine to the supplies (with the exception
of the electrical power supply).
■ Performing a functional test.
■ Instructing personnel.

B876en TruBend Series 5000 (B23) installation conditions - 2‐3

Version 12
 1. Planning aid

The planning aid provides an overview of the measures to be

taken and preparations to be made.
For details, refer to the corresponding sections of these installa-
tion conditions.

Time before the deliv- Planning criterion Required measures

ery of the machine
8 weeks Personnel and training ■ Appoint a member of staff to be responsible for
preparations for the delivery of the machine.
■ Appoint operating and service personnel and pro-
grammers.
■ Arrange training schedules for specialist personnel.
8 weeks Installation site ■ Determine the installation site of the machine, tak-
ing into account the space requirements according
to the installation plan.
■ Check floor requirements:
− Floor quality.
− Flatness.
− Oil-resistant floor without expansion joints.
■ Take the weight and dimensions of the machine
into account.
■ Check the requirements for ambient conditions:
− Room temperature.
− Exposure to sunlight.
− Purity of the ambient air.
■ Check transport route, e.g.:
− Gateway openings.
− Header heights.
− Cable rack heights.
− Shunting areas around corners.
8 weeks Electrical system ■ Install electrical connections at the installation site.
■ Lay the conductor cross-section and fuse protection
according to the legal requirements.
■ Have the work required for remote support carried
out.
■ For network connection: install the network connec-
tion at the installation site.
8 weeks Bending tools Order your initial set of bending tools after consulting
with TRUMPF.
6 weeks For 2-axis backgauge or ■ Arrange for the installation of the compressed air
6-axis backgauge (option) supply at the installation site.
and/or pneumatic I axis − Take into account connection, purity, com-
(option) and/or pressed air requirements.
BendMaster (option): com-
pressed air supply
3 weeks Transport Provide auxiliary transport equipment.
Note: If the machine is conveyed to the customer's
site by Technical Service, the required means of trans-
portation and auxiliary transport equipment is provided
by them.

2‐4 Planning aid - Version 12 B876en

 Time before the deliv- Planning criterion Required measures
ery of the machine
2-3 weeks Feedback ■ Provide TRUMPF with feedback to confirm that the
requirements of the installation conditions have
been implemented.
During installation and Electrical installation ■ At the start of the installation process: have the sys-
start-up tem connected by a trained electrician.
Planning aid Tab. 2-1

B876en Planning aid - Version 12 2‐5

 2. Installation site

What does the customer Please consult a structural analyst for professional support, par-
need to do? ticularly in the context of the topic of floor requirements. Hand
over the "Installation site" section and the installation plan to the
structural analyst.

2.1 Space requirements

The following is documented in the TRUMPF installation:

■ Arrangement of options.
■ Space requirements for installation.
■ Space requirements of the moving elements.

Hall height TruBend Height of the Hall height

machine
5085 / 5130 2440 mm min. 3500 mm
(96 in) (min. 138 in)
5085 (X) / 2900 mm min. 3900 mm
5085 (SX) / 5130 (X) (114 in) (min. 154 in)
5170 / 5170 (S) 3065 mm min. 4100 mm
(121 in) (min. 161 in)
5230 / 5230 (S) / 3265 mm min. 4300 mm
5320 (129 in) (min. 169 in)
Hall height: (X) = extended installation height, (S) = Tab. 2-2
extended length, (SX) = extended installation height/length

Space requirement for For machines with the following options, make sure that their
MagicShoe/wireless foot working ranges do not overlap:
switch ■ Wireless foot switch (option)
■ MagicShoe (option)
In the event of overlapping working ranges, the operator might
trigger the wrong machine by mistake. In the case of a wireless
foot switch, the operator might actuate the wrong EMERGENCY
STOP push-button by mistake.

2‐6 Installation site - Version 12 B876en

 A Working range
Fig. 90684

Press table length Working range in Z Working range in X

direction direction
2210 mm (87 in) 3030 mm (119 in) 2500 mm (98 in)
2720 mm (107 in) 3810 mm (150 in) 2500 mm (98 in)
3230 mm (127 in) 4500 mm (177 in) 2500 mm (98 in)
4250 mm (167 in) 6090 mm (240 in) 3045 mm (120 in)
4420 mm (174 in) 6180 mm (243 in) 3090 mm (122 in)
Tab. 2-3

2.2 Floor requirements

The quality of the prepared parts can be guaranteed only when

the floor conditions meet TRUMPF requirements.

Surface

Flatness The floor on which the machine stands must be even.

Permissible flatness deviation (flatness tolerance):

■ Footprint range: max. 12 mm (½ in) per 10 m (33 ft).
■ Load-bearing points range: max. 2 mm (0.08 in) per 0.5 m
(1.64 ft).
The flatness tolerance can be determined for different measur-
ing point distances from the following diagram.

B876en Installation site - Version 12 2‐7

A Flatness tolerance B Measuring point distance
Flatness tolerance depending on the measuring point distance Fig. 65278

Measuring point distance Flatness tolerance Area

0.5 m (1.64 ft) 2 mm (0.08 in) Load-bearing points.
10 m (33 ft) 12 mm (½ in) Installation surface.
Examples Tab. 2-4

Measuring procedure:
The straight edge is placed on the high points of the surface
and determines the depth gauge at the lowest point. For the
selected measuring point distance the depth gauge may not be
greater than the flatness tolerance.

1 Straightedge l1 Measuring point distance

2 Vanishing line of the straight- t1 Depth gauge
edge
3 Surface
Measuring procedure for determination of the depth gauge Fig. 65581

Expansion joints ■ The entire installation surface must not have any expansion
joints.
■ No joint of any kind may be located in the load-bearing point
range of the machine or within at least 275 mm (11 in) of it.

2‐8 Installation site - Version 12 B876en

 ■ The distance of the plug bore holes to the edge of the base
plate must be at least 200 mm (8 in).
■ ToolMaster (option): If foundations are present, the arrange-
ment of the expansion joints must be paid attention to.

1 Area without expansion joints

ToolMaster (option) Fig. 85812

Floor quality

Note
The floor must be oil-proof.

Elastically cushioned base ■ Carrying capacity of the subsurface at least ks = 5000

plate kN/m3.
■ Minimum thickness:
− TruBend 5085–5230: 200 mm (7.87 in).
− TruBend 5230 (S): 230 mm (9.05 in).
− TruBend 5320: 250 mm (9.84 in).

B876en Installation site - Version 12 2‐9

 ■ Concrete quality (equivalent to strength class C 25/30).
■ The reinforcement of the base plate should meet or exceed
the following specifications. The specifications apply to the
reconstruction of the base.

TruBend 5085 5085 (X) 5085 (SX) 5130 5130 (X)

Top lengthwise (xsi) 3.20 cm2/m 3.20 cm2/m 3.20 cm2/m 3.24 cm2/m 3.24 cm2/m
Top transverse (eta) 3.20 cm2/m 3.20 cm2/m 3.20 cm2/m 3.20 cm2/m 3.20 cm2/m
Bottom lengthwise (xsi) 3.20 cm2/m 3.20 cm2/m 3.20 cm2/m 3.20 cm2/m 3.20 cm2/m
Bottom transverse (eta) 3.20 cm2/m 3.20 cm2/m 3.20 cm2/m 3.72 cm2/m 3.72 cm2/m
Reinforcement in the base plate: (X) = extended installation height, (S) = extended length, Tab. 2-5
(SX) = extended installation height/length

TruBend 5170 5170 (S) 5230 5230 (S) 5320

Top lengthwise (xsi) 3.62 cm2/m 6.55 cm2/m 4.90 cm2/m 7.18 cm2/m 7.94 cm2/m
Top transverse (eta) 3.20 cm2/m 3.20 cm2/m 3.20 cm2/m 3.80 cm2/m 4.20 cm2/m
Bottom lengthwise (xsi) 3.53 cm2/m 4.83 cm2/m 4.92 cm2/m 5.04 cm2/m 5.33 cm2/m
Bottom transverse (eta) 4.24 cm2/m 5.83 cm2/m 5.84 cm2/m 6.24 cm2/m 6.22 cm2/m
Reinforcement in the base plate: (X) = extended installation height, (S) = extended length, Tab. 2-6
(SX) = extended installation height/length

US specification: rebar spaced 12 in on center, on both the top

and bottom faces and oriented in both the longitudinal and trans-
verse directions.
■ <4.3 cm2/m: 2 layers of #4 rebar
■ 4.3 - 6.66 cm2/m: 2 layers of #5 rebar
■ >6.66 cm2/m: 2 layers of #6 rebar

When is a structural analyst A structural analyst must be consulted under the following condi-
generally required? tions:
■ The previously mentioned requirements for an elastically
embedded base plate are not met.
■ The system is to be set up on a ceiling plate/free-span base
plate.
■ The system is to be set up on fiber-reinforced concrete or
roller-compacted concrete.
■ The system is to be installed on a floor other than the one
named above.

Vibration damping The machine must be damped against oscillations if other sensi-
tive machines are located directly next to the machine or if the
machine is located on a free-span surface which cannot tolerate
these oscillations.

2‐10 Installation site - Version 12 B876en

 Vibration damping can be implemented by the following meas-
ures:
■ Use Sylomer mats to isolate the machine; thickness 12 mm
(0.47 in), quality SR 1200, violet color, base plate to the sub-
surface and on the side.
■ Structure of the floor (from the bottom to the top):
− A layer of construction mat.
− At least 300 mm (11.8 in) gravel layer with compaction.
− 120 mm (4.72 in) underbody C12/15 reinforced with 1
mild steel grid layer (steel cross-section lengthwise/cross-
wise 1.96 cm²/m, mesh width lengthwise/crosswise
100 mm, wire thickness lengthwise/crosswise 5 mm).

2.3 Weight load

Structural analysis ■ Perform a structural stress analysis of the load-bearing

capacity of the floor surface prior to installation.
■ Take into account the weights of the relevant components
and the load on the support points.

Note
If the concrete floor has the minimum thickness and quality, it
will not have to be subject to a structural check.

TruBend 5085 5085 (X) 5085 (SX) 5130 5130 (X)

Weight of machine – – – – –
■ Basic machine 8000 kg 8700 kg 9500 kg 10700 kg 11800 kg
(17637 lb) (19180 lb) (20944 lb) (23589 lb) (26015 lb)
■ Bending aid (option) 400 kg 400 kg 400 kg 400 kg 400 kg
(882 lb) (882 lb) (882 lb) (882 lb) (882 lb)
■ Parking position for bend- 250 kg 250 kg 250 kg 250 kg 250 kg
ing aid/support bracket (551 lb) (551 lb) (551 lb) (551 lb) (551 lb)
(option)
■ ACB laser optical angle 46 kg 46 kg 48 kg 50 kg 50 kg
measuring system (option) (101 lb) (101 lb) (106 lb) (110 lb) (110 lb)
■ Support bracket (option) 40 kg 40 kg 40 kg 40 kg 40 kg
(88 lb) (88 lb) (88 lb) (88 lb) (88 lb)
Static load on each support 27 kN 29 kN 33 kN 38 kN 39.4 kN
point, front
Dynamic load per front sup- 33 kN 37 kN 42 kN 51 kN 53.1 kN
port point
Static load on each support 17 kN 18 kN 19 kN 19 kN 22.3 kN
point, rear
Dynamic load per rear sup- 17 kN 18 kN 19 kN 19 kN 22.3 kN
port point

B876en Installation site - Version 12 2‐11

 TruBend 5085 5085 (X) 5085 (SX) 5130 5130 (X)
Weight support at the front 21700 mm² 21700 mm² 21700 mm² 21700 mm² 21700 mm²
per base on a surface area (854 in²) (854 in²) (854 in²) (854 in²) (854 in²)
of ...
Weight support at the rear 21700 mm² 21700 mm² 21700 mm² 21700 mm² 21700 mm²
per base on a surface area (854 in²) (854 in²) (854 in²) (854 in²) (854 in²)
of ...
Weight load: (X) = extended installation height, (S) = extended length, (SX) = extended Tab. 2-7
installation height/length

TruBend 5170 5170 (S) 5230 5230 (S) 5320

Weight of machine – – – – –
■ Basic machine 14150 kg 17850 kg 17200 kg 19850 kg 23400 kg
(31195 lb) (39353 lb) (37920 lb) (43762 lb) (51588 lb)
■ Bending aid (option) 400 kg 400 kg 400 kg 400 kg 400 kg
(882 lb) (882 lb) (882 lb) (882 lb) (882 lb)
■ Parking position for bend- 250 kg 250 kg 250 kg 250 kg 250 kg
ing aid/support bracket (551 lb) (551 lb) (551 lb) (551 lb) (551 lb)
(option)
■ ACB laser optical angle 50 kg 50 kg 52 kg 55 kg 55 kg
measuring system (option) (110 lb) (110 lb) (115 lb) (121 lb) (121 lb)
■ Support bracket (option) 40 kg 40 kg 40 kg 40 kg 40 kg
(88 lb) (88 lb) (88 lb) (88 lb) (88 lb)
Static load on each support 54 kN 72 kN 65 kN 78 kN 92 kN
point, front
Dynamic load per front sup- 73 kN 94 kN 88 kN 107 kN 130 kN
port point
Static load on each support 19 kN 20 kN 24 kN 25 kN 27 kN
point, rear
Dynamic load per rear sup- 18.7 kN 20 kN 24 kN 25 kN 27 kN
port point
Weight support at the front 39000 mm² 39000 mm² 53500 mm² 53500 mm² 53500 mm²
per base on a surface area (1535 in²) (1535 in²) (2106 in²) (2106 in²) (2106 in²)
of ...
Weight support at the rear 21700 mm² 21700 mm² 21700 mm² 21700 mm² 21700 mm²
per base on a surface area (854 in²) (854 in²) (854 in²) (854 in²) (854 in²)
of ...
Weight load: (X) = extended installation height, (S) = extended length, (SX) = extended Tab. 2-8
installation height/length

ToolMaster (option)
Weight of machine ■ Net: 5060 kg (11155 lb)
■ Gross: 7760 kg (17108 lb)
Static load on each support point ■ Net: 12.65 kN
(4 pieces) ■ Gross: 19.40 kN
Weight support per base on a sur- 150 x 150 mm (6 x 6 in)
face area of ...
Weight load Tab. 2-9

2‐12 Installation site - Version 12 B876en

 2.4 Stress due to vibration

In the immediate area around the system, external influences

can lead to vibration loads. Vibration stress can effect the qual-
ity of workpieces.

External influences are e.g.:

■ Fork lifts, industrial trucks, etc.
■ Installation or removal of other machines in the immediate
vicinity of the system.
■ Machines which generate vibrations during operation, such
as punching presses etc.

2.5 Ambient conditions

Machine ambient conditions Notes

■ When installing the machine, ensure that optoelectronic
safety device BendGuard is protected against strong drafts
and temperature fluctuations. Drafts between the transmitter
and receiver can sporadically result in error messages from
the BendGuard, thereby influencing productivity.
■ Operation of the machine at low temperatures requires suffi-
cient antifreeze agent in the cooling water.

Machine status Temperature

Operation +5 °C ... +40 °C
(+41°F ... +104°F)
Electrical cabinet air conditioning up to an ambi-
ent temperature of 45 °C (option):
+5 °C ... +45 °C
(+41°F ... +113°F)
Machine ambient conditions Tab. 2-10

Ambient conditions for the Note

control system
Coolant can evaporate or become diluted by refilling during oper-
ation of the machine. This leads to the minimum temperature ris-
ing during storage to -10°C. If the machine is stored at tempera-
tures below -10°C: drain coolant.

B876en Installation site - Version 12 2‐13

 Control status Temperature Humidity
Transport –20 °C ... +70 °C 20 to 75 % relative
(–4°F ... +158°F) humidity
90 % temporarily, but
non-condensing
Storage (machine –20 °C ... +55 °C 20 to 75 % relative
switched off) (–4°F ... +131°F) humidity
90 % temporarily, but
non-condensing
Ambient conditions for the control system Tab. 2-11

ToolMaster (option): Status of the Temperature

Ambient conditions for the rechargeable batter-
ies
rechargeable batteries
Storage/transport ■ Storage for at most 1 year:
–20°C … +30°C (–4°F … +86°F)
■ Storage for at most 3 months:
–20°C … +45°C (–4°F … +113°F)
Operation ■ During loading:
0°C … +45°C (+32°F … +113°F)
■ During unloading:
–20°C … +60°C (–4°F … +140°F)
Ambient conditions for the rechargeable batteries Tab. 2-12

2‐14 Installation site - Version 12 B876en

 3. Compressed air supply

Note
The connection point is indicated on the installation plan using
this symbol.

The machine must have a compressed air supply if the machine

contains at least one of the following components:
■ 2-axis backgauge.
■ 6-axes backgauge (option)
■ Pneumatic I-axis.
■ Tool changer ToolMaster (option)
■ Pneumatically operated special option.

Compressed air supply The compressed air connection may consist of flexible or fixed
pipelines connected to the machine.
The ToolMaster needs a separate compressed air connection.

Connection and Property Requirement

consumption values Required pressure 6±1 bar (87±15 psi)
Average air consumption (required approx. 0.1 m3/h (0.06 cfm)
volume flow rate according to ISO
1217) ToolMaster (option): 33 m3/h
(19.42 cfm)
Connection and consumption values Tab. 2-13

Supply lines compressed Property Requirement

air supply Inside diameter of the connection min. 12.5 mm (½ in)
line
Inside diameter of main line min. 12.5 mm (½ in)
Length of the connecting line No limit
Supply lines compressed air supply Tab. 2-14

B876en Compressed air supply - Version 12 2‐15

Compressed air properties Property Requirement Quality Recommendation
at the tapping point class1
Dust-free Maximum particle 4 Air filter in front of the
size: 15 µm system
Maximum particle den-
sity: 8 mg/m3
Conden- Cooled down to 5 Cold dryer
sate-free +7 °C (+44.6 °F),
pressure dew point
Oil-free Maximum oil content: 4 Oil-free sealing screw-
5 mg/m3 type compressor with
active carbon filter
Compressed air properties at the tapping point Tab. 2-15

1 ISO°8573-1; 2010 edition

2‐16 Compressed air supply - Version 12 B876en

 4. Electrics

Target group The requirements specified in the "Electrical" section must be

met by a company which specializes in electrical installations.

IEC/NEC conditions The IEC conditions apply worldwide, the NEC conditions apply
only for Canada and the USA.

4.1 Power supply

Note
The central connection point is on the electrical cabinet and is
shown on the installation plan with the illustrated symbol.

Connected loads

Notes
■ Impermissible voltage fluctuations endanger the faultless
operation of the machines and reduce their performance. A
voltage stabilizer is necessary.
■ The tolerance range applies to brief fluctuations. Measures
to stabilize the mains must be taken in the event of continu-
ally non-permitted fluctuations. These measures must be
coordinated with the energy supplier.

Rated power: Frequency

400 V ±10%2 50 Hz ± 1%

460 V +10%/–5%3 60 Hz ± 1%
Nominal voltage and Frequency Tab. 2-16

Before shipping, the system is set to the power supply voltage

and frequency specified by the customer.

2 The tolerance of the line must be determined if the nominal voltage is

380 V or 415 V at 50 Hz. No isolating transformer is required if the
tolerance is between 360 V and 440 V.
3 Specification complies with the American National Standard (ANSI),
C84.1 table 1, "Voltage range A".

B876en Electrics - Version 12 2‐17

 The following values apply to a working speed of 10 mm/s:

TruBend 5085 5130 5170 5230 5320

Connected load (IEC) 13 kVA 17.5 kVA 24 kVA 33 kVA 40 kVA
Connected load (NEC) 13.5 kVA 18.0 kVA 24.5 kVA 33.5 kVA 40.5 kVA
Fuse protection 3 x 35 A 3 x 50 A 3 x 50 A 3 x 80 A 3 x 80 A
Maximum interruption time 10 ms/10 s 10 ms/10 s 10 ms/10 s 10 ms/10 s 10 ms/10 s
Connected loads Tab. 2-17

The following values apply to the option "Increased working

speed at maximum press force":

TruBend 5085 5130 5170 5230 5320

Connected load (IEC) 32 kVA 42 kVA 61 kVA 69 kVA 90 kVA
Connected load (NEC) 32.5 kVA 42.5 kVA 61.5 kVA 69.5 kVA 90.5 kVA
Fuse protection 3 x 50 A 3 x 63 A 3 x 80 A 3 x 100 A 3 x 125 A
Maximum interruption time 10 ms/10 s 10 ms/10 s 10 ms/10 s 10 ms/10 s 10 ms/10 s
Connected loads Tab. 2-18

ToolMaster (option)
Connected load (IEC) 12 kVA
Connected load (NEC) 14 kVA
Fuse protection 40 A
Fuse protection (NEC) Class J
Tab. 2-19

NEC conditions for fuses The use of slow-blow fuses is preferred. If these fuses are also
used for branch circuits, an ETI type fuse must be used to pro-
tect the machine from current peaks when switching the
machine on.

SCCR value In order to achieve an SCCR value of 35 kA, use the following
back-up fuse:
■ TruBend 5085 / 5130 / 5170:
− Fuse holder class J (e.g. Eaton JM60100-3CR and CVRI-
J-60100).
− Fuse link class J, 80 A (e.g. Eaton LPJ-80SP).
■ TruBend 5230 / 5320:
− Fuse holder class J (e.g. Eaton JM60100-3CR and CVRI-
J-60100).
− Fuse link class J, 100 A (e.g. Eaton LPJ-100SP).

2‐18 Electrics - Version 12 B876en

 Connecting cables

Establish the electric power supply in accordance with DIN EN

60204-1/4.3.1:

IEC
Electrical line Copper line, at least four-core (L1, L2, L3, PE)
Conductor cross-section Designed according to:
IEC 60364-4-43 (VDE 0100-430)
Ground wires Designed according to:
IEC 60364-5-54 (VDE 0100-540)
Requirements for the connecting cable Tab. 2-20

The following values apply to a working speed of 10 mm/s:

IEC
TruBend 5085 5130 5170 5230 5320
Conductor cross-sec- mm² 10 10 16 25 50
tion (multiwire)
Conductor cross-sec- mm² 10 16 25 35 50
tion (solid)
Conductor cross-section Tab. 2-21

The following values apply to the option "Increased working

speed at maximum press force":

IEC
TruBend 5085 5130 5170 5230 5320
Conductor cross-sec- mm² 10 16 25 50 704
tion (multiwire)
Conductor cross-sec- mm² 16 25 35 50 –
tion (solid)
Conductor cross-section Tab. 2-22

NEC
Electrical line ■ Copper line, four-core (L1, L2, L3, PE).
■ THHN copper or equivalent is recommended (2000 V test voltage) designed
for a maximum temperature of +90° C (+194° F).
■ No aluminum lines may be used for the machine connection.
Conductor cross-section ■ The conductor cross-section must meet NEC 670-4 (a). The conductor cross-
section must be designed for at least 125 % of the nominal current. The
nominal current is specified on the nameplate.
■ To ensure voltage stability and rating, the line dimension should be larger
than specified in the NEC table 310-16.
Requirements for the connecting cable Tab. 2-23

4 Do not use wire end ferrules.

B876en Electrics - Version 12 2‐19

 The following values apply to a working speed of 10 mm/s:

NEC
TruBend 5085 5130 5170 5230 5320
Conductor cross-sec- AWG 8 8 8 4 1
tion
Conductor cross-section Tab. 2-24

The following values apply to the option "Increased working

speed at maximum press force":

NEC
TruBend 5085 5130 5170 5230 5320
Conductor cross-sec- AWG 8 6 4 1 0
tion
Conductor cross-section Tab. 2-25

4.2 Power supply

Uninterruptible Power Supply (UPS)

The following applies in the event that it is necessary to connect

the system to an uninterruptible power supply (UPS):
■ When working out the dimensions of the UPS, the short-cir-
cuit and overload responses of the UPS system are to be
taken into account alongside the continuous power and the
electrical connected loads.
■ As a rule: overload capacity of the UPS ≥200 % for 0.5 s.
■ Due to the use of servo inverters or frequency converters,
power recovery is possible in certain load situations.

Note
The dimensioning of the uninterruptible power supply must be
established without fail by the manufacturer of the UPS plant!

Residual current device (RCD)

Notes
■ Whether a fault current circuit breaker has to be used
depends upon the local electricity company.

2‐20 Electrics - Version 12 B876en

 ■ On the line side, only residual current circuit breakers of
type B (sensitive to all types of fault current, EN
50178/[Link]; VDE 0160) are approved.

A fault current circuit breaker provides protection from fault cur-

rents due to directly or indirectly touching live parts.

Fault current circuit breaker If a fault current circuit breaker is used to provide protection
for direct contact from direct contact, an isolating transformer must be used
(EN 50178 section [Link], VDE 0160). This is because the
leakage current resulting from the design is >30 mA.

Fault current circuit breaker If a fault current circuit breaker is to be used to provide protec-
for indirect contact tion from indirect contact, this must be selected depending on
the machine's fault current.

Note
In rare cases, customer-side voltage fluctuations on the
machine's power input filter may lead to higher leakage currents
than the typical value specified. The main power supply and the
machine must then be separated by an isolating transformer.
Typical leakage currents are 300 mA.

If a fault current circuit breaker is used, observe the following

requirements:

Property Requirement
Back-up fuse (see "Tab. 2-17", pg. 2‐18)
Fault current circuit breaker 63 A / 300 mA
Min. permissible cross-section (see "Connecting cables", pg. 2‐19)
Tab. 2-26

TRUMPF recommends the following fault current circuit breaker:

■ DOEBKE: DFS 4B SKS 63-4 / 0.3

ToolMaster (option)
Back-up fuse 3-pole C40A
Fault current circuit 63 A / 300 mA
breaker
fault current circuit breaker sensitive to all
types of current, short-time delayed type B

B876en Electrics - Version 12 2‐21

 ToolMaster (option)
Min. permissible con- 10 mm²
ductor cross-section
(fine-stranded)

Connection to power Permanent connection or power socket CEE

supply 5 x 63 A
Tab. 2-27

Power supply configurations

A TN system with grounded star point is the standard power

supply configuration for the connection.
When connecting the machine to a power supply with a
grounded outer conductor, an isolating transformer must be used.
For IT and TT networks, as well as for asymmetrical mains sup-
plies (one phase grounded, corner-grounded delta network), the
machine must be connected via an isolating transformer by the
customer.

NEC conditions Power supply configuration:

■ A mains supply in star connection and with a grounded star
point (Solidly Grounded Wye) is required.
■ If the existing mains supply is in delta connection (Corner
Grounded Delta), the customer must install a grounded iso-
lating transformer in star connection (with grounded star
point) (see NEC item 450-5).

Grounding:
■ The machine and power distributor system must be equip-
ped with a grounding line in accordance with NEC article
250, "Grounding".
■ For details on grounding power distributor systems and
industrial plants, refer to the NEC standards or consult an
electrician or the power station.

IT system

A surge diverter is required if the machine is connected to an IT

system.

2‐22 Electrics - Version 12 B876en

 TRUMPF recommends surge diverters from the following manu-
facturers:
■ Phoenix Contact GmbH & Co. KG, Flachsmarktstrasse 8,
32825 Blomberg, Germany e-mail: info@[Link].
■ Dehn+Söhne, PO Box No. 1640, D-92306 Neumarkt, E-mail:
info@[Link].

Isolating transformer

Depending on the ordered configuration of the machine and on

the power supply at the installation site, the voltages can be
adjusted in the electrical cabinet at the 3-phase power supply
(= [Link] +CB1 –T3) for 3x 208 V, 3x 230 V, 3x 380 V,
3x 400 V, 3x 415 V, 3x 440 V, 3x 460 V, 3x 480 V, 3x 500 V,
3x 525 V and 3x 550 V.

4.3 Remote support

Notes
■ The connection point is indicated on the installation plan
using this symbol.
■ The connection point can be found in the machine's electri-
cal cabinet.

Remote support via Internet Note

Telepresence BoxThe machine electrical cabinet with a Teleser-
vice box.

■ A cable with an RJ45 plug is to be supplied to connect the

Telepresence Box to the internal customer network.
■ The machine must be configured via TCP-IP to enable
access to the customer network.
■ The machine must be able to connect to the TRUMPF Tele-
presence Portal via the customer network and the Internet.
The connection is made via IPSec using standard ports
UDP 500 and UDP 4500.
■ The firewall access rules should not be automatically deacti-
vated due to longer periods of non-use.

B876en Electrics - Version 12 2‐23

 4.4 Cloud connection

For the cloud connection, the following configuration is required

in the user's LAN:
■ TCP Port 443 and the protocols HTTPS and WSS (Secure
WebSocket), enabled for Internet access via the LAN.

Network requirements for The following connections are required for the cloud connection:
cloud connection ■ 1x LAN port.
■ Ethernet IEEE 802.3 10/100-BaseTX, RJ 45, Full Duplex,
Auto-MDIX.

4.5 Network link

TRUMPF provides the following interfaces for the network (e.g.

connection to a programming system) in the electrical cabinet of
the machine:
■ RJ 45 plugs for customers with shielded-twisted pair network
cabling.

Providing power supply ■ Worldwide (outside the USA and Canada): 230 V with
grounded socket or in accordance with the receptive national
standard. The grounded coupling is delivered with the
machine.
■ USA and Canada: 115 V with plug socket according to USA
standard.

2‐24 Electrics - Version 12 B876en

 5. Operating materials

5.1 Hydraulic oil

Notes
■ On delivery, the hydraulic oil tank is filled with the maximum
quantity of hydraulic oil permitted.
Exceptions:
Due to the dangerous goods regulations, the machine must
be delivered without filling in some countries. This exception
regulation is referred to at the conclusion of the contract.
For air freight, the hydraulic oil will be delivered separately.
If the machine is delivered with an unfilled hydraulic oil tank,
Technical Service will provide an oil pump.
■ Only filtered oil may be filled in the hydraulic oil tank. The fil-
ter used for this must have a filter fineness of 10 μm.

For initial filling, the following hydraulic oil is used:

■ TruBend Fluid (mat. no. 1555678).

Notes
■ Hydraulic oil from other manufacturers can also be used if it
is certified as having equivalent properties (specification in
accordance with DIN 51524-3).
■ TRUMPF recommends the use of TruBend Fluid. When
other hydraulic oils are used, this can lead to noise develop-
ment or impairment in the running behavior.

Hydraulic oil volume TruBend Hydraulic oil volume

5085 70 l (19 gal)
5085 (X) 70 l (19 gal)
5085 (SX) 70 l (19 gal)
5130 120 l (32 gal)
5130 (X) 120 l (32 gal)
5170 180 l (48 gal)
5170 (S) 220 l (58 gal)
5230 180 l (48 gal)
5230 (S) 220 l (58 gal)
5320 220 l (58 gal)
Hydraulic oil volume: (X) = extended installation height, (S) Tab. 2-28
= extended length, (SX) = extended installation height/length

B876en Operating materials - Version 12 2‐25

 6. Transport

The arrangements and transport of the system from the truck to

its final installation site need to be prepared and carried out.

Machine conveyance to In some countries the customer can have TRUMPF transport
customer's site by TRUMPF the system from the truck to the final installation site, the so-
called "Machine conveyance to customer's site". The transport
route may not exceed the length contractually agreed to. The
transport route must be flat, with no steps or ramps.
If the customer has assigned TRUMPF with conveying the
machine to the customer's site, the customer must only ensure
that the transport route satisfies the requirements mentioned
below. TRUMPF will deal with all the other points mentioned in
the following, including auxiliary tools and means of transporta-
tion.

6.1 Preparing transport

Before the machine is delivered, check the following:

■ Is there sufficient space for transport to the installation site?

■ Can the floor can be crossed with armored rollers, etc.?
■ Are the gateway openings, header heights and cable rack
heights sufficient?

Transport dimensions

TruBend 5085 5085 (X) 5085 (SX) 5130 5130 (X)

Weight 8000 kg 8700 kg 9500 kg 10700 kg 11800 kg
(17637 lb) (19180 lb) (20944 lb) (23589 lb) (26015 lb)
Length 3020 mm 3020 mm 3530 mm 3980 mm 3980 mm
(119 in) (119 in) (139 in) (157 in) (157 in)
Width 1800 mm 1800 mm 1800 mm 1800 mm 1800 mm
(71 in) (71 in) (71 in) (71 in) (71 in)
Height 2375 mm 2835 mm 2835 mm 2375 mm 2835 mm
(94 in) (112 in) (112 in) (94 in) (112 in)
Transport dimensions: (X) = extended installation height, (S) = extended length, (SX) = Tab. 2-29
extended installation height/length

TruBend 5170 5170 (S) 5230 5230 (S) 5320

Weight 14150 kg 17850 kg 17200 kg 19850 kg 23400 kg
(31195 lb) (39353 lb) (37920 lb) (43762 lb) (51588 lb)
Length 3980 mm 4970 mm 4150 mm 5140 mm 5180 mm
(157 in) (196 in) (163 in) (202 in) (204 in)

2‐26 Transport - Version 12 B876en

 TruBend 5170 5170 (S) 5230 5230 (S) 5320
Width 1900 mm 1900 mm 2055 mm 2055 mm 2055 mm
(75 in) (75 in) (81 in) (81 in) (81 in)
Height 3000 mm 3000 mm 3200 mm 3200 mm 3200 mm
(118 in) (118 in) (126 in) (126 in) (126 in)
Transport dimensions: (X) = extended installation height, (S) = extended length, (SX) = Tab. 2-30
extended installation height/length

ToolMaster (option)
Weight Net: 5060 kg (11155 lb)

Note
The machine may not be filled with tools during trans-
port.
Length 2950 mm (116 in)
Width 2150 mm (110 in)
Height 2800 mm (85 in)
Tab. 2-31

6.2 Permitted auxiliary tools

Note
The carrying capacity of the authorized auxiliary equipment must
be selected in such a way that the maximum load can be trans-
ported safely.

Authorized additional equipment Carrying capacity

Crane truck for unloading the truck According to the machine weight
Forklift truck for the transportation At least 3 t (6614 lb)
of the accessory parts
Gantry crane for transporting the According to the machine weight
machine
or
or
TruBend 5085 – 5230: at least
Armored rollers: 1 steerable, 2 10 t (22047 lb)
fixed TruBend 5320: at least 12 t
(26456 lb)
A minimum of 2 hydraulic hoisting TruBend 5085 – 5230: at least
jacks, adjustable height ≤50 mm 10 t (22047 lb)
(≤1.97 in) TruBend 5320: at least 12 t
(26456 lb)
Hoisting iron with extension. –
Length: 1 m (3.28 ft)
When transporting with a crane: According to the machine weight
two type A shackles (DIN 82101)
Adjustable crane chain According to the machine weight
Lifting belt According to the machine weight
Permitted auxiliary tools Tab. 2-32

B876en Transport - Version 12 2‐27

 Shackle When transporting the machine with a crane: use two type A
shackles (DIN 82101):

Type A shackle Fig. 52814

TruBend 5085 / 5130 5170 / 5230 / 5320

Permissible loading 118 kN 196 kN
Bolt diameter 2" 2 3/4"
d1 47 mm 58 mm
(1.9 in) (2.3 in)
d4 52 mm 68 mm
(2.0 in) (2.7 in)
h1 158 mm 211 mm
(6.24 in) (8.3 in)
b1 73 mm 90 mm
(2.9 in) (3.5 in)
Shackle dimensions, form A Tab. 2-33

ToolMaster (option): Permitted auxiliary

tools

Note
The carrying capacity of the authorized auxiliary equipment must
be selected in such a way that the maximum load can be trans-
ported safely.

2‐28 Transport - Version 12 B876en

 Authorized additional equipment Carrying capacity
Crane truck for unloading the truck According to the machine weight
and an indoor crane for transport-
ing the machine:
■ 4 adjustable crane chains with
eye hooks (DIN 7540), length
each at least 2 m (70 in).
or
■ 4 transport belts with shackle
form A (DIN 82101), length
each at least 2 m (70 in).
or
Forklift truck with long forks for In the centroid (see "Fig. 72333",
unloading the truck or for transport pg. 2‐34): at least 6 t (13228 lb)
Armored rollers for transport: At least 6 t (13228 lb)
1 steerable, 2 fixed
4 hydraulic hoisting jacks At least 6 t (13228 lb)
Tab. 2-34

Shackle When transporting the machine with a crane: use four type A
shackles (DIN 82101):

Type A shackle Fig. 72337

ToolMaster (option)
Carrying capacity 4000 kg (8818 lb)
d1 27 mm (1.06 in)
d2 30 mm (1.18 in)
d3 60 mm (2.36 in)
d4 M30
d5 29 mm (1.14 in)
b 42 mm (1.65 in)
h 91 mm (3.58 in)
Tab. 2-35

B876en Transport - Version 12 2‐29

 6.3 Checking, unloading and
transporting the machine

On delivery: check the machine

1. Examine all components for any transport damage.

2. Record visible damage caused during transport on the cargo
note and have the record countersigned by the truck driver.
3. Report any hidden transport damage to the insurance com-
pany and TRUMPF within six days.

Unloading and transporting the machine

Suspended load!
DANGER
Falling loads could lead to severe bodily injury or even
death.
Ø Observe safety regulations for the handling of heavy loads.
Ø Never walk under a suspended load.
Ø Use tested and appropriately sized tackle and means of
transportation.
Ø Employ qualified technicians to transport the machine.
Ø Carry out transport in accordance with the transport regula-
tions.

The machine tilts forward!

DANGER
Mortal danger!
Ø All persons must be clear of the danger zone during
machine transport.
Ø Only approved accessories and equipment may be used for
transport and installation.
Ø The machine may not be transported unless transport equip-
ment is installed.
Ø Transport equipment may not be removed until the the
machine is at the final installation site.
Ø The machine may be operated only if it is anchored firmly
in the foundation.

All transport securing devices must be stored in a safe place.

The transport securing devices must be reattached if the
machine is moved or converted at a later point in time.

2‐30 Transport - Version 12 B876en

 A Distance between the lifting X Distance between the upper
brackets edge of the machine and the
D Diameter center of the lifting brackets

Position of the lifting brackets Fig. 68985

TruBend 5085 5085 (X) 5085 (SX) 5130 5130 (X)

Diameter D 70 mm 70 mm 70 mm 70 mm 70 mm
(2.8 in) (2.8 in) (2.8 in) (2.8 in) (2.8 in)
Distance A between the lifting 1290 mm 1290 mm 1800 mm 2230 mm 2230 mm
brackets (50.8 in) (50.8 in) (70.9 in) (87.8 in) (87.8 in)
Distance X between the 180 mm 180 mm 180 mm 180 mm 180 mm
upper edge and the center of (7.1 in) (7.1 in) (7.1 in) (7.1 in) (7.1 in)
the lifting bracket
Thickness of the lifting bracket 40 mm 40 mm 40 mm 40 mm 40 mm
(1.6 in) (1.6 in) (1.6 in) (1.6 in) (1.6 in)
Dimensions of the lifting brackets: (X) = extended installation height, (S) = extended length, Tab. 2-36
(SX) = extended installation height/length

TruBend 5170 5170 (S) 5230 5230 (S) 5320 (X)

Diameter D 74 mm 74 mm 74 mm 74 mm 74 mm
(2.9 in) (2.9 in) (2.9 in) (2.9 in) (2.9 in)
Distance A between the lifting 2050 mm 3040 mm 2050 mm 3040 mm 3040 mm
brackets (80.7 in) (119.7 in) (80.7 in) (119.7 in) (119.7 in)
Distance X between the 120 mm 120 mm 160 mm 160 mm 160 mm
upper edge and the center of (4.7 in) (4.7 in) (6.3 in) (6.3 in) (6.3 in)
the lifting bracket
Thickness of the lifting bracket 70 mm 70 mm 70 mm 70 mm 70 mm
(2.8 in) (2.8 in) (2.8 in) (2.8 in) (2.8 in)
Dimensions of the lifting brackets: (X) = extended installation height, (S) = extended length, Tab. 2-37
(SX) = extended installation height/length

B876en Transport - Version 12 2‐31

 The machine can be transported to the installation site on arm-
ored rollers in the following ways:
■ Position the machine directly on armored rollers when
unloading it from the truck.
■ Due to a danger of tilting, only raise the machine using
hydraulic hoisting jacks at the points marked and insert arm-
ored rollers underneath.

Attachment points for the hydraulic hoisting jack Fig. 81818

1 Transport direction 3 Position of fixed armored roller

2 Position of steerable armored
roller
Transport with armored rollers Fig. 70835

2‐32 Transport - Version 12 B876en

 ■ The support areas of the armored rollers must be located
centrally below the respective support points of the machine.
■ The machine may not be pulled using a forklift truck.

1. Remove machine packaging.

2. Secure the shackles to the lifting brackets of the machine.
3. Unload the machine using a crane.
4. Transport the accompanying accessories box and any acces-
sory parts that may be separately packaged directly from the
truck to the installation site with a forklift.
5. Either
Ø Transport the machine to the installation site on armored
rollers.
or
Ø Transport the machine to the installation site using an
indoor crane with sufficient carrying capacity.
6. To remove armored rollers: Due to a danger of tilting, only
apply hydraulic hoisting jacks at the points marked and raise
the machine.

ToolMaster (option): Unloading and

transporting the machine

Suspended load!
DANGER
Falling loads could lead to severe bodily injury or even
death.
Ø Observe safety regulations for the handling of heavy loads.
Ø Never walk under a suspended load.
Ø Use tested and appropriately sized tackle and means of
transportation.
Ø Employ qualified technicians to transport the machine.
Ø Carry out transport in accordance with the transport regula-
tions.

B876en Transport - Version 12 2‐33

 Observe the position of the center of gravity when transporting
the machine:

Position of center of gravity Fig. 72333

1 Position for eyebolt

Transport using crane Fig. 72335

2‐34 Transport - Version 12 B876en

 Transporting by fork lift Fig. 72334

1 Position for armored rollers

Transport with armored rollers Fig. 79837

B876en Transport - Version 12 2‐35

 1 Attachment point for lashing straps
Transport securing pallet Fig. 72384

Unloading the machine from Note

the truck
The transport securing pallet must not be removed.
1. Remove machine packaging.
2. Unloading the machine:
Ø Attach the crane chains or transport belts at the provided
securing points.
Ø Unload the machine using a crane.
or
Ø Unload machine using a forklift truck.

Transporting the machine to 3. Transport the machine using a crane.

the installation site
or
Ø Transport the machine using a forklift truck.
or
Ø Transport the machine using armored rollers.
4. Transport additionally packed accessories using a forklift
directly from the truck to the machine installation site.

Removing the transport 5. Remove the transport securing pallet.

securing pallet

2‐36 Transport - Version 12 B876en

 Chapter 3

Description

1 Machine concept 3‐4

2 Machine axes 3‐5

2.1 Bending aid axes (option) 3‐6
2.2 Press beam inclination 3‐7

3 The most important assemblies 3‐8

3.1 Machine Frame 3‐9
3.2 Side safety doors 3‐10
3.3 On-demand servo drive with 4-cylinder equip- 3‐11
ment
3.4 Crowning 3‐12
Manual wedge crowning 3‐13
CNC-controlled wedge crowning (option) 3‐13
3.5 Backgauge 3‐13
2-axis backgauge 3‐14
4-axes backgauge (option) 3‐15
5-axes backgauge (option) 3‐15

B876en 2019-05-18 Description 3‐1

 6-axes backgauge (option) 3‐16
Additional backgauge fingers (option) 3‐17
3.6 Tool clamping 3‐17
Manual upper tool clamp 3‐18
Hydraulic upper tool clamp (option) 3‐19
Hydraulic lower tool clamp 3‐19
3.7 BendGuard (option) 3‐20
Increased working speed at maximum 3‐21
press force (option)
Manual BendGuard (option) 3‐22
Automatic BendGuard (option) 3‐22
3.8 Control system 3‐23
Operation panel with touchscreen 3‐23
Additional screen (option) 3‐24
Graphical shop floor programming 3‐25
Shop floor programming TecZone Bend 3‐26
(option)
3.9 Lower tool displacement (I axis) 3‐27
Pneumatic I axis 3‐27
CNC controlled I axis (Option) 3‐28
3.10 MobileControl 3‐28
3.11 MobileControl Pro (option) 3‐29
3.12 Wireless foot switch (option) 3‐30
3.13 MagicShoe (option) 3‐31
Notes on use 3‐32
Notes on maintenance 3‐34
3.14 Work area illumination (option) 3‐34
3.15 ACB laser optical angle measuring system 3‐35
(option)
3.16 Tactile ACB Wireless angle measuring sys- 3‐37
tem (option)
3.17 Angle measuring system ACB (option) 3‐40
3.18 Sheet thickness detection TCB (option) 3‐42
3.19 Angle measuring system OCB (option) 3‐44
3.20 Optical set up and positioning aid Tool Indica- 3‐44
tor (option)
3.21 Part Indicator insertion aid (option) 3‐45
3.22 2D code scanner (option) 3‐46
3.23 Simple support bracket (only in the area of 3‐47
application of the EC Machinery Directive)

3‐2 Description 2019-05-18 B876en

 3.24 Support bracket (option) 3‐48
Parking position for bending aid/support 3‐49
bracket (option)
Table length and table width extension 3‐50
3.25 Bending aid (option) 3‐51
Bending aid (option) 3‐52
Parking position for bending aid/support 3‐53
bracket (option)
3.26 Network connection 3‐54
3.27 Interfaces for robot (optional) 3‐54
3.28 MyTRUMPF customer portal 3‐54
3.29 Tool changer ToolMaster (option) 3‐55

4 Industry 4.0 with TruConnect 3‐57

4.1 What is Industry 4.0 at TRUMPF? 3‐57
4.2 Production overview 3‐57
4.3 Production control 3‐58
4.4 Connectivity 3‐59
4.5 Remote support 3‐60
4.6 TRUMPF machine apps 3‐60

5 Tools from TRUMPF 3‐62

6 Technical data 3‐65

B876en 2019-05-18 Description 3‐3

 1. Machine concept

TruBend is a CNC-controlled press brake for bending flat metal

sheets.

The press brake is made up of the following components:

■ Machine frame.
■ Press beam with tool clamp for upper tool (punch)
■ Press table with tool clamp for lower tools (die).
■ Press beam drive.
■ Backgauge for workpiece positioning.

How does a press brake In order to use a press brake for bending, a tool is required
work? which is mounted on the press beam or press table. Typical
tools used for this purpose are punches and dies. Punches are
mostly attached to the press beam and dies to the press table..
The required tool depends on the bending method, raw material,
sheet thickness and angle.
The workpiece is manually inserted into the machine. The work-
piece is placed on the lower tool. It is pushed into the machine
until it fits closely against the backgauge.
The stroke is triggered via the PRESS BEAM DOWN foot
switch. The press beam moves downwards. The punch presses
the workpiece into the die of the lower tool. The workpiece is
bent.
After the bending process, the press beam moves upwards
again. The workpiece can be removed and positioned for the
next bending operation.

3‐4 Machine concept 2019-05-18 B876en

 2. Machine axes

Machine axes (Example: 6-axes backgauge) Fig. 68988

Axis Description TruBend Serie 5000

Y Upward and downward movement of the press beam. CNC-controlled
R Upward and downward movement of the backgauge. CNC-controlled
X Forward and backward movement of the backgauge CNC-controlled
fingers.
Z Movement of the backgauge towards the right and left. For 2-axis backgauge: Manual
For 4, 5 and 6 axis backgauge:
CNC-controlled
V Crowning: Bowing the press table upwards, to compen- CNC-controlled
sate for the bowing of the press beam.
I Lower tool displacement: Forward and backward move- pneumatic
ment of the lower tool clamp.
or
CNC-controlled
Tab. 3-1

B876en 2019-05-18 Machine axes 3‐5

 2.1 Bending aid axes (option)

Bending aid axes (option) Fig. 78675

Axis Description TruBend Serie 5000

S Bending aid swivel axis (option): for supporting the CNC-controlled
workpiece during bending.
H Bending aid lift axis (option): automatic workpiece CNC-controlled
adjustment to lower tool height.
Tab. 3-2

3‐6 Machine axes 2019-05-18 B876en

 2.2 Press beam inclination

Press beam inclination Fig. 73970

The control system uses the program data to calculate the

required inclination of the press beam (Y1/Y2).

The inclination of the press beam can be corrected manually via

the Y2 axis, e.g. for a long bend length, when the bending
angle deviates over the entire length.
■ Positive value: Y2 positioned downwards.
■ Negative value: Y2 positioned upwards.

Note
The one-sided lowering of the press beam is allowed as the dif-
ference between Y1 and Y2 is max. 10 mm.

B876en 2019-05-18 Machine axes 3‐7

 3. The most important assemblies

1 On-demand servo drive with 4- 7 Nameplate and CE marking 13 Lower tool holder
cylinder equipment 8 Support bracket (option) 14 Lower tool displacement (I axis)
2 Electrical cabinet (control cabi- 9 Foot switch 15 BendGuard (option)
net)
10 ACB laser optical angle measur- 16 Upper tool clamping
3 MobileControl ing system (option) 17 Electrical cabinet (power cabi-
4 Operating panel 11 Crowning net)
5 Backgauge 12 Press table 18 Press Beam
6 Side safety doors
Machine assemblies Fig. 68989

3‐8 The most important assemblies 2019-05-18 B876en

 3.1 Machine Frame

C-frame Fig. 68992

Precise workpieces The machine frame is a bend-proof and torsion-free all-steel

combined with easy welded construction. The machine frame consists of the follow-
accessibility ing elements:
■ 2 Side parts
■ Press Table
■ 1 Cross beam.

B876en 2019-05-18 The most important assemblies 3‐9

 3.2 Side safety doors

Fig. 72891

The safety doors at the side are sliding doors.

Exception: With a parking position for the bending aid (option),
the safety door is a swing door on the side of the parking posi-
tion.

3‐10 The most important assemblies 2019-05-18 B876en

 3.3 On-demand servo drive with 4-
cylinder equipment

On-demand servo drive with 4-cylinder equipment Fig. 68991

Four times the power The press beam is driven via 4 electronically controlled
hydraulic cylinders.
The more evenly the press force is distributed over the press
beams, the smaller the deflection. Four hydraulic cylinders
instead of two reduce the deflection of the beam to a minimum.
The hydraulic system only works when the press beam is
moved.

B876en 2019-05-18 The most important assemblies 3‐11

 3.4 Crowning

Crowning principle Fig. 68995

Compensating deflection The crowning compensates for the bowing of the press beam
and table during bending, so as to ensure an even and straight
bending angle over the entire length of the bend.

A Result with crowning facility B Result without crowning facility

Fig. 32207

Characteristic features ■ A wedge system is installed in the press table. Before bend-
ing, the press table is lifted in the middle. During this, the
wedges are pushed over each other.

3‐12 The most important assemblies 2019-05-18 B876en

 Manual wedge crowning

The bowing of the press table is provided by wedges, which are

integrated into the press table. The wedges create a bending of
press table, lower tool clamp and lower tool by means of a
defined movement (longitudinal displacement).
The crowning can be centrally adjusted by means of a crank on
the press table. The current crowning position is indicated on a
display.

CNC-controlled wedge crowning (option)

The bowing of the press table is provided by wedges, which are

integrated into the press table. The wedges create a bending of
press table, lower tool clamp and lower tool by means of a
defined movement (longitudinal displacement).
The crowning works completely independently and calculates
the correct crowing value from the program data.
Direct programming by the operator is possible, but not required.
The drive for the crowning facility is integrated in the press table.

3.5 Backgauge

6-axes backgauge (option) Fig. 68993

Precise stops The backgauge is used to define the position of the workpiece
and the side length.
The workpiece is manually inserted into the machine. The work-
piece is placed on the lower tool. It is pushed into the machine

B876en 2019-05-18 The most important assemblies 3‐13

 until it fits closely against the backgauge finger of the back-
gauge.
The backgauge can move to the next programmed position at
different times.

Characteristic features In each system, the backgauge axes are controlled differently:

Backgauge R1 R2 X1 X2 Z1 Z2
2 axis CNC – CNC – Man- Man-
ual ual
4 axes CNC – CNC – CNC CNC
5 axis CNC – CNC CNC CNC CNC
6 axis CNC CNC CNC CNC CNC CNC
Tab. 3-3

■ For 6-axis backgauge: Central lubrication of the X and R

drives minimizes maintenance costs.

2-axis backgauge

The backgauge can move upwards and downwards (R axis) and

forwards and backwards (X axis) in a CNC-controlled manner.
The axes are controlled through the machine control system.
Both backgauge fingers move on the same R and X axis.
The backgauge fingers can be shifted manually towards the
right and left (Z axis). For this, the backgauge fingers must be
moved into a secure position in front of the tool clamp. The
operator may only shift the backgauge fingers outside the dan-
ger zone.
The gauge fingers have three levels and can be folded up.

3‐14 The most important assemblies 2019-05-18 B876en

 4-axes backgauge (option)

4-axes backgauge (option) Fig. 71516

The backgauge can move upwards and downwards (R axis), for-

wards and backwards (X axis) and to right and left (Z axis) in a
CNC-controlled manner. The axes are controlled through the
machine control system.
Both backgauge fingers move on the same R, X and Z axis.
The gauge fingers have three levels and can be folded up.

5-axes backgauge (option)

5-axes backgauge (option) Fig. 71517

The backgauge can move upwards and downwards (R axis), for-

wards and backwards (X axis) and to right and left (Z axis) in a

B876en 2019-05-18 The most important assemblies 3‐15

 CNC-controlled manner. The axes are controlled through the
machine control system.
Both backgauge fingers move on the same R, X and Z axis.
One of the two gauge fingers can also move in the X direction
in a CNC-controlled manner.
The backgauge fingers have three stages and can fold up.

Technical data Value

Traverse path of the X5-axis ±65 mm
Tab. 3-4

6-axes backgauge (option)

6-axes backgauge (option) Fig. 68993

The backgauge can move upwards and downwards (R axis), for-

wards and backwards (X axis) and to right and left (Z axis) in a
CNC-controlled manner. The axes are controlled through the
machine control system.
Both backgauge fingers move in the X, Z and R directions inde-
pendently from each other.
The gauge fingers have three levels and can be folded up.
Central lubrication of the X and R drives minimizes maintenance
costs.

Additional stop rails The stop rails increase the stop range in the X direction. They
1160 mm (option) are screwed to the gauge fingers at the side.

3‐16 The most important assemblies 2019-05-18 B876en

 Additional backgauge fingers (option)

Additional backgauge finger Additional backgauge fingers are available for 2 and 4 axis back-
860 mm/1000 mm (option) gauges.
Additional backgauge fingers enable an increased part precision
by providing additional securing points when bending long, nar-
row sheet metal strips.
The additional gauge fingers are positioned on the guide rail of
the backgauge and are manually positioned in the Z direction.

Backgauge fingers 1000 mm The backgauge fingers increase the maximum range before stop
(option) in the X direction.

3.6 Tool clamping

Hydraulic upper tool clamp (option) Fig. 74291

Tool clamping Tools are secured in the tool clamp. The tool clamp consists of
an upper tool clamp and a lower tool clamp.
The tool clamp is self-centering, which means that the tools are
automatically aligned at the center above the press table during
the clamping operation.
Head-bearing and shoulder-bearing tools can be clamped with
the upper tool clamp.

B876en 2019-05-18 The most important assemblies 3‐17

 Characteristic features The following versions are available:

Tool clamping Upper tool clamping Lower tool holder

Manual upper tool Clamping via Allen Automatic clamping
clampHydraulic lower screw via operating panel or
tool clamp (standard) the MobileControl unit
Hydraulic tool clamp Automatic clamping Automatic clamping
(option) via operating panel or via operating panel or
the MobileControl unit the MobileControl unit
Tab. 3-5

Manual upper tool clamp

1 Socket head screw SW 8

Manual upper tool clamp Fig. 69033

The tool clamp is opened and closed using Allen screws at the
front.

3‐18 The most important assemblies 2019-05-18 B876en

 Hydraulic upper tool clamp (option)

Hydraulic upper tool clamp (option) Fig. 74291

The hydraulic tool clamping clamps the tool using the clamp pis-
ton at intervals of 15 mm.
The tool clamp can be opened and closed automatically on the
operating panel or on the MobileControl unit.

Hydraulic lower tool clamp

Hydraulic lower tool clamp Fig. 69032

B876en 2019-05-18 The most important assemblies 3‐19

 The hydraulic tool clamping clamps the tool using the clamp pis-
ton at intervals of 15 mm.
The tool clamp can be opened and closed automatically on the
operating panel or on the MobileControl unit.

3.7 BendGuard (option)

1 Transmitter 4 Upper tool

2 Light field 5 Receiver
3 Lower tool
Fig. 69001

Definitely fast The optoelectronic safety device monitors the area in front of,
behind and below the upper tool during operation by means of a
light field.
The light field covers the lower part of the upper tool.
BendGuard detects the tool automatically and defines an area
around the tool tip which is monitored.
During bending, the area around the tool tip of the upper tool is
evaluated depending on the safety mode.
The press beam moves at a maximum speed between the
upper dead point and the mute point. The press beam will stop
if the light field is interrupted.
The press beam moves at reduced speed between the mute
point and the lower dead point. The optoelectronic safety device
is not active.

3‐20 The most important assemblies 2019-05-18 B876en

 Increased working speed at maximum
press force (option)

1 BendGuard light field

Fig. 65127

Working speeds up to The press beam can be run at a higher speed with BendGuard.
25 mm/s without angle The speed is not limited to 10 mm/s. The maximum press force
restrictions of the machine is available at all working speeds.
The BendGuard monitors the angular speed of the bending side.
If the maximum value is exceeded, the press beam stops and
the workpiece remains clamped. If the PRESS BEAM DOWN
foot switch is pressed again, the working speed of the safety
control system is limited to 10 mm/s and bending can continue.

Characteristic features ■ Only possible in connection with BendGuard.

■ The option increases the power consumed by the machine
(see the technical data).

B876en 2019-05-18 The most important assemblies 3‐21

 Manual BendGuard (option)

Fig. 97067

The BendGuard can be manually set to the required working

height.
The BendGuard can be manually moved to the rear to set up
the tools.

Automatic BendGuard (option)

Fig. 97066

The BendGuard will move automatically to the working height of

the programmed tool, as soon as the side safety doors and the
upper tool clamp are closed.

3‐22 The most important assemblies 2019-05-18 B876en

 To set up the tools, the BendGuard will automatically move up,
as soon as the upper tool clamp and a side safety door are
opened.

3.8 Control system

Software is protected by The software installed on the machine, including any storage
copyright media and documentation supplied may only be used for this
machine. The software may only be copied to make a backup.
The software may not be sold or passed on without the
machine. If the machine is sold, the buyer must assume a corre-
sponding obligation to this effect.

Operation panel with touchscreen

1 User interface (multi-touch 5 START

screen) 6 Unlock a machine with an ID
2 EMERGENCY STOP push-but- card (RFID)
ton 7 Setting inclination and height
3 USB port 8 Keyboard and mouse (incl.
4 STOP holder) (option)
Operating panel Fig. 69009

Operating and programming The machine is operated using the touchscreen. All functions
directly and input fields can be selected by pressing on the screen.
The important and useful aspects have been determined in
numerous practical tests. The user interface is easy to operate
and reflects the test results for maximum rapid operation and
programming.

B876en 2019-05-18 The most important assemblies 3‐23

 For entering letters, a keyboard or number pad is displayed on
the user interface.
The control system can also be operated via keyboard and
mouse (option).
Programs, tools, archive and data can be loaded and imported
via the USB connection.

Additional screen (option)

Fig. 85108

Paperless production The additional screen makes it possible to display more content,
e.g. drawings.
The same keyboard and mouse (option) is used for both
screens. The content displayed can be exchanged between the
two screens.
Both screens swivel but their height cannot be adjusted.

Tip
Additional content (attachments) can be added to the bending
program or can be opened on the additional screen via Program-
ming, "Program".

Characteristic features ■ Only possible with increased installation height.

3‐24 The most important assemblies 2019-05-18 B876en

 Graphical shop floor programming

Fig. 74299

Programming graphically on In addition to numerical NC programming, there is graphical

the machine shop floor programming on the machine. The graphical shop
floor programming is geared toward the quick programming of
simple 2D profiles directly on the machine.

Functions of the graphical shop floor programming:

■ Single bendings, seams and round bend can be graphically
programmed.
■ The 2D profile can be processed (e.g. mirrored) and modi-
fied.
■ The unfolded length of the bending part is displayed.
■ The bending sequence is calculated automatically; it can
however be modified.
■ Tools are automatically allocated to every bending.
■ A 3D simulation of the bending part, tools and gauge fingers
is displayed in the production.

Characteristic features A box cannot be programmed.

B876en 2019-05-18 The most important assemblies 3‐25

 Shop floor programming TecZone Bend
(option)

Fig. 88949

Programming on the basis With TecZone Bend it is quick and easy to produce programs
of 2D or 3D data on the machine on the basis of 2D or 3D data.
TecZone Bend automatically creates a program suggestion
which can be manually modified. TecZone Bend automatically
creates the 3D simulation with collision monitoring and the NC
program.

Note
50 programs can be created with the pre-installed demo version.
Contact TRUMPF to activate TecZone Bend.

3‐26 The most important assemblies 2019-05-18 B876en

 3.9 Lower tool displacement (I axis)

CNC-controlled lower tool displacement Fig. 68996

Forward and backward The lower tool displacement (I axis) moves the lower tool clamp
forwards or backwards. Lower tools can thus be used which are
not centered under the upper tool, e.g. folding bars, which are
attached to the lower tool at the front, or lower tools with sev-
eral dies.
How far the lower tool displacement is positioned toward the
front or rear depends on the lower tool.

Pneumatic I axis

1 Cover 3 Spacer for the position of the

2 Spacer for the length of the displacement path
translation path
Pneumatic I axis Fig. 69006

B876en 2019-05-18 The most important assemblies 3‐27

 The position of the I-axis can be defined via various spacers.

CNC controlled I axis (Option)

CNC controlled I axis (Option) Fig. 69005

The position of the I axis is entered via the control. The I-axis
can be positioned continuously.

3.10 MobileControl

MobileControl Fig. 68998

Quick operation MobileControl is an operating element that can be inserted in

the communications rail on the press beam.

3‐28 The most important assemblies 2019-05-18 B876en

 All main functions for running programs can be operated with
MobileControl.

The following actions can be initiated, e.g. directly from the

MobileControl:
■ Opening/closing the tool clamp.
■ Starting/stopping the program.
■ Activating/deactivating the bending aid (option).
■ Moving all CNC-controlled axes (fast).

3.11 MobileControl Pro (option)

MobileControl Pro (option) Fig. 68999

Save time MobileControl Pro is an operating element that can be inserted

in the communications rail on the press beam.
All main functions for running programs can be operated with
MobileControl Pro.
Important parameters can be entered directly at the machine,
e.g. bending step forwards/backwards, adjustment values.
The operator can configure the functions of the MobileControl
Pro.

The following actions can be initiated, e.g. directly from the

MobileControl Pro:
■ Opening/closing the tool clamp.
■ Starting/stopping the program.
■ Adjusting the part counter.
■ Entering global corrections in the bending program.

B876en 2019-05-18 The most important assemblies 3‐29

 ■ Entering local corrections in the bending step.
■ Moving all CNC-controlled axes (fast).
■ Activating/deactivating the bending aid (option).

3.12 Wireless foot switch (option)

1 EMERGENCY STOP push-but- 4 PRESS BEAM DOWN foot

ton (active: lights up red, inac- switch with stop function
tive: gray) 5 Compartment for Connector
2 Pilot lamp
3 PRESS BEAM UP foot switch
Wireless foot switch (option) Fig. 87847

High freedom of movement The wireless foot switch replaces the foot switch with a connec-
tion cable.
The foot switch may only be used within a defined working
range. The foot switch is wirelessly connected to the machine.
Ultrasonic sensors in the lower part of the press table checks
whether the operator is within the working range.

Characteristic features ■ Only possible in connection with the option "Interface for
wireless operational options".
■ Cannot be retrofitted.

3‐30 The most important assemblies 2019-05-18 B876en

 3.13 MagicShoe (option)

Fig. 74292

Maximum freedom of A MagicShoe replaces the PRESS BEAM DOWN and PRESS
movement and user BEAM UP buttons in the foot switch.
ergonomics
With MagicShoe, the following actions are possible:
■ Trigger stroke.
■ Stop downward movement of the press beam (stop function).
■ Move the press beam upward.
MagicShoe consists of a pair of safety shoes (safety class S2)
with sensors integrated into the right shoe. The sensors detect
foot movements. By building up pressure on the ball of your foot
in the right shoe, the stroke will be triggered.
MagicShoe is wirelessly connected to the machine. Ultrasonic
sensors in the lower part of the press table and a transmitter on
the MagicShoe checks whether the operator is within the work-
ing area.

B876en 2019-05-18 The most important assemblies 3‐31

 The system consists of the following components:
■ The required hardware and software components.
■ MagicShoe:
− 1 pair of safety shoes (safety class S2) with sensors inte-
grated into the right shoe.
− Available in sizes EU 39 to 47 (no half sizes).
■ MagicShoe Connector (including charging station):
− The MagicShoe Connector is connected to the Magi-
cShoe and provides the wireless transmission and power
supply.
■ MagicShoe Display
− Indicates the operating status of the MagicShoe.
− Can be freely positioned in the communications rail on
the press beam.

Characteristic features ■ Only possible in connection with the option "Interface for
wireless operational options".
■ Cannot be retrofitted.

Notes on use

General information The shoes have been tested in accordance with the European
standards EN ISO 20344 – EN ISO 20345, which means that
this model has been subject to a type-examination by an author-
ized European test center.
Test center: AUVA Sicherheitstechnische Prüfstelle der Allgemei-
nen Unfallversicherungsanstalt, test center number 0511, Adal-
bert Stifter Straße 65, 1201 Vienna, Austria.
The shoes have a CE mark and each safety shoe (EN ISO
20345) is also labelled with a permanently attached standard
mark.
This mark contains: a) size, b) the manufacturer's mark, c) the
manufacturer's type name (article number), d) year and quarter
of manufacture, e) number of the standard, f) symbols for the
protective function concerned.

Explanation of the symbols ■ S2: Safety shoe with 200 Joule protective toe cap, closed
heel area, antistatic characteristics, energy absorption
capacity in the area of the heel, waterproof upper material
■ HRO: Sole's resistance to hot contact up to 300 °C
■ FO: The resistance of the sole to fuel oil
■ SRC: Slip resistance characteristics

Antistatic shoes Antistatic shoes should be worn if it is necessary to reduce any

electrostatic charge by discharging electrical charges to rule out
the risk of the ignition e.g. of flammable substances and vapors

3‐32 The most important assemblies 2019-05-18 B876en

 by sparks, and if the risk of an electric shock by an electrical
device or live parts is not ruled out completely. However, bear in
mind that antistatic shoes cannot provide sufficient protection
against electric shocks, as they only create a resistance
between the floor and the feet. If the risk of an electric shock
cannot be ruled out completely, further measures need to be
taken to prevent such a hazard. Such measures and the checks
specified below should be part of the routine accident prevent
measures at the workplace.
Experience has shown, that, for antistatic purposes the electrical
resistance of the conductive path through a product over its
entire service life should not exceed 1000 MΩ. A value of
100 kΩ is specified for the lower limit for the resistance of a
new product, to ensure limited protection from hazardous electri-
cal shocks or ignition from a fault in an electrical unit when work-
ing at up to 250 V.
However, bear in mind that the shoes will not provide sufficient
protection under certain circumstances, which is why the person
wearing the shoes should always take additional protective
measures. The electrical resistance of this type of shoe may be
impaired significantly by bending, dirt or moisture. If these shoes
are worn in wet conditions, their intended function will not be
ensured. It is therefore necessary to ensure that the product is
able to provided its predefined function of discharging electrical
charges and providing protection during its duration of use. The
user is therefore advised to determine the electrical resistance
by means of an on-site check, if necessary, and to repeat this
check at regular, short intervals. Classification I shoes may
absorb moisture if used for a lengthy period and become con-
ductive in damp and wet conditions.
If the shoe is worn under conditions where the material of the
sole can be contaminated, the user should check the electrical
characteristics of their shoe each time that they enter a danger-
ous area.
In areas where antistatic shoes are worn, the the resistance of
the floor should be such that it does not negate the protection
provided by the shoes.
No insulating components should be used, with the exception of
normal socks worn between the shoe's inner sole and the user's
foot. If inlays are used between the shoe's inner sole and the
user's foot, the connection between shoe and the inlay should
be checked for its electrical properties.
Inlays: Safety shoes made and delivered with inlays, have been
tested in this state and meet the requirements of the standard
applicable in each case.

Note
Retrospectively inserting non-identical inlays can lead to the
safety shoe no longer meeting the requirements of the standard
concerned. The protective properties may be impaired.

B876en 2019-05-18 The most important assemblies 3‐33

 Safety parameters Component Safety parameter
MagicShoe with heel clamp, trans- PFHD = 2.69e-09 (SILCL3)
mitting unit and MagicShoe Con-
nector
Evaluation on the machine's side PFHD = 4.62e-09 (SILCL3)
(the hardware is on the inside of
the control cabinet door)
The triggering algorithm for "press PFHD < 1e-09 (SILCL3)
beam down"
The triggering algorithm for "press PFHD = 5.79e-07 (SILCL2)
beam up"
Tab. 3-6

Notes on maintenance

MagicShoe is maintenance-free.

3.14 Work area illumination (option)

Work area illumination (option) Fig. 70830

Exact stops with good The following areas are illuminated by LEDs:
lighting ■ Front work area illumination: work area in front of the
machine.
■ Rear work area illumination: work area inside the machine.

3‐34 The most important assemblies 2019-05-18 B876en

 3.15 ACB laser optical angle measuring
system (option)

ACB laser optical angle measuring system (option) Fig. 69008

Visual measuring procedure For the ACB Laser (Automatically Controlled Bending) optical
angle measuring system, two measuring units move in front of
and behind the bending line. The measuring units can move
independently of each other.
Each measuring unit consists of one laser and one camera. The
laser projects a line on the sheet. The camera detects the posi-
tion of the line and triggers the calculation of the bending angle
in real time.

Technical data Value

Minimum flange length from outside edge of See page 3‐36
lower tool (dependent on lower tool and sheet
thickness)
Measurement range 30 – 150°
Typical precision (for flange length of 20 mm ±0.3°
from the outer edge of the lower tool and with
a lower tool height of 100 mm)
Lower tool height 100 – 150 mm
Lower tool width Max. 145 mm
Die width Max. 120 mm
Traverse speed of the measuring units (incl. 470 mm/s
force limitation)
Dimensions of the measuring unit (L x W x H) 240 x 114 x 106 mm
Measurements per second 208
Tab. 3-7

B876en 2019-05-18 The most important assemblies 3‐35

 Minimum side length

1 Required measurement range 2 Minimum side length

Fig. 79797

The following values for the minimum side length apply for St37
and cold-rolled stainless steel (longer side lengths are required
for hot-rolled 2 mm stainless steel):

Bending angle
Lower tool Upper Material 90° 90° 150° 120° 60°
tool
Die Type Radius Sheet thick- Required measure- Minimum side length in
width in ness in mm ment range in mm mm
mm
6 EV001 30° 1 1 7.87 19 16 17 23
8 EV002 30° 1 1 9.75 21 18 19 25
10 EV003 30° 1 1 9.66 21 18 19 25
12 EV004 30° 1 1 9.54 23 20 21 27
16 EV005 30° 1 1 12.29 29 26 27 –
10 EV003 30° 1 2 7.07 19 16 17 –
12 EV004 30° 1 2 7.47 24 21 22 –
16 EV005 30° 1 2 7.78 25 22 23 –
30 EV W30/30° 1 4 14.74 46 42 43 –
30 EV W30/30° 4 4 14.74 46 42 43 –
50 EV W50/80° 4 4 15.66 52 48 49 –
50 EV W50/80° 1 4 16.02 52 48 49 –
50 EV W50/80° 1 6 14.17 53 43 46 –
50 EV W50/80° 4 6 13.85 53 43 46 –
80 EV W80/80° 4 6 24.04 80 70 73 –
Tab. 3-8

3‐36 The most important assemblies 2019-05-18 B876en

 3.16 Tactile ACB Wireless angle
measuring system (option)

Tactile ACB Wireless angle measuring system (option) Fig. 69002

Tactile measuring procedure With the ACB Wireless (Automatically Controlled Bending) angle
measuring system, the system for measuring angles is inte-
grated in the upper tool. The sensor tool is set up with the nor-
mal upper tools.

B876en 2019-05-18 The most important assemblies 3‐37

 1 Contact points on the insides 2 Distance of the centers of the
of the bending sides sensor disks
Four-point angle measurement principle with sensor disks Fig. 45857

In the sensor tool there are two sensor disks with different diam-
eters. During bending, the two sensor disks register four contact
points on the inner sides of the bend.
Depending upon the plunging depth of the sensor disks, the dis-
tance between their center points changes. The linear displace-
ment of the sensor disks is measured electronically and the
angle is determined.
The sensor tools communicate with the control system via a
data rail, which is integrated into the upper tool clamp. The posi-
tion of the sensor tools is automatically detected during setup.
The sensor tools are automatically assigned in the control sys-
tem.

Notes
■ The tool clamp with an integrated data rail must be cleaned
regularly.
■ For a tool clamp with an integrated data rail, no dirty tools
may be used. The tool's shank must be free from burrs.

Technical data Value

The minimum flange length (depending on the (see "Fig. 65149",
sensor disks and sheet thickness) pg. 7‐9)
Tool width 25 mm and 35 mm
for sensor tools for
thick sheet.
Max. number of sensor tools per machine 8
Max. number of sensor tools per bend 2
Measurement range (dependent on the sensor 45° – 135°
tool)

3‐38 The most important assemblies 2019-05-18 B876en

 Technical data Value
Precision ±0.3°
Measurements per second 250
(125 values per sec-
ond are processed by
the control unit.)
Tab. 3-9

Characteristic features ■ Only possible in combination with hydraulic upper tool clamp
with integrated data rail.
■ The data rail cannot be retrofitted.

B876en 2019-05-18 The most important assemblies 3‐39

 3.17 Angle measuring system ACB
(option)

Fig. 81146

The ACB angle measuring system consists of a sensor tool and

an ACB module for connecting to the control.
The ACB module is used in the communications rail on the
press beam. The sensor tool is connected to the ACB module
by means of a cable. The ACB module transmits the data to the
control via the contacts in the communications rail.
The sensor tool is set up with the normal upper tools.

3‐40 The most important assemblies 2019-05-18 B876en

 1 Contact points on the insides 2 Distance of the centers of the
of the bending sides sensor disks
Four-point angle measurement principle with sensor disks Fig. 45857

In the sensor tool there are two sensor disks with different diam-
eters. During bending, the two sensor disks register four contact
points on the inner sides of the bend.
Depending upon the plunging depth of the sensor disks, the dis-
tance between their center points changes. The linear displace-
ment of the sensor disks is measured electronically and the
angle is determined.

Technical data Value

Sensor tools All normal standard
upper tools. Special
tools on request.
Tool width 25 mm and 35 mm
for sensor tools for
thick sheet.
Max. number of sensor tools per machine 8
Max. number of sensor tools per bend 2
Measurement range (dependent on the sensor 45° – 135°
tool)
Precision ±0.3°
Measurements per second 250
(125 values per sec-
ond are processed by
the control unit.)
Tab. 3-10

B876en 2019-05-18 The most important assemblies 3‐41

 3.18 Sheet thickness detection TCB
(option)

a Air bending without TCB A Thinner sheet, angle not bent

b Air bending with TCB enough
B Thicker blank, blank bent too
much
Fig. 68679

Thickness Controlled The TCB(Thickness Controlled Bending) function reduces angle

Bending – Easy errors produced by fluctuations in sheet thickness.
compensation of
Fluctuations in sheet thickness of up to approx. ±10 % can
fluctuations in sheet
occur due to manufacturing tolerances in the production of metal
thickness
sheets. The sheet thickness can vary from one metal sheet to
the next. The thickness of one particular metal sheet can be dif-
ferent at the edges than in the middle. One cause of this is the
rolling process.
During air bending, the angle is determined by the plunging
depth of the upper tool. A deviation in sheet thickness of 10 %
will already lead to an angular deviation of 3 – 4°.
With TCB the press brake automatically recognizes the differ-
ence between programmed and actual sheet thickness and auto-
matically compensates for fluctuations in sheet thickness. This
means the press brake achieves a bending angle quality that is
independent of sheet thickness.

3‐42 The most important assemblies 2019-05-18 B876en

 1 Programmed sheet thickness 3 Corrected lower dead point
2 Actual sheet thickness 4 Programmed lower dead point
Operating principle Fig. 68752

The difference between programmed and actual sheet thickness

is identified via strain gauges on the machine frame and the
pressing depth of the upper tool is automatically corrected, i.e.
the programmed lower dead point (LDP) is corrected.

Characteristic features ■ Not available for TruBend Cell 5000.

■ Cannot be retrofitted.

B876en 2019-05-18 The most important assemblies 3‐43

 3.19 Angle measuring system OCB
(option)

Angle-measuring system OCB Fig. 70013

Operator Controlled Bending The OCB (Operator Controlled Bending) angle measurement
system is used to measure workpieces and transfer the meas-
urement data directly to the control by radio.
The adjustment value for the bending angle is automatically
transferred to the program.

3.20 Optical set up and positioning aid

Tool Indicator (option)

Optical set up and positioning aid Tool Indicator (option) Fig. 69034

Extremely quick setup The optical setup and positioning aid is an LED strip which is
integrated into the upper tool clamp.

3‐44 The most important assemblies 2019-05-18 B876en

 The setup and positioning aid has the following functions:
■ When loading tools acc. to setup plan: Show the positions
where the tools must be loaded.
■ During bending: Show the position where the workpiece has
to be inserted.

Characteristic features ■ Only possible in combination with hydraulic upper tool clamp.

3.21 Part Indicator insertion aid (option)

Fig. 90680

Inserting parts quickly and On the additional screen, the Part Indicator shows the operator
correctly how he has to insert the bending part in the machine.
The control knows the contour of the programmed bending part
(nominal insertion position). The inserted bending part is
recorded by both cameras in front of and behind the press
beam. The images of both cameras are joined to form an over-
all image and are displayed on the additional screen. The opera-
tor sees how he has to rotate and turn the bending part in order
to get to the insertion position of the next bend.

Characteristic features ■ Only possible in connection with additional screen (option).

B876en 2019-05-18 The most important assemblies 3‐45

 3.22 2D code scanner (option)

2D code scanner (option) Fig. 74290

Calling up programs easily Programs can be assigned and called up at the machine using
a data matrix code or bar code.

■ For versions with cables, the code can be a sticker on the

pre-cut part or in the printout of the setup plan.
■ For wireless versions with Bluetooth, the code directly on
the sheet can be a sticker on the pre-cut part or in the print-
out of the setup plan.
The code is read with the scanner and the relevant program is
called up automatically on the operating panel.
The program of the selected product needs to be contained in
the memory of the control system or be loadable using the net-
work.

3‐46 The most important assemblies 2019-05-18 B876en

 3.23 Simple support bracket (only in the
area of application of the EC
Machinery Directive)

Simple support bracket Fig. 95330

In the area of application of the EC Machinery Directive, the

machine will be delivered with a simple support bracket, if the
machine is not equipped with the support bracket or bending aid
option.
The support bracket serves as a tray for heavy and large parts.
The support bracket is fixed to the press table via threaded
holes and can be manually fixed to other threaded holes.

Technical data Value

Max. load-bearing capacity per support bracket 70 kg
Tab. 3-11

B876en 2019-05-18 The most important assemblies 3‐47

 3.24 Support bracket (option)

Support bracket (option) Fig. 85182

The support bracket is fastened to a guide rail on the press

table. The support bracket serves as a tray for heavy and large
parts.
A maximum of 2 support brackets can be installed on the
machine.
The brackets can be moved manually to the required position.

Maximum carrying capacity Fig. 81084

Technical data Value

Max. load-bearing capacity per support bracket 100 kg
Tab. 3-12

3‐48 The most important assemblies 2019-05-18 B876en

 Replaceable supports The following versions are available:
■ Plastic surface (standard).
■ Brush surface (option): to process parts with low scratching.
■ Ball roller surface (option): For the easy handling of heavy
parts.

Alignment functions The following stops can be mounted on the side guide rail:

Tilt stop with micrometer adjustment Fig. 74293

Lateral stop Fig. 81080

Parking position for bending aid/support

bracket (option)

The bending aid/support bracket can be moved to a parking

position as long as it is not used.
For the parking position, a support bracket is laterally mounted
on the press table.

B876en 2019-05-18 The most important assemblies 3‐49

 Technical data Value
Weight 250 kg
Length 1100 mm
Tab. 3-13

Table length and table width extension

Example: A support bracket with 1 table length extension Fig. 85181

and 1 table width extension

Table width extension A table width extension is possible left and right for each sup-
port bracket.

Technical data Value

Max. carrying capacity 20 kg
Weight 11.5 kg
Width 256 mm
Length 651 mm
Total table width (support bracket + 1x table 256 mm + 256 mm =
width extension) 512 mm
Total table width (support bracket + 2x table 256 mm + 256 mm
width extension) + 256 mm = 768 mm
Tab. 3-14

Table extension The table extension consists of cross-braces that can be pulled
manually.
A table extension is possible for each support bracket / table
width extension.

3‐50 The most important assemblies 2019-05-18 B876en

 Technical data Value
Weight 6 kg
Width 220 mm
Length 538.5 mm
Total table length (support bracket + table 689.5 mm
extension) + 538.5 mm =
1228 mm
Tab. 3-15

3.25 Bending aid (option)

Bending aid (option) Fig. 69003

Support is coming The bending aid supports the workpiece during the bending proc-
ess. The operator can let the workpiece go after clamping. The
bending aid swivels upward, depending on the opening angle.
The bending aid is electromechanically driven and programmed
via the control system.
The bending aid can be moved to the right to a parking position
(option) when it is not needed in order to ensure that a corre-
sponding amount of open space can be kept clear in front of
the machine, even when the bending aid is mounted.

Characteristic features ■ Various options and expansions are possible.

■ A parking position can be mounted for the bending aid
(option).
■ Can be used in combination with ACB Wireless and
ACB Laser.

B876en 2019-05-18 The most important assemblies 3‐51

 Bending aid (option)

A maximum of 2 bending aids can be installed per machine.

The 2nd bending aid can move separately or synchronously to
the 1st bending aid.

Maximum carrying capacity Fig. 81084

Technical data Value

Max. bending angle 30°
Maximum swivel angle 78°
Max. working speed of the swivel axis during 70°/s
the upward movement
Max. working speed of the swivel axis during 25°/s
the downward movement
Max. working speed of the swivel axis during 15°/s
the downward movement and with table length
extension extended (option)
Max. carrying capacity per bending aid for a 100 kg
distance between the center of gravity of the
workpiece and the bending line of 500 mm
Automatic height adjustment (based on a ±100 mm
100 mm lower tool)
Supported flange length (without table length 1000 mm
extension)
Lower tool height adjustment range 30 – 200 mm
Weight per bending aid 400 kg
Width 256 mm
Tab. 3-16

Replaceable supports The following versions are available:

■ Plastic surface (standard).
■ Brush surface (option): to process parts with low scratching.
■ Ball roller surface (option): For the easy handling of heavy
parts.

3‐52 The most important assemblies 2019-05-18 B876en

 Alignment functions The following stops can be mounted on the side guide rail:

Tilt stop with micrometer adjustment Fig. 74293

Lateral stop Fig. 81080

Parking position for bending aid/support

bracket (option)

The bending aid/support bracket can be moved to a parking

position as long as it is not used.
For the parking position, a support bracket is laterally mounted
on the press table.

Technical data Value

Weight 250 kg
Length 1100 mm
Tab. 3-17

B876en 2019-05-18 The most important assemblies 3‐53

 3.26 Network connection

Programs, tools and machine parameters can be directly

imported to the control system from a network drive or saved
from the control system onto a network drive.

Network server The connection mechanism to the network takes place directly
by means of the Ethernet interface available on the industrial
PC. The transmission protocol is defined as TCP/IP. Connection
via RJ45 interface.

3.27 Interfaces for robot (optional)

A robot can be connected to the machine via the interface pro-

vided for this purpose.
The interface is located in the electrical cabinet.

3.28 MyTRUMPF customer portal

Fig. 65300

Convenient online ordering Exclusive services are available to you in the MyTRUMPF cus-
of spare parts and tools tomer portal: whether you're interested in what's new with sheet
processing or whether you want to order spare parts and tools
around the clock – you're at the right place here!

3‐54 The most important assemblies 2019-05-18 B876en

 Advantages A number of individualized features make working with your
TRUMPF machine even easier:
■ E-shops: The selection of e-shops, which are available to
you, is country-specific. If necessary, contact the office in
your country about TRUMPF.
In the e-shop for spare parts, punching and bending tools,
you can order online 24 hours a day, 7 days a week. The
prices and availability are immediately displayed in the e-
shop for spare parts and tools. This gives you more transpar-
ency in your ordering procedure and saves you the work of
making inquiries for offers.
■ User knowledge: Helpful tips and tricks for the various tech-
nologies make working with your TRUMPF machine yet eas-
ier.
■ Training course calendar: Get information on the current
training offers of the TRUMPF Training Center in Ditzingen
and enroll online for the desired course right away.
■ Used machine exchange market: Look for or insert a
machine yourself: The TRUMPF online market for used
machines specializes in systems and machines for sheet
metal processing.
Register now at [Link]

3.29 Tool changer ToolMaster (option)

Fig. 85325

The ToolMaster is a tool changer, to quickly and automatically

set up tools in TRUMPF press brakes.
The tools are stored in the upper and lower tool magazine.
Tool changes are controlled via the operating panel.
Transport slides move the tools from the ToolMaster into the
press brake and vice versa.

B876en 2019-05-18 The most important assemblies 3‐55

 Note
Only TRUMPF tools may be used.

Tip
For further information, see the separate operator's manual
(document no. B1030).

3‐56 The most important assemblies 2019-05-18 B876en

 4. Industry 4.0 with TruConnect

4.1 What is Industry 4.0 at TRUMPF?

Industry 4.0 Industry 4.0 is the digital networking of production in the Smart
Factory. It has the objective of increasing overall productivity,
flexibility and process stability and to create company-wide value-
adding networks. The central requirement for this is that the dif-
ferent systems and machines in the production network can com-
municate with one another. For this to happen, they must under-
stand the language of each of the others and be able to inter-
pret the received signals.

Interfaces There are interfaces to make this possible. Interfaces define the
content of the signals and allow the data to be interpreted, even
if it was sent from another system.

Systems for data evaluation In order that the sent data can be used as effectively as possi-
ble, one requires intelligent systems which can evaluate the
data and can derive and execute the corresponding measures
from this.
Such systems could be, e.g., ERP/PPC systems for production
control or also monitoring systems, which monitor certain states
and react autonomously, as required.
The systems can be utilized both locally in the company as well
as online via Internet-based services and platforms.

TruConnect With TruConnect, TRUMPF provides both the necessary interfa-

ces for networking as well as the systems for evaluation and
control – offline and online.

Production areas The systems which TruConnect contains are distributed over the
following areas:
■ Production overview
■ Production control
■ Connectivity
■ Remote Support

4.2 Production overview

TruTops Monitor Machine data is acquired and analyzed with TruTops Monitor. If
an idle state or malfunction should occur, the software will pro-
vide information about the causes via e-mail or text message.
These can be remedied quickly, thereby reducing the idle times.
The entire machine park can be monitored in real time with the
TruTops Fab app for TruTops Monitor.

B876en 2019-05-18 Industry 4.0 with TruConnect 3‐57

Example Fig. 78487

4.3 Production control

TruTops Fab TruTops Fab consists of multiple modules which are based on
each other as configuration stages.
Thanks to the extensive functions for managing stocks, material
and customer data, and offers and orders, small companies can
manage and control nearly their entire workflow with the mod-
ules of TruTops Fab.
Thus, in some cases, an expensive and often over-dimensioned
ERP/PPC system can be done without, or an existing ERP/PPC
system can be sensibly supplemented.

The following modules belong to TruTops Fab:

■ The TruTops Fab Customer Module manages complete cus-
tomer orders, from the offer to the delivery note all the way
to the invoice.
■ The TruTops Fab Quickjob Module controls and manages
production orders.
■ The TruTops Fab Production Module manages all production
steps.

3‐58 Industry 4.0 with TruConnect 2019-05-18 B876en

 ■ The TruTops Fab Storage Module manages inventories.
■ The TruTops Fab Purchase Module manages ordering opera-
tions.
■ The TruTops Fab app puts all this information onto one
mobile terminal device.

4.4 Connectivity

The ability to establish connections between computers, sys-

tems and networks is called connectivity.

Central Link and OPC UA Central Link is the TRUMPF technology to network machine
tools, so that they become "Industry 4.0 ready". It belongs to
the machine's scope of delivery.
Central Link consists of OPC UA Server and Device Gate. It is
the interface via which the machine is networked with the cloud
and cloud applications can be realized.
This is based on the Open Platform Communications Unified
Architecture (OPC UA), a standard of the OPC Foundation, that
allows access to data and device functions.

Central Link overview Fig. 85015

Remote Control Interface The Remote Control Interface (RCI) consists of a message and
order interface.
The production plan of the machine can be controlled directly
via the order interface. This way, the machine can be connected
to higher-ordered control systems or ERP/PPC systems, which
can then load orders directly onto the machine.
Thanks to the open architecture of the interface, the assignment
and control can both be realized with TRUMPF systems, such

B876en 2019-05-18 Industry 4.0 with TruConnect 3‐59

 as TruTops Fab, as well as with systems from other manufactur-
ers.
The message interface outputs production data of the machine
in real time, thereby making system monitoring possible, e.g.,
with TruTops Monitor.

4.5 Remote support

Remote support Remote support is established between the machine and a Tech-
nical Service employee at TRUMPF via the telepresence portal.
This way, the machine operator can be supported on site via
remote control.
Thanks to remote diagnostics, errors in practically all control
components can be detected and remedied.

4.6 TRUMPF machine apps

Apps for displaying machine data Fig. 87687

If a machine is connected to the Cloud, the data produced dur-

ing production can be evaluated. The results of the evaluations
are visualized and displayed in the respective app.
The information in the apps can be called up from a PC, tablet
or smartphone. The access data required for this will be sent to
the customer by email upon purchase of a machine. Cloud-
based data evaluation supplements the solutions for the Smart
Factory.

3‐60 Industry 4.0 with TruConnect 2019-05-18 B876en

 The information will be provided in the following apps:

App Function
Live Status Shows the current status of the machines connected to the Cloud and informs users in
the event of an idle state. It provides access to the machine status from everywhere and
enables the remaining time of programs to be read.
Machine Analytics Indicates the machine data and statuses for the past three days. It indicates the
operating hours and when there were idle states or interruptions in the production proc-
ess.
Program Analytics Shows the status of the programs started.
Material Analytics Shows which material and which volume of material has been processed in a specific
period of time.
Punching Tool Ana- This app indicates which tools are being used and how often and supports the user in
lytics selecting the standard tools. The strokes overview can help the user to decide when to
regrind a tool or order a new one.
Tab. 3-18

B876en 2019-05-18 Industry 4.0 with TruConnect 3‐61

 5. Tools from TRUMPF

In order to use a press brake for bending, a tool is required

which is mounted on the press beam or press table. Typical
tools used for this purpose are punches and dies. Punches are
mostly attached to the press beam and dies to the press table..
The required tool depends on the bending method, raw material,
sheet thickness and angle.
All tools from TRUMPF that can be used for the TruBend have
already been stored in the control system. Data for special tools
is delivered along with the special tools and must be imported.
Tools can be ordered via the E-Shop for bending tools or the
tool catalog.

1 Upper tool (punch) 6 Lower tool radius

2 Workpiece 7 Upper tool radius
3 Internal workpiece radius Ri 8 Lower tool (die)
4 External workpiece radius Ri α Die angle
5 Die width W
Tool and workpiece Fig. 12763

3‐62 Tools from TRUMPF 2019-05-18 B876en

 Head-bearing and shoulder-
bearing tools

A Head-bearing tool B Shoulder-bearing tool

Fig. 76232

Head-bearing and shoulder-bearing tools are available. Shoulder-

bearing tools transfer the press force evenly onto the workpiece,
even in the event of large tool heights or lateral forces (e.g. for
folding).

Safety-Click® safety element Safety-Click® is a safety element for upper tools. It locks the
tools in the tool clamping and prevents the tools from falling out
of the tool clamping. The lock can be released by pushing a but-
ton:
Tools with Safety-Click® can be inserted into the tool clamp
from the front.

Safety-Click® is possible for the following tools:

■ Head-bearing tools from 10 mm onwards.
■ Shoulder-bearing tools from 25 mm onwards.
■ Tools with up to 100 mm in length have a safety element.
■ Tools with a length 100 mm or longer and with a maximum
tool weight of 13.5 kg are equipped with 2 securing ele-
ments. Exception: tool holder and adapter.

Locking pin Upper tools with a tool weight of more than 13.5 kg are secured
by locking pins. The locking pins are mounted in the clamping
groove of the tools and secure the tool in the upper tool clamp.
The upper tools can only be pushed into the tool clamp laterally.
The locking pin wears out when the tool is moved back and
forth in the tool clamp. When the locking pin on the tool is worn
to the extent that the clamping bolt of the tool clamp no longer
hits the clamping groove on the tool, the locking pin must be
replaced.

B876en 2019-05-18 Tools from TRUMPF 3‐63

 TRUMPF bending tools The work surfaces and radii of all tools and the support areas of
LASERdur the lower tool clamp are hardened. This has the following advan-
tages:
■ Long service life of the tools.
■ High levels of machine accuracy maintained over a long
time.

Tools of varying lengths All tools exist in various divisions and lengths that can be com-
bined with one another.

Inserting upper tools

rotated through 180°

Inserting upper tools rotated through 180° Fig. 70016

TRUMPF upper tools can be inserted on both sides.

Self-centering The upper tool clamp for TRUMPF tools is self-centering. The
upper tools need not be aligned.

3‐64 Tools from TRUMPF 2019-05-18 B876en

 6. Technical data

TruBend 5085 5085 (X) 5085 (SX) 5130 5130 (X)

Machine Press force 850 kN 850 kN 850 kN 1300 kN 1300 kN
Max. press force 850 kN 850 kN 850 kN 1300 kN 1300 kN
with increased work-
ing speed
Bending length 2210 mm 2210 mm 2720 mm 3230 mm 3230 mm
Max. distance 505 mm 735 mm 735 mm 505 mm 735 mm
between press
table and press
beam
Usable open heights 385 mm 615 mm 615 mm 385 mm 615 mm
Ram tilt ±10 mm ±10 mm ±10 mm ±10 mm ±10 mm
Width between col- 1750 mm 1750 mm 2260 mm 2690 mm 2690 mm
umns
Throat 420 mm 420 mm 420 mm 420 mm 420 mm
Press table width 120 mm 120 mm 120 mm 120 mm 120 mm
Working height5 1095 – 1095 – 1095 – 1095 – 1095 –
1115 mm 1115 mm 1115 mm 1115 mm 1115 mm
Speeds6 Y axis rapid tra- 220 mm/s 220 mm/s 220 mm/s 220 mm/s 220 mm/s
verse7
Y axis work cycle 10 mm/s 10 mm/s 10 mm/s 10 mm/s 10 mm/s
25 mm/s8 25 mm/s8 25 mm/s8 25 mm/s8 25 mm/s8
Y axis withdrawal 220 mm/s 220 mm/s 220 mm/s 220 mm/s 220 mm/s
X axis – – – – –
■ 4-axes back- 1000 mm/s 1000 mm/s 1000 mm/s 1000 mm/s 1000 mm/s
gauge (option)
■ 6-axes back- 1750 mm/s 1750 mm/s 1750 mm/s 1750 mm/s 1750 mm/s
gauge (option)
R axis 330 mm/s 330 mm/s 330 mm/s 330 mm/s 330 mm/s
Z axis – – – – –
■ 4-axes back- 2500 mm/s 2500 mm/s 2500 mm/s 2500 mm/s 2500 mm/s
gauge (option)
■ 6-axes back- 1750 mm/s 1750 mm/s 1750 mm/s 1750 mm/s 1750 mm/s
gauge (option)
Positioning Y axis 0.005 mm 0.005 mm 0.005 mm 0.005 mm 0.005 mm
accuracy
X axis 0.04 mm 0.04 mm 0.04 mm 0.04 mm 0.04 mm
R axis 0.08 mm 0.08 mm 0.08 mm 0.08 mm 0.08 mm

5 With lower tool height 100 mm. Working height varies depending on
the height of the installation material.
6 Travel speed freely adjustable.
7 For BendGuard (option).
8 For the "Increased working speed at maximum press force" option.
The value depends on the selected die width, the operating cycle and
the local regulations.

B876en 2019-05-18 Technical data 3‐65

TruBend 5085 5085 (X) 5085 (SX) 5130 5130 (X)
Traversing Stroke, Y axis 445 mm 445 mm 445 mm 445 mm 445 mm
paths,
Traverse path of 600 mm 600 mm 600 mm 600 mm 600 mm
range
the X axis
before stop
Maximum stop 860 mm 860 mm 860 mm 860 mm 860 mm
range in the X direc- 1000 mm9 1000 mm9 1000 mm9 1000 mm9 1000 mm9
tion
Traverse path of 250 mm 250 mm 250 mm 250 mm 250 mm
the R axis10
Travel range, I axis –36.2 mm/ –36.2 mm/ –36.2 mm/ –36.2 mm/ –36.2 mm/
+32.7 mm +32.7 mm +32.7 mm +32.7 mm +32.7 mm
Control Basic circumference Intel Core i5, 2.7 GHz, dual-core processor; Windows embedded stand-
system ard 7
User interface Touchpoint Touchpoint Touchpoint Touchpoint Touchpoint
Bend Bend Bend Bend Bend
Color monitor 21.5" 21.5" 21.5" 21.5" 21.5"
Touchscreen Yes Yes Yes Yes Yes
Connected Connected load 13 kVA11 13 kVA11 13 kVA11 17.5 kVA11 17.5 kVA11
loads (IEC)
32 kVA12 32 kVA12 32 kVA12 42 kVA12 42 kVA12
Connected load 13.5 kVA11 13.5 kVA11 13.5 kVA11 18.0 kVA11 18.0 kVA11
(NEC)
32.5 kVA12 32.5 kVA12 32.5 kVA12 42.5 kVA12 42.5 kVA12
Pneumatic connec- – 6±1 bar 6±1 bar 6±1 bar 6±1 bar
tion13
Operating Hydraulic oil volume 70 l 70 l 70 l 120 l 120 l
materials

9 For 1000 mm backgauge fingers (option).

10 For 100 mm lower tool height
11 At working speed of 10 mm/s.
12 For the option "Increased working speed at maximum press force".
13 For a 2-axis backgauge or 6-axis backgauge (option) and/or pneu-
matic I axis (option) and/or bending aid (option) and/or BendMaster
(option)

3‐66 Technical data 2019-05-18 B876en

 TruBend 5085 5085 (X) 5085 (SX) 5130 5130 (X)
Weight and Length (basic 3020 mm 3020 mm 3530 mm 3980 mm 3980 mm
dimensions machine)
Width (basic 1800 mm 1800 mm 1800 mm 1800 mm 1800 mm
machine)
Height (basic 2375 mm 2835 mm 2835 mm 2375 mm 2835 mm
machine)
Height of the instal- 45 – 65 mm 45 – 65 mm 45 – 65 mm 45 – 65 mm 45 – 65 mm
lation material
(wedge mounts +
shim)
Weight – – – – –
■ Basic machine 8000 kg 8700 kg 9500 kg 10700 kg 11800 kg
■ Bending aid 400 kg 400 kg 400 kg 400 kg 400 kg
(option)
■ Parking position 250 kg 250 kg 250 kg 250 kg 250 kg
for bending aid/
support bracket
(option)
■ ACB laser opti- 46 kg 46 kg 48 kg 50 kg 50 kg
cal angle meas-
uring system
(option)
■ Support bracket 40 kg 40 kg 40 kg 40 kg 40 kg
(option)
Painting / Textured paint ■ White: NCS S 0505 R80B
Coloring ■ Blue: approx. RAL 250 20 20
■ Black: RAL 9005
■ Silver: RAL 9006
Permissi- Upper tool height 100 – 100 – 100 – 100 – 100 –
ble tool incl. adapter 320 mm 490 mm 490 mm 320 mm 490 mm
height for
BendGuard
(option)
Max. tool Manual upper tool 180 kg/m 180 kg/m 180 kg/m 180 kg/m 180 kg/m
weight clamp
Hydraulic upper tool 300 kg/m 300 kg/m 300 kg/m 300 kg/m 300 kg/m
clamp (option)
Maximum weight of 400 kg 400 kg 400 kg 400 kg 400 kg
the lower tool for
lower tool displace-
ment (I axis), pneu-
matic or CNC-con-
trolled (option)
Technical data: (X) = extended installation height, (S) = extended length, (SX) = extended Tab. 3-19
installation height/length

B876en 2019-05-18 Technical data 3‐67

TruBend 5170 5170 (S) 5230 5230 (S) 5320
Machine Press force 1700 kN 1700 kN 2300 kN 2300 kN 3200 kN
Max. press force with 1700 kN 1700 kN 2300 kN 2300 kN 3200 kN
increased working speed
Bending length 3230 mm 4250 mm 3230 mm 4250 mm 4420 mm
Max. distance between 735 mm 735 mm 735 mm 735 mm 735 mm
press table and press
beam
Usable open heights 615 mm 615 mm 615 mm 615 mm 615 mm
Ram tilt ±10 mm ±10 mm ±10 mm ±10 mm ±10 mm
Width between columns 2690 mm 3680 mm 2690 mm 3680 mm 3680 mm
Throat 420 mm 420 mm 420 mm 420 mm 420 mm
Press table width 120 mm 180 mm 180 mm 180 mm 200 mm
Working height14 1095 – 1095 – 1095 – 1095 – 1095 –
1115 mm 1115 mm 1115 mm 1115 mm 1130 mm
Speeds Y axis rapid traverse15 220 mm/s 220 mm/s 220 mm/s 220 mm/s 220 mm/s
Y axis work cycle 10 mm/s 10 mm/s 10 mm/s 10 mm/s 10 mm/s
25 mm/s8 25 mm/s8 25 mm/s8 25 mm/s8 25 mm/s8
Y axis withdrawal 220 mm/s 220 mm/s 220 mm/s 220 mm/s 220 mm/s
X axis – – – – –
■ 4-axes backgauge 1000 mm/s 1000 mm/s 1000 mm/s 1000 mm/s 1000 mm/s
(option)
■ 6-axes backgauge 1750 mm/s 1750 mm/s 1750 mm/s 1750 mm/s 1750 mm/s
(option)
R axis 330 mm/s 330 mm/s 330 mm/s 330 mm/s 330 mm/s
Z axis – – – – –
■ 4-axes backgauge 2500 mm/s 2500 mm/s 2500 mm/s 2500 mm/s 2500 mm/s
(option)
■ 6-axes backgauge 1750 mm/s 1750 mm/s 1750 mm/s 1750 mm/s 1750 mm/s
(option)
Position- Y axis 0.005 mm 0.005 mm 0.005 mm 0.005 mm 0.005 mm
ing accu-
X axis 0.04 mm 0.04 mm 0.04 mm 0.04 mm 0.04 mm
racy
R axis 0.08 mm 0.08 mm 0.08 mm 0.08 mm 0.08 mm
Traversing Stroke, Y axis 445 mm 445 mm 445 mm 445 mm 445 mm
paths,
Traverse path of the X 600 mm 600 mm 600 mm 600 mm 600 mm
range
axis
before
stop Maximum stop range in 860 mm 860 mm 860 mm 860 mm 860 mm
the X direction 1000 mm16 1000 mm16 1000 mm16 1000 mm16 1000 mm16
Traverse path of the R 250 mm 250 mm 250 mm 250 mm 250 mm
axis
Travel range, I axis –36.2 mm/ –36.2 mm/ –36.2 mm/ –36.2 mm/ –36.2 mm/
+32.7 mm +32.7 mm +32.7 mm +32.7 mm +32.7 mm

14 With lower tool height 100 mm. Working height varies depending on
the height of the installation material.
15 For BendGuard (option).
16 For 1000 mm backgauge fingers (option).

3‐68 Technical data 2019-05-18 B876en

TruBend 5170 5170 (S) 5230 5230 (S) 5320
Control Basic circumference Touchpoint Touchpoint Touchpoint Touchpoint Touchpoint
system Bend Bend Bend Bend Bend
Color monitor 21" 21" 21" 21" 21"
Touchscreen Yes Yes Yes Yes Yes
Con- Connected load (IEC) 24 kVA11 24 kVA11 33 kVA11 33 kVA11 40 kVA11
nected
loads 61 kVA12 61 kVA12 69 kVA12 69 kVA12 90 kVA12
Connected load (NEC) 24.5 kVA11 24.5 kVA11 33.5 kVA11 33.5 kVA11 40.5 kVA11

61.5 kVA12 61.5 kVA12 69.5 kVA12 69.5 kVA12 90.5 kVA12
Pneumatic connection17 6±1 bar 6±1 bar 6±1 bar 6±1 bar 6±1 bar
Operating Hydraulic oil volume 180 l 220 l 180 l 220 l 220 l
materials
Weight Length 3980 mm 4970 mm 4150 mm 5140 mm 5180 mm
and dimen-
Width 1900 mm 1900 mm 2055 mm 2055 mm 2055 mm
sions
Height (basic machine) 3000 mm 3000 mm 3200 mm 3200 mm 3200 mm
Height of the installation 45 – 45 – 45 – 45 – 45 –
material (wedge mounts 65 mm 65 mm 65 mm 65 mm 65 mm
+ shim)
Weight – – – – –
■ Basic machine 14150 kg 17850 kg 17200 kg 19850 kg 23400 kg
■ Bending aid (option) 400 kg 400 kg 400 kg 400 kg 400 kg
■ Parking position for 250 kg 250 kg 250 kg 250 kg 250 kg
bending aid/support
bracket (option)
■ ACB laser optical 50 kg 50 kg 52 kg 55 kg 55 kg
angle measuring sys-
tem (option)
■ Support bracket 40 kg 40 kg 40 kg 40 kg 40 kg
(option)
Painting / Textured paint ■ White: NCS S 0505 R80B
Coloring ■ Blue: approx. RAL 250 20 20
■ Black: RAL 9005
■ Silver: RAL 9006
Permissi- Upper tool height incl. 100 – 100 – 100 – 100 – 100 –
ble tool adapter 490 mm 490 mm 490 mm 490 mm 490 mm
height for
BendGuard
(option)

17 For a 2 or 6-axis backgauge (option) and/or pneumatic I axis (option)

and/or bending aid (option) and/or BendMaster (option)

B876en 2019-05-18 Technical data 3‐69

 TruBend 5170 5170 (S) 5230 5230 (S) 5320
Max. tool Manual upper tool clamp 180 kg/m 180 kg/m 180 kg/m 180 kg/m 180 kg/m
weight
Hydraulic upper tool 300 kg/m 300 kg/m 300 kg/m 300 kg/m 300 kg/m
clamp (option)
Maximum weight of the 400 kg 400 kg 400 kg 400 kg 400 kg
lower tool for lower tool
displacement (I axis),
pneumatic or CNC-control-
led (option)
Technical data: (X) = extended installation height, (S) = extended length, (SX) = extended Tab. 3-20
installation height/length

3‐70 Technical data 2019-05-18 B876en

 Chapter 4

Operation

1 Description of the operating elements 4‐5

1.1 Operating panel 4‐5
User interface layout 4‐6
General notes on operation 4‐6
Status displays at the user interface 4‐8
Auxiliary systems at the user interface 4‐11
Operating elements on the additional 4‐11
screen (option)
1.2 MobileControl 4‐12
Use MobileControl 4‐12
1.3 MobileControl Pro (option) 4‐13
Use MobileControl Pro 4‐13
Select/adjust parameter 4‐14
1.4 Foot switch 4‐14
1.5 Wireless foot switch (option) 4‐16
Using wireless foot switch 4‐19
1.6 MagicShoe (option) 4‐19
Use MagicShoe 4‐23

B876en 2019-05-18 Operation 4‐1

 1.7 Operating elements on the rear side of the 4‐26
machine
ROBOT-MODE (option) key switch 4‐26
1.8 Side safety doors 4‐27

2 Switching on the machine 4‐28

2.1 Unlock EMERGENCY STOP 4‐28
2.2 Switching on the machine 4‐28

3 Switching off the machine 4‐31

3.1 Switching off the machine in the case of mal- 4‐31
functions
3.2 Switching off the machine 4‐31

4 What to do in an emergency and in case 4‐32

of a malfunction
4.1 Rescuing trapped persons 4‐32

5 Operating modes of the machine 4‐33

6 BendGuard (option) 4‐34

6.1 Manual BendGuard (option) 4‐34
Setting the working height 4‐34
6.2 Automatic BendGuard (option) 4‐36
Setting the setup/work position 4‐36
Automatic BendGuard (option): Setting 4‐36
the working height
6.3 Running the Tool Align function 4‐37
6.4 Selecting protect mode 4‐40
6.5 Disabling BendGuard (option) 4‐41
6.6 Define the mute point with check plates 4‐42

7 Manual operation 4‐44

7.1 Programming individual bends 4‐44
7.2 Producing individual bendings 4‐53

8 Program special functions (Manual opera- 4‐54

tion/Program)
8.1 Programming an increased working speed 4‐54
(option)
8.2 Programming fast folding (for BendGuard, 4‐55
option)

4‐2 Operation 2019-05-18 B876en

 8.3 Programming a bend with ACB (option) 4‐57
8.4 Programming a bend with ACB Wireless 4‐58
(option)
8.5 Programming a bend with ACB Laser (option) 4‐59
8.6 Sheet thickness detection TCB (option) 4‐59
Programming individual bend with TCB 4‐60
(Option) (Manual operation)
Programming bending program with TCB 4‐60
(option) (Programming)
Programming learned bending with TCB 4‐61
(option) (Programming)

9 Programming 4‐62
9.1 Creating programs numerically 4‐62
9.2 Creating programs graphically with 4‐63
BendGraph
Change to BendGraph 4‐65
Creating a program 4‐65
Creating profile 4‐66
Deleting profile 4‐68
Modifying profile 4‐68
Create unfolding 4‐69
Returning to the user interface 4‐70
9.3 Programming tool stations 4‐70

10 Production 4‐71
10.1 Loading program 4‐71
10.2 Displaying a setup plan 4‐71
10.3 Producing a part 4‐72
10.4 Producing a part with ACB Speed 4‐72
10.5 Producing a bend with fast folding 4‐73
10.6 Use bending aid 4‐74
10.7 Entering local corrections in the bending step 4‐76
10.8 Entering global corrections in the program 4‐76
10.9 Using the Part Indicator insertion aid (option) 4‐77

11 Technology 4‐79
11.1 Configuring the ID card (RFID) 4‐79
11.2 Configuring the remote connection 4‐80

12 Angle measuring system OCB (option) 4‐81

12.1 Using the angle-measuring system OCB 4‐81

B876en 2019-05-18 Operation 4‐3

 13 Online Update Manager 4‐83
13.1 Call up Online Update Manager (on 4‐83
machines with TOSh)
13.2 Switch off Online Update function 4‐84

14 Help in case of problems 4‐85

14.1 Automatically calculated press force too high 4‐85
Checking the calculated press force 4‐85
14.2 Activate remote support 4‐86
14.3 The date and time are lost 4‐87

15 ToolMaster (option) 4‐88

15.1 Checking the tool inventory in the ToolMaster 4‐88
15.2 Transferring the setup plan to ToolMaster 4‐88
15.3 Importing the tool inventory of the 4‐88
ToolMaster onto the press brake
15.4 Transferring the tool inventory of the 4‐89
ToolMaster to the press brake
15.5 Setting a tool inventory in the ToolMaster 4‐89

4‐4 Operation 2019-05-18 B876en

 1. Description of the operating elements

1.1 Operating panel

1 User interface (multi-touch 5 START

screen) 6 Unlock a machine with an ID
2 EMERGENCY STOP push-but- card (RFID)
ton 7 Setting inclination and height
3 USB port 8 Keyboard and mouse (incl.
4 STOP holder) (option)
Operating panel Fig. 69009

B876en 2019-05-18 Description of the operating elements 4‐5

 User interface layout

1 Select operation 6 Status bar 11 Displaying quantity/changing

2 Current operation 7 Call up the BendGuard status quantity
3 Open diagnostics display/status of the Tool Align 12 Call up the online help
function 13 Display other parameters
4 Current user
8 For a hydraulic upper tool 14 Change settings, e. g. lan-
5 Change user/exit HMI (Human
clamp (option): Open/close guage, system of units, pass-
Machine Interface)
UPPER TOOL CLAMP word
9 Open/close LOWER TOOL
CLAMP
10 Display bending step
User interface Fig. 74289

General notes on operation

Unlocking the machine The machine can be unlocked by the user group which was
active at the time the machine was locked or by a user group
with higher rights.

4‐6 Description of the operating elements 2019-05-18 B876en

 Unlock a machine with an ID card (RFID) Fig. 92207

To unlock the machine enter the password or use an ID card.

Note
Each ID card can be used 30 times. Thereafter the password
for the user group will have to be entered once.

Locking the machine The machine disables itself automatically after 15 minutes
(default setting) of inactivity, i.e. no operating activity or increase
of the piece counter.
The locked time for inactivity can be set (see Technology, "Set-
tings", Global, "Time limit for lockout when inactive").

Display further information If required, the following additional information can be displayed.
Bear in mind that the procedure depends on the initial situation,
i.e. some steps are optional.

Target Activity Procedure

Display other parameters Manual operation ■ Press Parameters (in the central area).
for the bend.
Programming ■ Press "Bending steps" (below).
■ Press Parameters (in the central area).
Display bends. Programming ■ Press Bending steps (right).
■ On the "Program"tab: Press Bending steps (top right).
Production ■ Press Bending steps (left).
Display programs. Programming ■ Press Bending steps (right).
■ Press Bending programs (top right).
Production ■ Press Bending steps (left).
■ Press Bending programs (top left).
Tab. 4-1

B876en 2019-05-18 Description of the operating elements 4‐7

 Status displays at the user interface

Status bar The following symbols may appear in the status bar:

Connection to the machine control

Symbol Description
Connection to the control system
The machine is ready for operation.
There is a connection to the control. The control has
not started up yet.
There is no connection to the control system

Tab. 4-2

Status of the referencing of the axes

Symbol Description
Axes are referenced.

Axes are not referenced.

Tab. 4-3

Press beam status

Symbol Description
The press beam moves downwards.

The press beam moves upwards.

Tab. 4-4

BendGuard status

Symbol Description
BendGuard is active.
The protected range of the BendGuard has been cor-
rectly generated.
BendGuard is not active.

4‐8 Description of the operating elements 2019-05-18 B876en

 Symbol Description
Error.

The protected range of the BendGuard is being gener-

ated.
The tool align function is active.
Interruption on the bending line.

Interruption before the bending line.

Interruption before and on the bending line.

Interruption behind the bending line.

Interruption on and behind the bending line.

Interruption before and behind the bending line.

Interruption before, on and behind the bending line.

Tab. 4-5

Upper tool clamp status

Symbol Description
The upper tool clamp is opened.

The upper tool clamp is closed.

Tab. 4-6

Lower tool clamp status

Symbol Description
The lower tool clamp is opened.

The lower tool clamp is closed.

Tab. 4-7

B876en 2019-05-18 Description of the operating elements 4‐9

 Emergency stop status

Symbol Description
Emergency stop is active.

Tab. 4-8

Operating elements The following symbols can also appear on the operating ele-
ments in the user interface:

Symbol Description
Error

Wrong value

Error: value too high

Error: value too low

Warning: value too high

Warning: value too low

Warning

Changes not saved

Mandatory value

User setting

Factory setting

Default value

Calculated value

Measured value

Tab. 4-9

4‐10 Description of the operating elements 2019-05-18 B876en

 Auxiliary systems at the user interface

Context help The contextual help contains detailed information on operating

elements in the user interface. The information is shown in a
separate window by the operating element concerned.
The contextual help can be called by tapping with 2 fingers on
the operating element.

Online help The online help contains all descriptions and instructions that
are important for safety, operation, setting work and mainte-
nance.
Online help can be called up by pressing the button (bot-
tom right).

Operating elements on the additional

screen (option)

The following symbols may appear:

Symbol Description
Switch on the Part Indicator insertion aid (option).
The camera image is displayed and is superimposed
with the part geometry for the corresponding bending
step (nominal insertion position).
Show additional content, e.g. drawings.

Open the on-screen keyboard.

Switch the screen display.

Part Indicator insertion aid (option): Adjust the bright-

ness and contrast of the camera image.

Call up remote connection to a freely configurable

VNC server reachable in the network.

Does the display remain white?

■ Check settings (see Technology, "Settings", VNC
connection).
■ Make sure that the server is reachable.
Tab. 4-10

B876en 2019-05-18 Description of the operating elements 4‐11

 1.2 MobileControl

Use MobileControl

Notes
■ The operating element can be freely positioned in the com-
munications rail.A maximum of 8 items can be operated
simultaneously in the communications rail (e.g.
MobileControl, MobileControl Pro, MagicShoe Display).
■ The operating element may not be moved along the commu-
nications rail since this could lead to damage to the electri-
cal contacts. To select another position: Remove the operat-
ing element and insert it at the desired place.

1 For a hydraulic upper tool 6 Open/close LOWER TOOL

clamp (option): Open/close CLAMP
UPPER TOOL CLAMP 7 LEFT BENDING AID (option)
2 Switch WORK AREA ILLUMI- activate/deactivate
NATION on/off. 3 levels: off/ 8 RIGHT BENDING AID (option)
half brightness/full brightness. activate/deactivate
3 Increase/reduce speed in jog 9 Jog button -
mode. 3 levels.
10 STOP
4 Jog button +
5 START
Operating element MobileControl Fig. 74297

1. Put the operating element in the communications rail.

LEDs flash on the operating element: The operating element
is being synchronized.
START or STOP is lit/flashes: the operating element is ready.
2. Operating the machine via the operating element.

4‐12 Description of the operating elements 2019-05-18 B876en

 1.3 MobileControl Pro (option)

Use MobileControl Pro

Notes
■ The operating element can be freely positioned in the com-
munications rail.A maximum of 8 items can be operated
simultaneously in the communications rail (e.g.
MobileControl, MobileControl Pro, MagicShoe Display).
■ The operating element may not be moved along the commu-
nications rail since this could lead to damage to the electri-
cal contacts. To select another position: Remove the operat-
ing element and insert it at the desired place.

1 For a hydraulic upper tool 5 START

clamp (option): Open/close 6 Open/close LOWER TOOL
UPPER TOOL CLAMP CLAMP
2 Display 7 CONFIGURATION: Show/hide
3 BACK: Change to the previous menu options, specify
level sequence.
4 Turn-press button: choose/set 8 STOP
parameter
The MobileControl Pro operating element (option) Fig. 73968

1. Put the operating element in the communications rail.

LEDs flash on the operating element: The operating element
is being synchronized.
START or STOP is lit/flashes: the operating element is ready.
2. Operating the machine via the operating element.

B876en 2019-05-18 Description of the operating elements 4‐13

 Select/adjust parameter

Condition
■ The control system is at STOP.

1. Select parameter:
− Turn the turn-press button until the required parameter
appears.
− Press the turn-press button to select the parameter.
2. Set parameter:
− Turn the turn-press button until the required value
appears.
− Press the turn-press button to apply the value.

Tip
To apply an adjustment value for all bend steps: Hold the
turn-press button for a long time.

3. To change to the previous level: Press BACK.

1.4 Foot switch

1 EMERGENCY STOP push-but- 3 PRESS BEAM UP foot switch

ton 4 PRESS BEAM DOWN foot
2 Pilot lamp switch with stop function
Foot switch Fig. 69000

4‐14 Description of the operating elements 2019-05-18 B876en

 Notes
■ A maximum of three foot switches may be connected to the
machine. With MagicShoe (option), two foot switches can
also be connected.
■ The PRESS BEAM DOWN foot switch is active if the pilot
lamp lights up.
■ The EMERGENCY STOP push-button and PRESS BEAM
UP foot switch are active as long as the foot switch is con-
nected to the machine.

PRESS BEAM DOWN foot The foot switch has the following positions:
switch with stop function
Position Description
The foot switch is not The press beam is stationary or remains sta-
pressed. tionary.
The foot switch is The press beam moves downwards.
pressed as far as the
first pressure point
(neutral position).
The foot switch is The stop function leads to the following:
pressed all the way ■ Control stops.
down.
■ The press beam stops.
■ Stop all axis motions of the backgauge.
■ The hydraulic unit is switched off.
Tab. 4-11

PRESS BEAM UP foot The press beam can be moved upwards using the PRESS
switch BEAM UP foot switch.

The foot switch has the following positions:

Position Description
The foot switch is not No effect on the press beam.
pressed.
The foot switch is The press beam moves upwards.
pressed.
Tab. 4-12

The PRESS BEAM UP foot switch is not active in the following

cases:
■ EMERGENCY STOP was triggered.
■ Both side protection doors were opened.
■ The rear roller gate was opened.

B876en 2019-05-18 Description of the operating elements 4‐15

 1.5 Wireless foot switch (option)

1 EMERGENCY STOP push-but- 4 PRESS BEAM DOWN foot

ton (active: lights up red, inac- switch with stop function
tive: gray) 5 Compartment for Connector
2 Pilot lamp
3 PRESS BEAM UP foot switch
Wireless foot switch (option) Fig. 87847

The wireless foot switch replaces the foot switch with a connec-
tion cable.
The foot switch may only be used within a defined working
range. The foot switch is wirelessly connected to the machine.
Ultrasonic sensors in the lower part of the press table checks
whether the operator is within the working range.

Notes
■ The PRESS BEAM DOWN foot switch is active if the pilot
lamp lights up.
■ The EMERGENCY STOP push-button is only active if it is
illuminated red, i.e. as long as the operator is within the
working range.
■ The operator may only use the foot switch if they see the
red colour of the EMERGENCY STOP push-button.
■ Recommendation: When using multiple wireless foot
switches, indicate to which machine the respective foot
switch is allocated.

Working range The wireless foot switch can only be used within a defined work-
ing range.

4‐16 Description of the operating elements 2019-05-18 B876en

1 Machine Z Working range in Z direction X Working range in the X direction
L Press table length
Working range Fig. 74298

Press table length Working range in Z Working range in X

direction direction
2210 mm (87 in) 3030 mm (119 in) 2500 mm (98 in)
2720 mm (107 in) 3810 mm (150 in) 2500 mm (98 in)
3230 mm (127 in) 4500 mm (177 in) 2500 mm (98 in)
4250 mm (167 in) 6090 mm (240 in) 3045 mm (120 in)
4420 mm (174 in) 6180 mm (243 in) 3090 mm (122 in)
Tab. 4-13

PRESS BEAM DOWN foot The foot switch has the following positions:
switch with stop function
Position Description
The foot switch is not The press beam is stationary or remains sta-
pressed. tionary.
The foot switch is The press beam moves downwards.
pressed as far as the
first pressure point
(neutral position).
The foot switch is The stop function leads to the following:
pressed all the way ■ Control stops.
down.
■ The press beam stops.
■ Stop all axis motions of the backgauge.
■ The hydraulic unit is switched off.
Tab. 4-14

PRESS BEAM UP foot The press beam can be moved upwards using the PRESS
switch BEAM UP foot switch.

B876en 2019-05-18 Description of the operating elements 4‐17

 The foot switch has the following positions:

Position Description
The foot switch is not No effect on the press beam.
pressed.
The foot switch is The press beam moves upwards.
pressed.
Tab. 4-15

The PRESS BEAM UP foot switch is not active in the following

cases:
■ EMERGENCY STOP was triggered.
■ Both side protection doors were opened.
■ The rear roller gate was opened.

Charging station for

Connector

1 Status LED
Charging station Fig. 69014

Status LED Color Status Description

1 green Flashing Connector is being
charged.
Lights up Connector is charged.
yellow Lights up The charging station
requires an electrical
power supply.
Tab. 4-16

Note
Only use the charger with its supplied power supply. Do not con-
nect the charger via the USB connector to a PC as the charging
current is insufficient (up to 1500 mA).

4‐18 Description of the operating elements 2019-05-18 B876en

 Using wireless foot switch

Conditions
■ Ultrasound sensors in the lower area of the press table are
not covered, for example, by a sheet metal stack.
■ Wireless foot switch is programmed for the bending opera-
tion.

Preparatory work 1. Insert the Connector.

Activating wireless foot 2. Either

switch on the operating Ø Press Manual mode, .
panel
or
Ø Press Production, "Run in", "Wireless operating option".
3. Select user.
4. Press Log-on.
5. Follow the instructions on the screen.
− Press the EMERGENCY STOP push-button.
− Rotate the EMERGENCY STOP push-button to the right
and pull it out.

Moving the press beam 6. Move press beam as usual with the foot switches.

1.6 MagicShoe (option)

A MagicShoe replaces the PRESS BEAM DOWN and PRESS

BEAM UP buttons in the foot switch.

Operating elements

1 Transmitting unit 4 MagicShoe Connector (Service

2 Safety shoe (safety class S2) life: approx. 20 hours)
3 2x status LED 5 Heel clip (with integrated vibra-
tion motor)
MagicShoe (option) Fig. 69013

B876en 2019-05-18 Description of the operating elements 4‐19

 Status LED Status Description
3 Both LEDs flash (bright/ The MagicShoe is ready to
dark have same duration). couple to the machine.
Both LEDs flash briefly The MagicShoe is coupled
(are briefly lit and dark for to the machine, is in radio
a longer period). range and ready for use.
Both LEDs briefly flash The MagicShoe is coupled
twice. to the machine, but is not
within radio range.
All other states. Error: remove the Magi-
cShoe Connector and plug
it in again.
Tab. 4-17

Notes
■ Only wear the MagicShoe in a dry environment to prevent a
malfunction due to contamination. Do not dry wet shoes on
the heating.
■ Only dry brush the MagicShoe. Do not use any cleaning
agent.
■ If a MagicShoe is worn without the MagicShoe Connector
inserted, insert the supplied connector cover in the heel
clamp.
■ If the MagicShoe is not used: disconnect the MagicShoe
Connector from the MagicShoe. Store the MagicShoe in a
dry room, if possible in the box supplied with it.
■ Replace the MagicShoe no later than one year after first
using it.
Dispose of the MagicShoe or the rechargeable battery in the
MagicShoe Connector according to the applicable laws.

A Version with knobs ∅7 mm, C Smooth version

height 1 mm
A Version with knobs ∅16 mm,
height 1 mm
Tested workplace mats from Sytech Andreas Winter GmbH Fig. 78674

Note
MagicShoe has been tested and approved together with mats
from Sytech Andreas Winter GmbH. The mats are available in

4‐20 Description of the operating elements 2019-05-18 B876en

 smooth version or with knobs (∅7 mm to ∅16 mm, height
1 mm). If different mats are used, the perfect operation of the
MagicShoe cannot be ensured.

1 Status LED
Charging station Fig. 69014

Status LED Color Status Description

1 green Flashing Connector is being
charged.
Lights up Connector is charged.
yellow Lights up The charging station
requires an electrical
power supply.
Tab. 4-18

Note
Only use the charger with its supplied power supply. Do not con-
nect the charger via the USB connector to a PC as the charging
current is insufficient (up to 1500 mA).

Indicator element The indicator element shows the operating status of the Magi-
cShoe.

MagicShoe (option): MagicShoe Display indicator element Fig. 73969

B876en 2019-05-18 Description of the operating elements 4‐21

Position Status Description
1 The bars illuminate. The quality of the wireless connection.
The dot illuminates. An operator has been detected in the working area.
The dot is not illuminated. No operator has been detected in the working area.
2 Illuminates. The press beam moves upwards.
Flashing. The press beam can be moved upwards.
3 Illuminates. The press beam moves downwards.
Flashing. The press beam can be moved downwards.
4 The bars illuminate. The status of the MagicShoe Connector rechargeable bat-
tery.
5 Button pressed. Data from operator 1 is being displayed.
The edge illuminates white.
The button lights up blue. MagicShoe has been selected for the following bend.
6 Button pressed. Data from operator 2 is being displayed.
The edge illuminates white.
The button lights up blue. MagicShoe has been selected for the following bend.
7 All of the bars illuminate. Pressure is building up in the MagicShoe.
The bars are illuminated but inter- Excessively high pressure.
rupted.
Tab. 4-19

Notes
■ The indicator element can be freely positioned in the commu-
nications rail. A maximum of 8 items can be operated simul-
taneously in the communications rail (e.g. MobileControl,
MobileControl Pro, MagicShoe Display).
■ The indicator element may not be slid along the communica-
tions rail since this could lead to damage to the contacts. To
select another position: remove the indicator element and
insert at the desired place.

Working range MagicShoe may only be used within a defined working area.

4‐22 Description of the operating elements 2019-05-18 B876en

1 Machine Z Working range in Z direction X Working range in the X direction
L Press table length
Working range Fig. 74298

Press table length Working range in Z Working range in X

direction direction
2210 mm (87 in) 3030 mm (119 in) 2500 mm (98 in)
2720 mm (107 in) 3810 mm (150 in) 2500 mm (98 in)
3230 mm (127 in) 4500 mm (177 in) 2500 mm (98 in)
4250 mm (167 in) 6090 mm (240 in) 3045 mm (120 in)
4420 mm (174 in) 6180 mm (243 in) 3090 mm (122 in)
Tab. 4-20

Use MagicShoe

Conditions
■ The working area includes a foot switch so there is an
EMERGENCY STOP push-button near the operator for haz-
ardous situations.
■ Ultrasound sensors in the lower area of the press table are
not covered, for example, by a sheet metal stack.
■ MagicShoe is programmed for the bending operation.

Notes
■ If the vibration motor on the MagicShoe fails: use the foot
switch and contact Technical Service.

B876en 2019-05-18 Description of the operating elements 4‐23

 ■ The MagicShoe remains active until it is logged out. Use
caution when returning from longer absences, e.g. a lunch
break.
■ The MagicShoe Connector, the heel clamp and the transmit-
ting unit can result in an increased risk of stumbling in partic-
ular situations (e.g., going down stairs).

Preparatory work 1. Insert display element MagicShoe Display in the communica-

tions rail.
2. Check safety shoe for damage (visual inspection). In case of
damage: use the foot switch and replace safety shoe.
3. Check the MagicShoe Connector and heel clamp for dam-
age (visual inspection). In case of damage: use the foot
switch and contact Technical Service.
4. To start up the MagicShoe: connect the MagicShoe Connec-
tor to the MagicShoe.

Tip
To shut down MagicShoe: remove MagicShoe Connector.

Activating the MagicShoe 5. Either

on the operating panel Ø Press Manual mode, .
or
Ø Press Production, "Run in", "Wireless operating option".
6. Select user.
7. Press Log-on.
8. Follow the instructions on the screen.
9. Select the desired operator on the display element.

Move the press beam 10. Assume parking position, that is, the right foot is flat on the
downward floor.
11. Perform the two-step motion sequence:
− Lift the front part of your right foot and then lower it
again onto the floor (your heel stays on the floor).
The motor in the shoe vibrates briefly.
− Within 5 seconds, maintain the pressure in the front part
of your foot until the stroke is triggered. Maintain the
pressure for as long as the press beam is to move. Try
to ensure that you do not move your foot here.
Motor in the shoe vibrates twice?
Sufficient pressure in the front of the foot was not built up
within 5 seconds, or too much pressure was exerted or the
front of the foot moved too much.
Ø Perform the two-step motion sequence again:
12. To stop the press beam:
Ø Remove the pressure from the front part of your foot.

4‐24 Description of the operating elements 2019-05-18 B876en

 To move the press beam downward again: build up pres-
sure in the front of the foot within 5 seconds.
To move the press beam upward: Within 5 s, lift the
front part of your foot and keep it up for as long as the
press beam needs to move. Try to ensure that you do
not move your foot to the left or right. To move it back
down after having moved it up, the operator must repeat
the entire two-step pattern of movement.
After 5 seconds, the two-stage movement pattern must
be carried out again.
or
Ø Suddenly move your foot in any direction.
Motor in the shoe vibrates twice.
To initiate another stroke: Repeat the two-step move-
ment sequence.
or
Ø Step firmly down with the front part of your foot.
Motor in the shoe vibrates twice.
To initiate another stroke: press START and perform the
two-stage motion sequence again.

Move the press beam 13. Assume parking position, that is, the right foot is flat on the
upward floor.
14. Perform the two-step motion sequence:
− Lift the front part of your right foot and then lower it
again onto the floor (your heel stays on the floor).
The motor in the shoe vibrates briefly.
− Within 5 seconds, lift the front part of your foot and keep
it up for as long as the press beam is to move. Try to
ensure that you do not move your foot to the left or right.
Motor in the shoe vibrates twice?
The front of the foot was not sufficiently raised within 5 sec-
onds or the front of the foot moved too much.
Ø Perform the two-step motion sequence again:
15. To stop the press beam:
Ø Lower the front part of your foot.
To move the press beam upward again: Within 5 s, lift
the front part of your foot and keep it up for as long as
the press beam needs to move. Try to ensure that you
do not move your foot to the left or right.
After 5 seconds, the two-stage movement pattern must
be carried out again.
or
Ø Suddenly move your foot in any direction.
Motor in the shoe vibrates twice.

B876en 2019-05-18 Description of the operating elements 4‐25

 To initiate another stroke: Repeat the two-step move-
ment sequence.

1.7 Operating elements on the rear side

of the machine

1 Open the roller gate 3 USA, Canada, Mexico, South

2 Close the roller gate America: Key switch for DEAC-
TIVATE DOOR LOCK
Operating elements on the rear side of the machine: To the Fig. 69012
right on the control cabinet

1 MAIN SWITCH with EMERGENCY SHUTDOWN function

Operating elements on the rear side of the machine: To the Fig. 69017
left on the power cabinet

ROBOT-MODE (option) key switch

The robot can be activated/deactivated using the key switch.

4‐26 Description of the operating elements 2019-05-18 B876en

 A The robot is deactivated. B The robot is activated.
ROBOT-MODE (option) key switch Fig. 90442

1.8 Side safety doors

Fig. 72891

The safety doors at the side are sliding doors.

Exception: With a parking position for the bending aid (option),
the safety door is a swing door on the side of the parking posi-
tion.
The sliding doors can only be opened if the electrical cabinet
door concerned is closed.

B876en 2019-05-18 Description of the operating elements 4‐27

 2. Switching on the machine

2.1 Unlock EMERGENCY STOP

EMERGENCY STOP push-buttons are located at the following

points:
■ On the operating panel.
■ On the foot switch.

Conditions
■ The doors on the control cabinet and on the power cabinet
are closed.
■ Side safety doors are closed.
■ Roller gate is closed.

Ø To release the EMERGENCY STOP push-button: rotate the

EMERGENCY STOP push-button to the right and pull it out.

2.2 Switching on the machine

Conditions
■ EMERGENCY STOP is released.
■ Roller gate is closed.
■ The doors on the control cabinet and on the power cabinet
are closed.
■ Side safety doors are closed.
■ The BendGuard (option) is in the work position.
■ For 2-axis backgauge or 6-axis backgauge (option) and/or
pneumatic I axis (option) and/or BendMaster (option): com-
pressed air supply is switched on.

Means, Tools, Materials

■ For BendGuard (option): check plates.

1. Turn the MAIN SWITCH to I.

The control starts. This may take some time.
The start page of the user interface will appear.
"Log on" appears.

4‐28 Switching on the machine 2019-05-18 B876en

 Note
If the user has not logged in after 60 seconds, the "user
group" "Standard" is logged in automatically.
2. Select "user group".
3. If necessary, enter "password".
or
Ø Unlock a machine with an ID card (RFID).
4. Press Log-on.
The user interface appears.
The symbol appears in the status bar.
STOP flashes.
5. Check if the following happens:
− The pilot lamp on foot switch 1 illuminates.
− The pilot lamps on the other foot switches flash for 16
seconds.
If pilot lamp is defective: have Technical Service replace the
foot switch.

6. Press Manual.

A collision of the backgauge fingers of the backgauge with

CAUTION loaded tools is possible.
Ø The positions of the X and R axes currently programmed in
the manual mode must be suitable for the loaded tools or
Ø adjust the position of the X axis to >500 mmor
Ø remove the loaded tools.

7. On the operating panel or MobileControl unit, press START.

The press beam moves upward.
Crowning travels to the reference point.
8. Press the PRESS BEAM DOWN foot switch and keep it
pressed until the press beam has reached its reference point.
The press beam doesn't move?

Ø Check whether a message appears on the operating

panel. If necessary, follow the instructions on the screen.

For BendGuard (option): do 9. "Bending method" Select "Air bending".

a run-on path test 10. Make sure that the fitted tool matches the programmed tool.
11. Close the tool clamp.
12. Make sure that the BendGuard is set to the working height
of the upper tool which is fitted.

B876en 2019-05-18 Switching on the machine 4‐29

 Note
During the overtravel measurement, an idle stroke is not
allowed.
13. Either
Ø Adjust the check plates on a lower tool to the program-
med sheet thickness.
or
Ø Place sheet metal strip with the programmed sheet thick-
ness on a lower tool.
14. Select profile mode:
− Display other parameters for the bend (see "Tab. 4-1",
pg. 4‐7).
− Press "Safety, Functions".
− Select "BendGuard mode", "1: Profile mode".
15. On the operating panel or MobileControl unit, press START.
16. Either
Ø Press BendGuard TOOL ALIGN.
or
Ø Press Production, "Run-in", Production settings,
Tool Align.
17. Press the PRESS BEAM DOWN foot switch.

Note
The traverse path for press beam overtravel measurement is
50 mm. The tools must be loaded such so as to enable this
traverse path.
18. Press the PRESS BEAM DOWN foot switch.
The press beam moves downwards.
Overtravel measurement is carried out.
A message will appear that the run-on path measurement
has been done.
19. Release the PRESS BEAM DOWN foot switch.
The press beam will move up to its reference point.
20. Press the PRESS BEAM DOWN foot switch.
The press beam moves downwards.
Overtravel measurement is carried out.
A message will appear that the run-on path measurement
has been done.
21. Release the PRESS BEAM DOWN foot switch.
The machine is ready for operation.

4‐30 Switching on the machine 2019-05-18 B876en

 3. Switching off the machine

3.1 Switching off the machine in the

case of malfunctions

1. Press the EMERGENCY STOP push-button on the operating

panel.
or
Ø Press the EMERGENCY STOP push-button on the foot
switch.
2. If possible: Shut down the control system at the operating
panel (see "Switching off the machine", pg. 4‐31).
or
Ø If the control is no longer responding: Turn MAIN
SWITCH to 0.

3.2 Switching off the machine

Note
If the machine is switched off for extended periods, the press
beam can be secured with square wooden beams. Position the
press beam with a clearance of 7 to 10 mm above the square
wood beams.

1. For hydraulic tool clamping (option): open the tool clamp

2. Press (top right).
or
Ø Press (bottom left), Log out user.
"Log on" appears.
3. Press Close HMI.
TOSh (TRUMPF Operating Shell) appears.
4. (lower left), press Shutdown.
The control system will shut down, the screen will go dark.

Note
The main switch may only be switched off once the control
has been completely shut down.
5. Turn the MAIN SWITCH to 0.

B876en 2019-05-18 Switching off the machine 4‐31

 4. What to do in an emergency and in
case of a malfunction

The operator must use their experience to decide which meas-

ures are necessary:

Situation Necessary action Effect

■ Trapped body parts. ■ Press the PRESS BEAM UP ■ The press beam moves upward.
■ There is a risk of body parts get- foot switch.
ting trapped.
■ All other situations. ■ Release the PRESS BEAM UP ■ The press beam stops.
foot switch.
or
■ Press the EMERGENCY STOP
push-button.
■ The malfunction cannot be elimi- ■ If possible: Shut down the ■ The machine is switched off and
nated quickly e.g. during mainte- control system at the operating the machine's electrical power
nance work. panel (see "Switching off the supply has been interrupted.
machine", pg. 4‐31).
or
■ If the control is no longer
responding: Turn MAIN SWITCH
to 0.
Tab. 4-21

4.1 Rescuing trapped persons

Fig. 85048

1. If EMERGENCY STOP was triggered: release the EMER-

GENCY STOP(see "Unlock EMERGENCY STOP", pg. 4‐28).
2. Press the PRESS BEAM UP foot switch.

4‐32 What to do in an emergency and in case of a 2019-05-18 B876en

malfunction
 5. Operating modes of the machine

Notes
■ When using MagicShoe (option) there must be a foot switch
in the working area so that there is an EMERGENCY STOP
push-button near the operator for hazardous situations.
■ Any operating units with foot switches not used must be
removed from the working area and stored sealed.

Operation mode Number Activating operating elements Moving the press beam
of opera-
tors
Foot operation 1 ■ 1 foot switch with the PRESS Trigger stroke with the operating
BEAM DOWN switch. element.
or
■ 1 MagicShoe (option)
Station bend, i.e. 1 ■ Max. 3 foot switches with the Trigger stroke at each tool station
bend over several tool PRESS BEAM DOWN foot with the operating element.
stations switch.
or
■ 1 MagicShoe (option)
Two-foot mode 2 ■ 2 foot switches with the PRESS Trigger stroke at the same time
(optional) BEAM DOWN switch. with each operating element.
or
■ 1 MagicShoe (option)
■ 1 foot switch with the PRESS
BEAM DOWN switch.
Tab. 4-22

B876en 2019-05-18 Operating modes of the machine 4‐33

 6. BendGuard (option)

The press beam can move down at rapid speed (>10 mm/s) if
the machine is secured with an optoelectronic safety device.

1 Transmitter 4 Upper tool

2 Light field 5 Receiver
3 Lower tool
Fig. 69001

6.1 Manual BendGuard (option)

Setting the working height

BendGuard must be set to the working height of the loaded

upper tool.

4‐34 BendGuard (option) 2019-05-18 B876en

 Condition
■ Programmed upper tool is loaded (see Chapter 5 "Setting
work").

1 Working height
Upper tool Fig. 30199

1. Read off the working height at the loaded upper tool.

1 Magnetic bolt 2 Working height display

Fig. 97068
2. Lift/lower the BendGuard to the desired working height.
3. Run the Tool Align function and check the BendGuard's sta-
tus display.

B876en 2019-05-18 BendGuard (option) 4‐35

 6.2 Automatic BendGuard (option)

Setting the setup/work position

Work position Tooling position

Automatic BendGuard (option) Fig. 91707

Setting up the setup 1. Open the upper tool clamp.

position 2. Open a side safety door.

Setting the work position 3. Close upper tool clamp.

4. Close the side safety door.

Automatic BendGuard (option): Setting the

working height

Condition
■ Programmed upper tool is loaded (see Chapter 5 "Setting
work").

1. Close the side safety doors.

2. Close upper tool clamp.
■ The BendGuard will automatically move to the program-
med working height.
■ The Tool Align function will be run automatically.
3. Check the BendGuard's status display.

4‐36 BendGuard (option) 2019-05-18 B876en

 6.3 Running the Tool Align function

Run the Tool Align function in the following cases:

■ If there is a corresponding error message on the user inter-
face.
■ In the event of severe temperature fluctuations.
■ For a manual BendGuard (option): After every change of the
upper tool.
The Tool Align function checks whether BendGuard correctly
generates the protected range.

The Tool Align function will automatically be run:

■ If START is pressed.
■ If the hydraulic upper tool clamp (option) is closed.

Conditions
■ Control is on START, that is, the program or manual mode
has been started.
■ The press beam is at the upper dead point.
■ Programmed upper tool is loaded (see Chapter 5 "Setting
work").
■ The upper tool clamp is closed.

Note
While the Tool Align function is being run, the foot switch may
not be actuated since otherwise the enable from the control sys-
tem will be withdrawn and the Tool Align function will have to be
repeated.

1. In the status bar (right) press the BendGuard symbol and, in

the pop-up window, press the button.
or
Ø Press Production, "Run-in", Production settings,
Tool Align.
2. Check the BendGuard's status display.
3. If necessary: Check and adjust BendGuard (see Section 5
"Setting work").

The minimum mute point depends on the upper tool. The mute
point is referenced at the lowest point (tool tip/sensor disk).

B876en 2019-05-18 BendGuard (option) 4‐37

 Radius Mute point Tool size
<37 mm 2 mm "small"
37 - 67 mm 6 mm "medium"
>67 mm 20 mm "large"
Mute point with radius inserts Tab. 4-23

Tool width Mute point Tool size

<20 mm 2 mm "small"
20 - 46 mm 6 mm "medium"
>46 mm 20 mm "large"
Mute point for flat punches Tab. 4-24

Wide sensor disk Mute point Tool size

<20 mm 2 mm "small"
20 - 46 mm 6 mm (2 mm18) "medium"
>46 mm 20 mm (2 mm18) "large"
Mute point for sensor tools Tab. 4-25

Note
If upper tools are used that are wider than the light field of
the BendGuard, a test stroke must be carried out. The dan-
ger zone is not completely secured in front of and behind
the upper tool. The danger situation is reduced to a mini-
mum by the test stroke.
4. Carry out a test stroke in the following cases:
− Upper tool is recognized as "large"(see "Do a test
stroke.", pg. 4‐38).
− For over-wide upper tool (see "Do a test stroke.",
pg. 4‐38).
− For over-wide sensor tools (see "Carrying out a test
stroke for an over-wide sensor tool", pg. 4‐39).

Do a test stroke. If BendGuard does not detect a tool tip during Tool Align (due to
a large width or geometry, for example, for flat punches, wide
special tools), a test stroke must be carried out.

Note
The mute point is first set 20 mm higher and the operator is
notified that the mute point has to be adjusted as needed. If
need be, acknowledge existing messages.
5. Start test stroke.
The press beam stops at the mute point.

18 If the ACB is only being used at one tool station

4‐38 BendGuard (option) 2019-05-18 B876en

 Test body Fig. 76237
6. Using the test specimen (included in the machine's scope of
delivery), ensure there is no collision.
7. If there is no collision with the test specimen, press OK.
The test stroke can be completed.
8. If a collision has been determined, press Cancel.
The press beam automatically moves upwards.

Carrying out a test stroke If during Tool Align, BendGuard detects an over-wide sensor
for an over-wide sensor tool tool (width >60 mm), then a test stroke will be required. If owing
to the shift, a sensor disk is detected during a test stroke, then,
from the next stroke, you can again work with a lower mute
point.

Notes
■ For several tool stations with sensor tools, all of the sen-
sor disks must be displaced, for the shift to be detected.
To detect the sensor disks, we recommend putting pre-
bent 90° sheet metal plates under all of the sensor disks
fitted. If no sensor disks are detected, then you can con-
tinue to work with a higher mute point.
■ The overhang of the sensor disks past the upper tool tip
may be no more than 4 mm. This is true for all
TRUMPF sensor disks. For an overhang >4 mm, the
overhang must be added to the minimal mute point.
■ If a sensor disk is detected during a test stroke, the
BendGuard will automatically trigger a Tool Align at the
next upper dead point. The protected field at the upper
dead point must be free.
■ To detect sensor disks, the mute point will automatically
be set 20 mm higher. If need be, acknowledge existing
messages.
9. Do a test stroke.
If a sensor disk is detected during a test stroke, the
BendGuard will automatically trigger a Tool Align at the next
upper dead point.
As soon as Tool Align was successful, from the next stroke
you may again work with a lower mute point.

B876en 2019-05-18 BendGuard (option) 4‐39

 6.4 Selecting protect mode

Conditions
■ Programmed upper tool is loaded (see Chapter 5 "Setting
work").
■ BendGuard is set to the working height of the loaded upper
tool.
1. Either
Ø Press Manual mode, "Safety, functions".
or
Ø Press Program, "Bending steps", "Safety, functions".
2. Select "BendGuard mode":

Mode Application Description Sequence

"1: Profile For bendings which do not The area in front, behind ■ Load a workpiece.
mode" have side flanges projecting and under the tool tip is ■ Press the PRESS BEAM
upwards. active. DOWN foot switch.
The press beam stops if the The press beam moves up
light field is interrupted. to the mute point in rapid
"2: Box bend- For bendings which have The area below the tool tip traverse and then automati-
ing mode" side flanges projecting is active. cally onward at reduced
upwards. speed during the work cycle.
The press beam stops if the
Height of the side flanges to light field is interrupted.
secure the area above the
flanges.
"3: Profile For bendings which do not The area in front, behind ■ Load a workpiece.
mode: Stop at have side flanges projecting and under the tool tip is ■ Press the PRESS BEAM
the mute point" upwards. active. DOWN foot switch.
Protect mode to exactly posi- The press beam stops if the The press beam moves
tion the workpiece in front light field is interrupted. up to the mute point in
of the bending, for example, rapid traverse and stops.
for interior flanges. ■ Press the PRESS BEAM
"4: Box bend- For bendings which have The area below the tool tip DOWN foot switch.
ing mode: Stop at side flanges projecting is active. The press beam moves
the mute point" upwards. onward at reduced speed.
The press beam stops if the
Protect mode to exactly posi- light field is interrupted.
tion the workpiece in front
of the bending, for example,
for interior flanges.
Height of the side flanges to
secure the area above the
flanges.

4‐40 BendGuard (option) 2019-05-18 B876en

 Mode Application Description Sequence
"7: Profile mode. For bendings which do not The area in front, behind ■ Load a workpiece.
Reduced opening" have side flanges projecting and under the tool tip is ■ Press the PRESS BEAM
upwards. active. DOWN foot switch.
Mode to optimize process- The press beam stops if the The press beam moves
ing time, e.g., when bending light field is interrupted. up to the mute point in
large, complex parts. rapid traverse and then
automatically onward at
"8: Box bending For bendings which have The area below the tool tip
reduced speed during the
mode. Reduced side flanges projecting is active.
work cycle.
opening" upwards.
The press beam stops if the Once the bend is com-
Mode to optimize process- light field is interrupted. plete, the press beam
ing time, e.g., when bending automatically returns to
large, complex parts. the mute point.
Height of the side flanges to
secure the area above the
Notes
flanges.
■ The first stroke must
be done manually.
■ The foot switch must
be released while
the press beam is
moving upward.
■ The bend itself must
always be done man-
ually.
■ If the machine is not
used for 30 s, a
stroke must be man-
ually initiated once
again.
Protect mode Tab. 4-26

6.5 Disabling BendGuard (option)

The opto-electronic guard can be disabled. The press beam

then moves with reduced speed (max. 10 mm/s).
1. Either
Ø Press Manual mode, "Safety, functions".
or
Ø Press Program, "Bending steps", "Safety, functions".
2. Select "BendGuard mode":
− "5: Off".
− "6: Off. Stop at mute point".

B876en 2019-05-18 BendGuard (option) 4‐41

 6.6 Define the mute point with check
plates

The machine will automatically define the mute point, as soon

as a bend is done for the 1st time with a workpiece. For sheet
thicknesses < 1 mm or for die widths ≥ 40 mm, in the following
cases, instead of the workpiece, the check plate must be used:
■ If tools with a different working height are used.
■ If the sheet thickness has been changed to another value <
1 mm.

The check plate is responsible for the following:

■ For sheet thicknesses < 1 mm, it simulates the sheet thick-
ness.
The check plate is moved up by one sheet thickness using
the imprinted millimeter scale.
■ For die widths ≥ 40 mm: The light field is shielded below the
mute point.
The check plate prevents the light field from shining through
the die width of the lower tool.

Conditions
■ Control is on START, that is, the program or manual mode
has been started.
■ The programmed upper tool has been set up (see chapter 5
"Setting work").

Means, Tools, Materials

■ Magnetic plate.

Check plate Fig. 35733

4‐42 BendGuard (option) 2019-05-18 B876en

 1. Attach the check plate on the side of the tool.
2. Slide the check plate upwards by the amount of the sheet
thickness.

Tip
With corrugated sheets: Move the check plate upwards to
avoid the stroke interruptions.

3. Press the PRESS BEAM DOWN foot switch.

Press beam moves downwards.
The mute point is defined automatically.

B876en 2019-05-18 BendGuard (option) 4‐43

 7. Manual operation

In the activity Manual operation, a single bend is programmed.

This bend can be done immediately.

7.1 Programming individual bends

Select Manual operation 1. Press Manual.

Specify the parameters for 2. Define the desired parameters:

the bend
Operating element Description
"Raw material" Select material.

"Sheet thickness" Enter sheet thickness.

Selection of upper tool or Select the upper/lower tool.

lower tool
If BendGuard (optional) is used: note the permissible upper tool height (see chap-
ter 3, "Technical data").
"Bending method" "Air bending" (path-dependent):
■ The bending part will be bent without a positive fit resulting between the upper
and lower tools.
■ The position of the press beam (Y-axis) will be calculated with the entered bend-
ing angle. The press beam will move with no more than the calculated pressure
to the calculated position.

"Folding" (path-dependent):
■ A sheet pre-bent to 30° will be pressed together depending on the path (fold
with a standoff height).
■ This requires seaming tools and displacement of the lower tool (I-axis) or special
seaming tools.

"Hemming" (force-dependent):
■ A sheet pre-bent to 30° will be pressed together depending on the pressure (fold
without a standoff height).
■ This requires seaming tools and displacement of the lower tool (I-axis) or special
seaming tools.

"Bottom bending" (force-dependent):

■ The material will be pressed to a positive fit between the upper and lower tools.
■ The press beam moves with the maximum calculated pressure (at least 3x
higher than when air bending) to a position on the Y-axis which creates a control-
led collision. By the collision, the specified pressure will be reached.
Depending on the selected bending method, different input fields will be displayed.
"Bending angle" Only active for "Bending method" "Air bending".
Enter the bending angle.

4‐44 Manual operation 2019-05-18 B876en

Operating element Description
Correction "Bending Only active for "Bending method" "Air bending".
angle"

Adjust value if for example the sides have sprung back after the bend:
■ Positive value (example): programmed bending angle of 90°, adjustment value
+2°, i.e. 92° will be bent.
■ Negative value (example): programmed bending angle of 90°, adjustment value
-2°, i.e. 88° will be bent.
The springback of a bent sheet depends upon the type of material, the sheet thick-
ness, the radius of the upper tool, the die width and the rolling direction when the
sheet was manufactured.

Note
For bends with ACB, if the adjustment value lies outside of the value range: cal-
ibrate sensor tool.
"Lower dead point cor- Only active for "Bending method" "Folding", "Bottom bending" or "Hemming".
rection"
Correction of the lower dead point (LDP).
Adjust the value, e.g. when bending with special tools.
"Bending length" Enter the length of the bending line.

"Bending position" Enter the point on the Z-axis on which the left edge of the part is in contact.
The inclination of the press beam will be adjusted according to the bending task.

Tip
A lateral offset of the part relative to the gauge finger can be set in Technology,
"Settings", Global, "Distance of finger to sheet". Application example: Parts with
notches.
For angle measuring sys- ■ Activated: Perform bend with angle measuring system:
tem (option): "ACB" − Angle measuring system ACB (option)
− Tactile ACB Wireless angle measuring system (option)
− ACB laser optical angle measuring system (option)
For angle measuring sys- Specify the parameters for the ACB bending operation.
tem (option): / /
Also see
■ Program a bend with the angle measuring system ACB (option) (see
page 4‐57).
■ Program a bend with the angle measuring system ACB Wireless (option) (see
page 4‐58).
■ Program a bend with the angle measuring system ACB Laser (option) (see
page 4‐59).
For sheet thickness meas- ■ Activated: Perform bend with TCB sheet thickness [Link] TCB(Thick-
uring TCB (option): "TCB" ness Controlled Bending) function reduces angle errors produced by fluctuations
in sheet thickness.

Also see
■ Sheet thickness measuring TCB (option) (see page 4‐59).
Only for a 6-axis backgauge.
■ Activated: Values linked.

B876en 2019-05-18 Manual operation 4‐45

 Operating element Description
"Flange" Enter the side length, i.e. the distance between the bending line and the edge in
contact with the backgauge finger.
Correction "Flange" Enter correction value of the backgauge in X direction.
Dimensioning of the side Select the dimensioning of the side:
■
: Outer dimensioning with bend deduction.
■
: Inner dimensioning with bend deduction.
■
: Absolute dimensions without bend deduction.

Collision check Perform collision check. An additional symbol will show the result of the collision
check:
■ : No collision
■ : Collision. Check the parameters and correct if necessary.
The graphical collision check is a static check and is done for all path points.
Calculated values Show the calculated values.

MagicShoe ■ Activate and set MagicShoe.

■ Carry out diagnostics.
■ Watch the video for the application.
Parameters for the bend Tab. 4-27

Specify the press beam's 3. Display other parameters for the bend (see "Tab. 4-1",
parameters pg. 4‐7).
4. Press "Press beam".
5. Define the desired parameters:

Operating element Description

"Mute distance 1" Only active with "Bending method" "Air bending" or "Coining".

At the mute point, the max. speed ( "Rapid downwards") will automatically be
switched over to the reduced speed ( "Clamping").
The mute point is above the top edge of the lower tool.

"Mute distance 1" + programmed sheet thickness = distance between the tip of
the upper tool and the upper edge of the lower tool.

Only USA: Only the "Customer administrator" user can change mute point 1 (
"mute distance 1")/mute point 2 ( "mute distance 2").

"Mute distance 2" Only active for "Bending method" "Folding" or "Hemming".
If standard tools are used, the press beam moves up to the 2nd mute point during
quick folding ( "Mute distance 2") at max. speed ( "Rapid downwards").

Only USA: Only the "Customer administrator" user can change mute point 1 (
"mute distance 1")/mute point 2 ( "mute distance 2").

Also see
■ Programming fast folding (see page 4‐55).
"Clamping point cor- Adjust the value too compensate for variations in sheet thickness.
rection"

4‐46 Manual operation 2019-05-18 B876en

 Operating element Description
"Waiting time at The delay is mostly required by automated machines. During the waiting time, the
clamping point" press beam will stop at the clamping point.
Adjust the value e.g. if a robot's gripper reaches around the part.
"Multiple sheet bends" ■ Activated: Bend multiple layers of the sheet, e. g. bend the fold again.
"Sheet thickness correc- Adjust the value too compensate for variations in sheet thickness.
tion"
"Press force" In the calculation of the press force, the following is considered:
■ Material properties.
■ Tool properties.
■ Bending length.
■ The frictional losses when bending.
■ Sheet thickness.
The automatically calculated press force is at least 5% of the maximum press
force of the machine. The actual press force during bending might be less, depend-
ing on the bending method(see "Automatically calculated press force too high",
pg. 4‐85).
"Inclination" The inclination of the press beam can be corrected manually via the Y2 axis, e.g.
for a long bend length, when the bending angle deviates over the entire length.
■ Positive value: Y2 positioned downwards.
■ Negative value: Y2 positioned upwards.
"Hold time at LDP" The press beam will remain at the lower dead point (LDP) during the stop time.
Due to the stop time, the material has enough time available during the bend, to
deform.
Increase the value e.g. when air bending thicker sheets or when coining.
"Auto-decompression" ■ Activated (standard): Select the value determined empirically by TRUMPF for the
decompression path.
"Decompression path" With the decompression path, the tension in the machine's frame is released in a
controlled fashion after a bend, as it is under maximum tension at the lower dead
point (LDP).
The decompression path moves the press beam upwards at a slow speed.
"Opening" The press beam opening is the amount by which the press beam moves up after a
bending operation.
■ Positive value: The press beam will be positioned above the mute point.
■ Negative value: The press beam will be positioned below the mute point.
"Press Beam" Tab. 4-28

Specifying the parameters 6. Press "Backgauge".

for the backgauge 7. Define the desired parameters:

Area Operating element Description

Backgauge strategy Stop strategy, –
(diagram to the left/
right)
Stop strategy,
right
■ Activated: Values linked.

""Suggest sheet"" –

B876en 2019-05-18 Manual operation 4‐47

Area Operating element Description
"Offset" – Define offset, i. e. the value by which the backgauge finger is
moved toward the programmed sheet position.
"X1" ■ Positive value: Move backgauge finger towards the back.
■ Negative value: Move backgauge finger towards the front.
"R1" ■ Positive value: Move backgauge finger upwards.
■ Value "0": The lower edge of the backgauge finger is 0.30 mm
above the top edge of the lower tool.
■ Negative value: Move backgauge finger downwards.
"Z1" Only for 4, 5 or 6-axis backgauges.
■ Positive value: Move backgauge finger to the right.
■ Negative value: Move backgauge finger to the left.
"Offset" "X2" Only for 5 and 6 axis backgauges.
■ Positive value: Move backgauge finger towards the back.
■ Negative value: Move backgauge finger towards the front.
"R2" Only for a 6 axis backgauge.
■ Positive value: Move backgauge finger upwards.
■ Value "0": The lower edge of the backgauge finger is 0.30 mm
above the top edge of the lower tool.
■ Negative value: Move backgauge finger downwards.
"Z2" Only for 4, 5 or 6-axis backgauges.
■ Positive value: Move backgauge finger to the right.
■ Negative value: Move backgauge finger to the left.
– "Parallel withdrawl" ■ Activated: Move the backgauge away from the part simultane-
ously with the press beam.
■ Deactivated (default): Stop the press beam at the clamping
point until the backgauge has moved away from the part.
– "Movement strategy" ■
"ASV (automatic safety velocity)": The backgauge
bypasses the danger zone with a programmed speed (50 mm
behind and over the tool). The backgauge will finally move for-
wards (X axis). The backgauge will move at reduced speed
when the distance between the backgauge finger and the tool
is less than 50 mm.
■
"ASW (automatic safety way)" (not for 5-axis backgauge):
The backgauge bypasses the danger zone (50 mm behind and
over the tool). The backgauge will finally move downwards (R
axis). All axes move at the programmed speed.
Conditions
− The press beam opening is so large that the distance
between the backgauge finger and the tool cannot become
less than 50 mm.
− The travel range of the axes is sufficient.
− The backgauge fingers can be folded upwards.

4‐48 Manual operation 2019-05-18 B876en

 Area Operating element Description
"Withdrawal" – Define withdrawal, i. e. value by which the backgauge finger auto-
matically moves away from the stop edge of the part once the
part is clamped between the upper and lower tools (clamping
point).
"X1" Adjust the value, e.g. for thicker sheets (≥ 3 mm) or if there is a
risk of collision between a part and the X-axis (e.g. for Z bends).
■ Positive value: Move backgauge finger towards the back.
■ Negative value: Move backgauge finger towards the front.
"R1" ■ Positive value: Move backgauge finger upwards.
■ Negative value: Move backgauge finger downwards.
"Z1" Not for 2-axis backgauge.
■ Positive value: Move backgauge finger to the right.
■ Negative value: Move backgauge finger to the left.
"Withdrawal" "X2" Only for 5 and 6 axis backgauges.

Adjust the value, e.g. for thicker sheets (≥ 3 mm) or if there is a

risk of collision between a part and the X-axis (e.g. for Z bends).
■ Positive value: Move backgauge finger towards the back.
■ Negative value: Move backgauge finger towards the front.
"R2" Only for a 6-axis backgauge.
■ Positive value: Move backgauge finger upwards.
■ Negative value: Move backgauge finger downwards.
"Z2" Only for 4, 5 or 6-axis backgauges.
■ Positive value: Move backgauge finger to the right.
■ Negative value: Move backgauge finger to the left.
"Additional steps" Define withdrawal sequentially over a maximum of 3 steps.
If the values are only entered in the 1st line, the control system
will determine the order in which the axes move.
"Backgauge" Tab. 4-29

Adjusting other functions 8. Press "Safety, functions".

and the BendGuard (option) 9. Define the desired parameters:

Operating element Description

For a CNC-controlled I- Enter adjustment value for the lower tool displacement (I-axis).
axis (option): "Dis- Adjust the value in order to avoid a collision between the upper and lower tool, for
placement correction" example.
For a pneumatic I-axis: ■ Activated: Lower tool (I axis) is moved to the preset position.
Lower tool moved
Tip
The position can be defined under Technology, "Settings", Global, Center posi-
tion lower tool displacement.
For a pneumatic I-axis: The required spacer is displayed.
"Spacer"

B876en 2019-05-18 Manual operation 4‐49

Operating element Description
"Crowning value cor- For angular deviations along longer bending lengths: Adjust value if the bending
rection" angle deviates in the middle of the part.
The crowning compensates for the bowing of the press beam and table during
bending, so as to ensure an even and straight bending angle over the entire length
of the bend.

A: Result with crowning facility

B: Result without crowning facility
For BendGuard (option): ■
"1: Profile mode":
"BendGuard mode" − For bendings which do not have side flanges projecting upwards.
■
"2: Box bending mode":
− For bendings which have side flanges projecting upwards.
■
"3: Profile mode: Stop at the mute point":
− For bendings which do not have side flanges projecting upwards.
− Protect mode to exactly position the workpiece in front of the bending, for
example, for interior flanges.
■
"4: Box bending mode: Stop at the mute point":
− For bendings which have side flanges projecting upwards.
− Protect mode to exactly position the workpiece in front of the bending, for
example, for interior flanges.
■
"5: Off".
■
"6: Off. Stop at mute point".
■
"7: Profile mode. Reduced opening"
− For bendings which do not have side flanges projecting upwards.
− Mode to optimize processing time, e.g., when bending large, complex parts.
■
"8: Box bending mode. Reduced opening"
− For bendings which have side flanges projecting upwards.
− Mode to optimize processing time, e.g., when bending large, complex parts.
For BendGuard (option): For box bending mode: Height of the side flanges to secure the area above the
"Box height" flanges.

4‐50 Manual operation 2019-05-18 B876en

 Operating element Description
"Foot switch (standard)" Choose how the stroke is to be triggered.
"1st additional foot
switch:" Note
"2nd additional foot
When using MagicShoe (option) there must be a foot switch in the working area
switch:"
so that there is an EMERGENCY STOP push-button near the operator for haz-
"1st additional MagicShoe" ardous situations.
"2nd additional Magi-
cShoe"
For foot operation consider the following:
■ If "Upper dead point (BEAM DOWN foot switch)" is selected in "Speeds, step
change" for "Step change" and if two-foot operation is selected for the following
bend, the backgauge only moves by confirming with an active foot switch (this
can be seen by the pilot lamp).
■ If two foot operation is selected in "Speeds, step change" under "Step change"
"Upper dead point, control stops" and for the subsequent bend, the backgauge
will only move after confirmation with START.

For two-foot operation (option) consider the following:

■ The user is logged on as "Expert" or "Customer administrator".
"Automatic front support ■ Activated: Use left-hand bending aid.
left"
"Automatic front support ■ Activated: Use right-hand bending aid.
right"
Bending aid settings Set the bending aid parameters.

Tip
For further information, see the contextual [Link] contextual help can be
called by tapping with 2 fingers on the operating element.
"Safety, functions" Tab. 4-30

Adjusting the speeds of the 10. Press "Speeds, step change".

axes and step change 11. Define the desired parameters:

Operating element Description

"Rapid downwards" The speed of the press beam up to the mute point.

"Clamping" The speed of the press beam between the mute point and the clamping point.

Also see
■ With the option "Increased working speed at maximum press force": program
increased working speed (see page 4‐54).
"Press" The speed of the press beam between the clamping point and the machine's lower
dead point (LDP).

Also see
■ With the option "Increased working speed at maximum press force": program
increased working speed (see page 4‐54).
"Decompression" Speed of the press beam along the decompression path(decompression).

"Rapid upwards" Speed of the press beam after the decompression path(decompression).

B876en 2019-05-18 Manual operation 4‐51

 Operating element Description
"Fast Folding" Only active for "Bending method" "Folding" or "Hemming".
■ Activated: If standard tools are used, the press beam moves up to the 2nd mute
point during quick folding ( "Mute distance 2") at max. speed ( "Rapid down-
wards").

Also see
■ Programming fast folding (see page 4‐55).
"X1" Speed of the left backgauge finger when moving forwards/backwards.

"X2" Only for 5 and 6 axis backgauges.

Speed of the right backgauge finger when moving forwards/backwards.
"R1" Speed of the left backgauge finger when moving up/down.

"R2" Only for a 6 axis backgauge.

Speed of the right backgauge finger when moving up/down.
"Z1" Only for 4, 5 and 6-axis backgauges.
Speed of the left backgauge finger when moving left/right.
"Z2" Only for 4, 5 and 6-axis backgauges.
Speed of the right backgauge finger when moving left/right.
" Step change" Choose the time when the backgauge moves to the next programmed position.

Automatic:
■
"Decompression point":
− The backgauge automatically moves to the next index position at the end of
the bending operation.
■
"Mute point":
− The backgauge automatically moves to the next stop position when the
press beam has moved upwards up to the mute point.
■
"Upper dead point":
− Default setting.
− The backgauge automatically moves to the next stop position when the
press beam has moved upwards up to the upper dead point.

Manual:
■
"Upper dead point. Control stops":
− the press beam moves to the upper dead point (UDT). The control stops.
− The backgauge moves to the next index position when START is pressed.
■
"Upper dead point (BEAM DOWN foot switch)":
− the press beam moves to the upper dead point (UDT).
− The backgauge moves to the next index position when the PRESS BEAM
DOWN foot switch is pressed.
"Waiting time before During the waiting time, the backgauge will not move.
step change" Adjust the value, e.g. to make it easier to remove complex parts.
"Speeds, step change" Tab. 4-31

The bending is programmed and can be produced.

4‐52 Manual operation 2019-05-18 B876en

 7.2 Producing individual bendings

Conditions
■ Force manual operation is active.
■ The programmed upper tool has been set up (see chapter 5
"Setting work").
■ When using the manual BendGuard (option):
− BendGuard is in its working position.
− BendGuard is set to the working height of the loaded
upper tool.
− The protected range of the BendGuard has been cor-
rectly generated (see the BendGuard's status display).
■ ACB sensor tools are calibrated (see chapter 5 "Setting
work").
■ If the pneumatic I-axis is used (option): The required spacer
is inserted.

Note
For sheet thicknesses < 1 mm or for die widths ≥ 40 mm: If nec-
essary, define the mute point with check plates (see "Define the
mute point with check plates", pg. 4‐42).

1. On the operating panel or MobileControl unit, press START.

2. Place workpiece between the upper and the lower tool and
bring it against the backgauge.
3. To move the beam downwards: press the PRESS BEAM
DOWN foot switch.

B876en 2019-05-18 Manual operation 4‐53

 8. Program special functions (Manual
operation/Program)

8.1 Programming an increased working

speed (option)

The working speed of the press beam is monitored and can

only be more than 10 mm/s if BendGuard (option) is used:
■ In profile mode there may be no tabs in the range up to
30 mm in front of the bending line at the upper edge of the
sheet. If tabs have already been bent, then select a box
bending mode, as the underside of the sheet is measured in
this mode.
■ For parts with tabs already bent, select a box bending
mode. In this mode, the calculation of the angular speed of
the sheet is adjusted to the already bent tabs. There may be
no tabs in the range up to 30 mm in front of the bending
line at the lower edge of the sheet.

Increased working speed can lead to problems in the following

cases:
■ Obstacles on the sheet (e.g. press-on nuts, bolts, back-
gauge fingers, seams) on the upper or lower side of the
sheet up to 30 mm in front of the bending line will interfere
with the measurement.
■ Loaded folding bars can interfere (even if folding is not pro-
grammed).
■ Sheet thickness > 6 mm
■ Die width > 50 mm
■ Angle at upper tool >90°
If a restriction occurs which does not allow an increased work-
ing, an error message occurs. Pressing the BEAM DOWN foot
switch again continues the bending at 10 mm/s.

Increased working speed is not possible in the following applica-

tions:
■ Use of special tools (upper tools).
■ Use of sensor tools with sensor disks that were not recog-
nized by BendGuard.
■ Using the bending method of folding (slow or fast).

4‐54 Program special functions (Manual operation/ 2019-05-18 B876en

Program)
 The maximum permissible working speed depends on the die
width:

Die width Maximum working speed

6, 8, 10 mm 10 mm/s
12 mm 12 mm/s
16 mm 16 mm/s
20 mm 20 mm/s
≥25 mm 25 mm/s
Tab. 4-32

Choosing Manual mode/ 1. Press Manual mode, "Speeds, step change".

Program
or
Ø Press Program, "Bending steps", "Speeds, step change".

Selecting speeds 2. For "Clamping", enter the speed at which the press beam
moves down from the mute point to the clamping point.
3. For "Press", enter the speed at which the press beam
moves down from the clamping point to the lower dead point
(LDP).

8.2 Programming fast folding (for

BendGuard, option)

Quick folding can be used for the bending methods folding and
hemming.
If standard tools are used, the press beam moves up to the 2nd
mute point during quick folding ( "Mute distance 2") at max.
speed ( "Rapid downwards").

B876en 2019-05-18 Program special functions (Manual operation/ 4‐55

Program)
 Conditions
■ Maximum flattening width: 13 mm.
■ Flattening height (from the tool tip to the press-shut surface):
70 mm.
■ Remaining opening width (from press-shut surface of upper
tool to press-shut surface of lower tool): at least 2x flattening
width

1 Flattening width 3 Flattening height (from the tool

2 Remaining opening width (from tip to the press-shut surface)
press-shut surface of upper
tool to press-shut surface of
lower tool)
Example Fig. 46313

Choosing Manual mode/ 1. Press Manual operation.

Program
or
Ø Press Program, "Bending steps".

Defining parameters 2. Select the upper and lower tools for folding or hemming.
3. Select "Bending method" "Folding" or "Flattening".
4. Press "Speeds, step change".
5. Activate "Fast folding".
6. Press "Press beam".

Note
"Mute distance 1" cannot be modified in combination with
fast folding.

4‐56 Program special functions (Manual operation/ 2019-05-18 B876en

Program)
 7. For "mute distance 2" enter at least 2x flattening width.
8. Press "Safety, Functions".
9. Select "BendGuard mode" "1: Profile mode".

8.3 Programming a bend with ACB

(option)

Notes
■ Within a program, the ACB angle measuring systems can be
combined (example: 1. Bend with ACB, 2. Bend with ACB
Laser, 3. Bend with ACB Wireless).
■ The program allows the TCB sheet thickness detection and
the angle measuring system ACB to be combined (example:
1. bending with ACB, 2. bending with TCB).
The bending program does not allow TCB sheet thickness
detection and ACB angle measuring system to be combined
as ACB bends in an angle-controlled manner and therefore
already takes sheet thickness deviations into consideration.

Choosing Manual mode/ 1. Press Manual operation.

Program
or
Ø Press Program, "Bending steps".

Setting up tools 2. Set up the sensor tool and module, and the lower tool.
3. Close the tool clamp.

Specify the parameters for 4. "Bending method" Select "Air bending".

the bend 5. Define the desired parameters.

Tip
For further information, see the contextual help. The contex-
tual help can be called by tapping with 2 fingers on the oper-
ating element.

Specifying the parameters 6. Activate "ACB".

for ACB 7. Press / / .

8. Press "ACB".
9. Define the desired parameters.
10. Press Confirm.

B876en 2019-05-18 Program special functions (Manual operation/ 4‐57

Program)
 8.4 Programming a bend with ACB
Wireless (option)

Notes
■ Within a program, the ACB angle measuring systems can be
combined (example: 1. Bend with ACB, 2. Bend with ACB
Laser, 3. Bend with ACB Wireless).
■ The program allows the TCB sheet thickness detection and
the angle measuring system ACB to be combined (example:
1. bending with ACB, 2. bending with TCB).
The bending program does not allow TCB sheet thickness
detection and ACB angle measuring system to be combined
as ACB bends in an angle-controlled manner and therefore
already takes sheet thickness deviations into consideration.

Choosing Manual mode/ 1. Press Manual operation.

Program
or
Ø Press Program, "Bending steps".

Setting up tools 2. Set up the ACB sensor tool and lower tool.
3. Close the tool clamp.
Once the position of the tool has been automatically
detected, the LED lights up in blue on the sensor tool.

Specify the parameters for 4. "Bending method" Select "Air bending".

the bend 5. Define the desired parameters.

Tip
For further information, see the contextual help. The contex-
tual help can be called by tapping with 2 fingers on the oper-
ating element.

Specifying the parameters 6. Activate "ACB".

for ACB 7. Press / / .

8. Press "ACB Wireless".

9. Define the desired parameters.
10. Press Confirm.

4‐58 Program special functions (Manual operation/ 2019-05-18 B876en

Program)
 8.5 Programming a bend with ACB Laser
(option)

Notes
■ Within a program, the ACB angle measuring systems can be
combined (example: 1. Bend with ACB, 2. Bend with ACB
Laser, 3. Bend with ACB Wireless).
■ The program allows the TCB sheet thickness detection and
the angle measuring system ACB to be combined (example:
1. bending with ACB, 2. bending with TCB).
The bending program does not allow TCB sheet thickness
detection and ACB angle measuring system to be combined
as ACB bends in an angle-controlled manner and therefore
already takes sheet thickness deviations into consideration.

Choosing Manual mode/ 1. Press Manual operation.

Program
or
Ø Press Program, "Bending steps".

Specify the parameters for 2. "Bending method" Select "Air bending".

the bend 3. Define the desired parameters.

Tip
For further information, see the contextual help. The contex-
tual help can be called by tapping with 2 fingers on the oper-
ating element.

Specifying the parameters 4. Activate "ACB".

for ACB 5. Press / / .

6. Press "ACB Laser".

7. Define the desired parameters.
8. Press Confirm.

8.6 Sheet thickness detection TCB

(option)

The TCB(Thickness Controlled Bending) function reduces angle

errors produced by fluctuations in sheet thickness.

B876en 2019-05-18 Program special functions (Manual operation/ 4‐59

Program)
 Application ■ TCB can only be programmed with the "Air bending" bend-
ing method.
■ The press force calculated by the control unit measures at
least 1 % of the maximum press force of the machine.
■ Different minimum bending lengths are produced depending
on the material, sheet thickness and die width. As the sheet
thickness increases, the minimum bending length for TCB
goes down. For short bending lengths a learned bending
can be used.
■ The program allows the TCB sheet thickness detection and
the angle measuring system ACB to be combined (example:
1. bending with ACB, 2. bending with TCB).
■ The bending program does not allow TCB sheet thickness
detection and ACB angle measuring system to be combined
as ACB bends in an angle-controlled manner and therefore
already takes sheet thickness deviations into consideration.
■ TCB cannot be programmed for bending operations with a
delay at the clamping point.
■ If withdrawal is programmed, "Parallel withdrawal" must be
activated.
■ There must be no tool without technology support in the tool
station.
■ Prebends can be bent with TCB if the prebend has been
identified with TCB.

Programming individual bend with TCB

(Option) (Manual operation)

1. Press Manual.
2. "Bending method" Select "Air bending".
3. Activate "TCB".

Programming bending program with TCB

(option) (Programming)

1. Press Program, "Bending steps".

2. Select the desired bending.
3. "Bending method" Select "Air bending".
4. Activate "TCB".
5. Select "TCB method" "Identification bend".

4‐60 Program special functions (Manual operation/ 2019-05-18 B876en

Program)
 Tip
In order to deactive TCB for an individual bend: select the
desired bend and deactivate "TCB".

Programming learned bending with TCB

(option) (Programming)

For short bending lengths a learned bending can be used.

Condition
■ The learned bending is preceded by at least one bend car-
ried out with the "TCB method" "Identification bending", that
can be learned.

Note
If a clamping point correction is programmed for the "Identifica-
tion bend", the same clamping point correction must be program-
med into the learned bending.

1. Press Program, "Bending steps".

2. Activate "TCB".
3. Select the required bend under "TCB method".

B876en 2019-05-18 Program special functions (Manual operation/ 4‐61

Program)
 9. Programming

Programs can be produced at the machine in the following ways:

■ Numerically (all bendings programmed individually).
■ Graphically with graphics shop floor programming
(BendGraph, 2D profile drawing).

9.1 Creating programs numerically

1. Press Program, "Program".

2. Press Bending steps (right).
3. Press Bending programs.
4. Press .
A bending program will be created.
5. Define the desired parameters.

Tip
For further information, see the contextual help. The contex-
tual help can be called by tapping with 2 fingers on the oper-
ating element.

Programming bendings 6. Press "Bending steps" (below).

7. Display the bends (see "Tab. 4-1", pg. 4‐7).
8. Define the desired parameters.

Tips
■For further information, see the contextual help. The con-
textual help can be called by tapping with 2 fingers on
the operating element.
■ For further information on the programming of special
functions, e.g. fast folding, increased working speed or
angle measuring system ACB, see page 4‐54.
9. To create a new bend:
− Press .
− Define the desired parameters.
or
Ø To copy a bend:
− Press .
− Define the desired parameters.
10. To delete a bend: press .
The current bend is deleted. The remaining bendings are
renumbered.

4‐62 Programming 2019-05-18 B876en

 11. To move a bend:
− Select the bending which is to be moved.
− Press or .
The bendings are renumbered in accordance with the modi-
fied sequence.

Saving the bending program 12. If necessary, press Bending programs (top right).
13. Press .
"Save file" will appear.
14. Select the desired directory.
15. Enter "name".
16. Select the required "Type".
17. Press Confirm.

Tip
Any program from the program storage unit can be used as a
template for a new program.
The template can be defined under Technology, "Settings",
Bending program, Program template.
To edit the template: press Programming, show the program
area (right) and press Edit template.

9.2 Creating programs graphically with

BendGraph

Simple profiles can be programmed graphically (2D) at the

machine using the graphic shop floor programming system
(BendGraph).

Note
Only make changes to the bends in BendGraph.

B876en 2019-05-18 Programming 4‐63

 Fig. 74299

Creating segments in Segments can be created in various ways:

BendGraph
Icon Description
Creating segment:
■ Enter "Angle".
■ Enter "Side length".
Creating segment:
■ Enter "Angle" and "Dx".
■ or enter "Angle" and "Dy".
■ or enter "Dx" and "Dy".
Create a segment with a radius bend:
■ Enter "Angle".
■ Enter "Side length".
■ Enter the "radius" of the bending.
■ Enter "Number of segments".
■ The "Segment length" is calculated automatically.

4‐64 Programming 2019-05-18 B876en

 Icon Description
Create a segment with a fold:
■ Enter "Distance".
■ Enter "Seam length".
■ Select "Folding direction".
■ Enter "Number of segments".
■ The "Segment length" is calculated automatically.
Sketch mode: when this character appears in the drawing
sheet, segments of the profile can be sketched directly in
the drawing sheet.

Sketching segment:
■ Tap on the drawing sheet.
■ Open "Details".
■ Configure settings.
■ Press "Apply".
■ Enter values.
Tab. 4-33

Change to BendGraph

Ø (bottom left), press Start BendGraph.

Creating a program

1. Press Programming, "Bending part".

2. Press New Program.
The "New program" screen appears.
3. Enter the data for the "DESIGNATION >":
− Enter "Description" (can be entered alphanumerically and
is used for identifying the programs in the database).
− Enter "Drawing number".
4. Select "MATERIAL DATA >":
− Using , select "Raw material".
− Enter "Sheet thickness".
− Enter "Quantity req.".
5. Select "Program type" "Numeric".
6. Press OK.
A new program is created. The entries appear on the user
interface.
7. Fill in additional fields if desired.

B876en 2019-05-18 Programming 4‐65

 Creating profile

Condition
■ Program (graphically, 2D) has already been created.

Defining settings 1. Press "Profile editor".

2. Use to open "Settings".

Note
The settings are default settings. The selected values apply
either to all segments or to all the following segments that
are selected.
3. Defining Default settings.
4. Press Apply.

Drawing the first segment 5. Either

Ø Press .
or
Ø Press .
or
Ø To set the start point of the profile: tap on the drawing
sheet.
Ø To draw a segment: tap on the drawing sheet once
again.
6. Enter values.
A preview of the segment is displayed.
7. Using , open "Details...".
8. Select Settings.
9. Press Apply.
10. To draw the segment: press "OK" ( ).
11. To cancel the procedure: Press Cancel ( ).

Drawing further segments 12. Either

Ø Press .
or
Ø Press .
or
Ø To draw a segment with a round bend: press .
or
Ø Only TruBend series 5000: To draw a segment with a
fold: Press .

4‐66 Programming 2019-05-18 B876en

 or
Ø To draw a segment: tap on the drawing sheet.
13. Enter values.
A preview of the segment is displayed.
14. Using , open "Details...".
15. Select Settings.
16. Press Apply.
17. To draw the segment: press "OK" ( ).
18. To cancel the procedure: Press Cancel ( ).

Modifying segment Note

Segments can be modified directly in the "Profile editor" or
in the "Profile table".
19. Either
Ø Select the desired segment.
Ø Modify values.
Ø Press "OK" ( ).
or
Ø Press "Profile table".
Ø Select the desired segment.
Ø Modify values.
Ø Press "OK" ( ).
Ø To return to the profile editor: press "Profile editor".

Delete Segment Note

Segments can be deleted directly in the "Profile Editor" or in
the "Profile Table". Only the first or the last segment of the
profile can be deleted.
20. Either
Ø Select the desired segment.
Ø "Deleting..." Press ( ).
Ø Press Yes.
or
Ø Press "Profile table".
Ø Select the desired segment.
Ø "Deleting..." Press ( ).
Ø Press Yes.
Ø To return to the "Profile editor": press "Profile editor".

Continuing the profile 21. To add the next segment to the other end of the profile:
drawing on the other side Press Continue on the other side.

Modifying profile 22. To flip, scale or rotate the entire profile: press Modify profile.

B876en 2019-05-18 Programming 4‐67

 23. Configure settings.
24. Press Apply.
The profile has been created.

Deleting profile

Condition
■ A profile is drawn.

1. Press "Profile table".

2. Press Delete profile.
3. Press Yes.

Modifying profile

To modify a program at a later time, all modifications that affect

the profile must be made directly in the profile.

Condition
■ A profile is drawn.

Note
If the profile is modified later, the unfolding, tool stations and
bending parameters are re-calculated.

Note
Segments can be modified directly in the "Profile editor" or
in the "Profile table".
1. Either
Ø Press "Profile editor".
or
Ø Press "Profile table".
2. Select the desired segment.
3. Modify values.
4. Press "OK" ( ).
The profile has been modified.

4‐68 Programming 2019-05-18 B876en

 Create unfolding

The drawn profile must be developed and the bending sequence

must thereby be calculated. Tool stations and bendings are cre-
ated and calculated automatically.

Create unfolding 1. Press "Unfolding".

The unfolding is created.
Possible bending sequences are calculated.
The bend allowance of the profile is displayed.

Using other calculated Note

bending sequences
All possible bending sequences are always calculated.
2. To display further calculated bending sequences: Press
Other bending sequence.

Defining a bending 3. To define the bending sequence: press Define bending

sequence sequence.
4. Mark bendings according to the sequence.
The bending sequence is defined.

Recalculating the bending 5. To recalculate the bending sequence: press Calculate

sequence sequence.

Display dimensioning 6. To display the dimensioning of the development: press Dis-

play dimensions.

Adjusting lengths Note

If there are deviations between the workpiece dimensions
and the unfolded length, the side on which the dimension
deviation should be placed can be selected. The bending
program is adjusted automatically.
7. Press Adjust lengths.
8. Enter "Real length".
9. Activate desired side by pressing:
− (green): side activated.
− (red): side deactivated.
10. Press Adjust lengths.

Defining process data 11. Press Process data.

12. Configure settings.
13. Press Apply.

B876en 2019-05-18 Programming 4‐69

 Returning to the user interface

Ø Press Save and hide.

9.3 Programming tool stations

Note
If the program was programmed with graphical shop floor pro-
gramming (BendGraph), the tool stations are created automati-
cally.

Creating tool stations 1. Press Programming, "Setup plan".

The first tool station has already been specified and can be
changed if necessary.

Tip
To automatically generate the setup plan: press .
2. As needed, create all other tool stations:
− To create a new tool station: Press .
− To copy a tool station: Press .
3. As required, press the tool station concerned and enter
the"Length" of the tool station.
4. As required, press the tool station concerned and enter
the"Position" of the tool station.
5. To center all tool stations: press .

Customizing segmentation 6. In the tool station press the required upper and/or lower tool
and press .
Segmentation cannot be modified?
Multiple upper or lower tools are selected.
Ø Press a maximum of one upper tool and one lower tool.

Tip
To add a new tool segment: Press the placeholder segment
(indicated with three dots) and select the desired segment
from the list on the right side.

4‐70 Programming 2019-05-18 B876en

 10. Production

10.1 Loading program

1. Either
Ø Press Programming.
or
Ø Press Production.
2. Display programs (see "Tab. 4-1", pg. 4‐7).
3. Press .
"Load file" will appear.
4. Select the desired directory.
All programs that are stored in this directory will be dis-
played in the list.
5. Limiting/sorting the list of programs:

Filter/search function Description

"Name" Show all programs which contain the
search term.
"Name", "Ascending" Sort the programs in ascending order.
"Name", "Descending" Sort the programs in descending order.
"Date of change", "Ascend- Sort the programs in ascending order.
ing"
"Date of change", Sort the programs in descending order.
"Descending"
Tab. 4-34

6. Mark the desired program.

7. Press Load.
The program check is carried out.
Faults found will be shown in the "Messages" dialog box.
Faults can also be viewed later on in the messages ("Cur-
rent messages" or "Archive").

10.2 Displaying a setup plan

Ø Either
Ø Press Production, "Set up".
or
Ø Press Programming, "Setup plan".
The setup plan is displayed.

B876en 2019-05-18 Production 4‐71

 10.3 Producing a part

Conditions
■ The desired program is loaded.
■ The programmed upper tool has been set up (see chapter 5
"Setting work").
■ When using the manual BendGuard (option):
− BendGuard is in the working position .
− BendGuard is set to the working height of the loaded
upper tool .
− The protected range of the BendGuard has been cor-
rectly generated (see the BendGuard's status display).
■ ACB sensor tools are calibrated (see chapter 5 "Setting
work").
■ If the pneumatic I-axis is used (option): The required spacer
is inserted.

Note
For sheet thicknesses < 1 mm or for die widths ≥ 40 mm: If nec-
essary, define the mute point with check plates (see "Define the
mute point with check plates", pg. 4‐42).

1. Press Production.
2. On the operating panel or MobileControl unit, press START.
3. Place workpiece between the upper and the lower tool and
bring it against the backgauge.
4. To move the beam downwards: press the PRESS BEAM
DOWN foot switch.

10.4 Producing a part with ACB Speed

When using the ACB Speed function, the springback angles are
only measured once for each bending angle (applies to all
parts). All other bends refer to these bends.
Reactivating the "ACB Speed" checkbox initiates new spring-
back angle measurements.
If the deviation of the measured springback angle is greater
than 0.5° for an identification bend, identification must be per-
formed again the next time the bend is carried out.
In the Manual mode operation, no bending parameters are
saved.

4‐72 Production 2019-05-18 B876en

 The bending parameters are reset in the following cases:
■ When the "ACB Speed" checkbox is activated/deactivated.
The next time the bending part is processed, an identifica-
tion bend is performed for each bend with the ACB method
"Identification of spring-back".
■ If another program is loaded.
■ If the bending angle, the bending angle correction, the sheet
thickness or a tool is modified.

The bending parameters are retained in the following cases:

■ When changing from a program in the Programming or Pro-
duction operation to the Manual mode operation. This allows
bends to be carried out in Manual mode in the interim. Bend-
ing parameters are retained when the Production operation
is resumed.

Conditions
■ The desired program is loaded.
■ The programmed tool is loaded.
■ The sensor tools are calibrated.
■ Each bending angle is run through in the program at least
once with the ACB method "Springback identification", i.e.
the springback angle is measured.

1. Press Production, "Run in".

2. Press Production settings.
3. Activate "ACB speed".
4. Press Close.
5. On the operating panel or MobileControl unit, press START.
6. Place workpiece between the upper and the lower tool and
bring it against the backgauge.
7. To move the beam downwards: press the PRESS BEAM
DOWN foot switch.

10.5 Producing a bend with fast folding

Conditions
■ Fast folding has been programmed (see "Programming fast
folding (for BendGuard, option)", pg. 4‐55).
■ A displacement of the I axis which matches the tool has
been programmed.
or

B876en 2019-05-18 Production 4‐73

 Special folding tools will be used, which do not require the I
axis to be moved.
■ The part has been pre-bent by 30°.

Danger of injury due to the workpiece suddenly tipping

CAUTION over!
Ø Place the workpiece (from the operator's point of view ) at
least 50 mm in front of the bending line into the tool station
or
Ø Only place the workpiece into the tool station if the press
beam stops at mute point 2.

1. Press Production.
2. On the operating panel or MobileControl unit, press START.
3. Press the PRESS BEAM DOWN foot switch.
The press beam travels at rapid speed up to mute point 2
and stops.
4. Place part and fasten.
5. Press the PRESS BEAM DOWN foot switch.
The fold will be bent at working speed.

10.6 Use bending aid

The bending aid automatically swivels as far out as required for

the programmed angle of the active bend.

Conditions
■ The user is logged on as "Expert" or "Customer administra-
tor".
■ The bending aid has been programmed:
− Manual mode, "Safety, functions", "Left bending
aid"/"Right bending aid"
or
− Programming, "Bending step", "Safety, functions", "Left
bending aid"/"Right bending aid"
■ The required table width extensions are mounted.

Impermissible work in the bending line danger zone!

WARNING
Risk of injury.
Ø The tooling status of the bending aid may not be changed
while the program is running.

4‐74 Production 2019-05-18 B876en

 Impermissibly or incorrectly loaded tools!
WARNING
Risk of injury.
Ø Only use TRUMPF standard tools.
Ø Ensure that the tool and the bending aid are correctly pro-
grammed and set up for the work. Example: Offset tools are
inserted in the correct position.

An unsecured support table can slide forwards during the

WARNING swivel movement of the bending aid!
Risk of injury between support table and tool.
Ø Ensure that the support table is engaged in the rear posi-
tion or moved completely in the direction of the tool clamp
and thus secured magnetically.

Risk of injury at exposed bore holes during the swivel

CAUTION movement of the bending aid!
Ø Only use bending aid with supports mounted.

Unexpected movements of the bending aid

WARNING
Risk of injury.
Ø Keep a sufficient distance to the bending aid.
Ø Keep away from the swiveling range of the bending aid.
Ø Keep away from the swiveling range of the table extension
(option) and the table width extension (option).
Ø Do not put anything under the table extension (option) or
table width extension (option).
Ø Deactivate the bending aid in the program and at the
MobileControl unit, when not needed.
Ø Push the bending aid out of the working area (e.g. to the
edge or into its parking position) when not needed.

1. Push the bending aid by hand to the desired position on the

press table and apply the brake, i.e. shift the lever down-
wards.

Note
The bending aid must be activated at the MobileControl
before pressing the START button or before the step change
is performed. The bending aid status applies to the active
bend.
2. At the MobileControl activate the desired bending aid. Possi-
ble statuses of the button BENDING AID:

B876en 2019-05-18 Production 4‐75

 − Button illuminates: a bending aid is programmed in the
active bending step.
− Button flashes: a bending aid is programmed in at least
one bending step in the program.
− Button does not illuminate: no bending aid is program-
med in the program.
3. Press Production.
4. On the operating panel or MobileControl unit, press START.
5. Place workpiece between the upper and the lower tool and
bring it against the backgauge.

Notes
■ The bending aid swivels up or down only as long as the
BEAM DOWN foot switch is pressed.
■ With the table extension pulled out, the speed of the
downward movement is reduced for safety reasons. The
control automatically and dynamically adapts to the
speed.
6. Press the PRESS BEAM DOWN foot switch and keep it
pressed.

10.7 Entering local corrections in the

bending step

Locale corrections apply to the bending step marked in the

active program. They have no effect on other bending steps
within the program.
Global corrections can be overwritten by local corrections.

1. Press Production, "Run in".

2. Enter corrections.

Tip
For further information, see the contextual help. The contex-
tual help can be called by tapping with 2 fingers on the oper-
ating element.

10.8 Entering global corrections in the

program

Global corrections apply to all bending steps in the program.

Global corrections can be overwritten by local corrections.

4‐76 Production 2019-05-18 B876en

 1. Press Production, "Program values".
2. Enter corrections.

Tip
For further information, see the contextual help. The contex-
tual help can be called by tapping with 2 fingers on the oper-
ating element.

10.9 Using the Part Indicator insertion aid

(option)

On the additional screen, the Part Indicator shows the operator

how he has to insert the bending part in the machine.

1. On the additional screen, press to switch on Part Indica-

tor.
The camera image is displayed and is superimposed with
the part geometry for the corresponding bending step (nomi-
nal insertion position).
2. To adjust the brightness and contrast parameters, press .
The following dialog box will appear:

Fig. 90740

3. Define the desired parameters:

Pos. Description
1 Activated: Use automatic exposure, i.e. adjust the exposure to
the ambient lighting automatically.
2 Correct the brightness within the automatic exposure.

B876en 2019-05-18 Production 4‐77

 Pos. Description
3 Activated: Adjust the brightness to the special lighting situa-
tion (e.g. for direct incidence of light, strongly reflective surfa-
ces).
4 Select the geometry color.
5 Adjust the transparency of the superimposed geometry.
6 Activated: Show contour of the programmed geometry.
7 Close dialog box.
Tab. 4-35

4‐78 Production 2019-05-18 B876en

 11. Technology

Tab Description
"Tool management" ■ Loading, creating, editing, copying and deleting tools.
■ Importing and exporting tools from a tool archive.
"Materials manage- ■ Creating, editing and deleting raw material.
ment"
"Bend Deductions" Bend deductions depend on the material, sheet thickness, punch radius, die radius, die
angle and die width. One bend deduction can be specified for each bending angle.
The bend deduction is calculated for all bending angles which lie between the already-cre-
ated bending angles of a material. The order in the calculation: Use-defined bend deduc-
tions, TRUMPF database, calculation to DIN, no bend deduction.

Create new bend deductions in the following cases:

■ Bend deductions for special bending angles are required for an existing material and
sheet thickness.
■ New tool with deviating tool properties (punch/die radius, die angle, die width) was cre-
ated.
■ Material with new sheet thickness was created.
■ New material was created.

Requirements for using the bend deduction:

■ User-defined bend deductions are activated (see Technology, "Settings", Bending pro-
gram, "Bend deduction", "Own values").
■ The properties assigned for the bend deduction (material, sheet thickness and bending
angle) correspond to the programmed bend.
"Settings" ■ Define global settings.
■ Define settings in the program.
■ Define connections, e.g. to TruTops Boost.

Note

For changes, press .

"User management" ■ Configuring the ID card (RFID)
Tab. 4-36

11.1 Configuring the ID card (RFID)

10 ID cards are included i the scope of delivery. The customers'

own ID cards can be used if the RFID chip meets the
ISO 15693 standard.

Condition
■ The user is authenticated as the administrator.

1. Press Technology, "User management".

2. Hold the ID card next to the reader to register the card.

B876en 2019-05-18 Technology 4‐79

 In the toolbar (at the top) the ID will appear.

3. Press .
4. Select "user group".
5. Press .

11.2 Configuring the remote connection

If the machine is equipped with an additional screen, a remote

connection to a freely configurable VNC server that can be
accessed within the network may be displayed on the second
operating panel.

1. Press Technology, "Settings", VNC connection.

2. Configure settings.
3. Press .
4. Restart the HMI.
5. To start the remote connection: Press on the second
screen.

4‐80 Technology 2019-05-18 B876en

 12. Angle measuring system OCB
(option)

12.1 Using the angle-measuring system

OCB

Condition
■ Angle measuring system OCB has been activated.

Note
The USB flash drive must remain inserted during the entire
transmission. If there is an interruption, the control must be re-
started.

1 Transmission device 3 USB flash drive

2 Digital angle measuring unit
Angle-measuring system OCB Fig. 61828

1. Check whether the rechargeable battery is charged (LED

flashes green) at the transmission device. If need be, charge
the batter using the supplied cable at a USB port on the
machine or any USB port which has 5 V available.
2. Set the goniometer to degrees with the <0°0´/0.00°> button.
3. Set the direction of rotation of the adjustable side with the
<ZERO/Ω> button in such a way that the goniometer counts
positively up in the clockwise direction.
4. Plug the USB flash drive into a USB port on the machine.

B876en 2019-05-18 Angle measuring system OCB (option) 4‐81

 5. Produce a bend with the currently loaded program.
6. Measure the angle at the bending part and press OCB at
the transmission device.
The angle displayed is transferred to the control.
All position LEDs light up briefly at the transmission device.
7. Press ENTER.
8. If need be, perform further bends and correct bending
angles in the same way.

4‐82 Angle measuring system OCB (option) 2019-05-18 B876en

 13. Online Update Manager

If a machine is online, TRUMPF will make suitable software

updates available via a portal.

13.1 Call up Online Update Manager (on

machines with TOSh)

Condition
■ The machine must be connected to the Telepresence portal.

Opening the TRUMPF 1. Swipe the screen from top left towards the centre.
Operating Shell (TOSh) − Select TcHostShell.
The user interface is not closed.
The "TRUMPF Operating Shell" dialog is shown.
2. Press System Update.

TRUMPF Operating Shell: System Update Fig. 91416

The "System Update" dialog appears.

Start Online Update 3. Press Online Update.

The "TRUMPF Online Update" dialog appears.
If no updates are available, the following dialog is displayed:
"No updates available. Your system is up to date!" System is
up to date.)

B876en 2019-05-18 Online Update Manager 4‐83

 If updates are available, the following dialog is displayed:
"Available updates".

Notes
■ Suitable updates for the machine are made available by
TRUMPF and downloaded. Updates in the state "Down-
loaded" can be installed.
■ You can decide whether downloaded updates should be
installed immediately or at the next restart.
■ Updates marked "Service package" (service package)
can only be installed by TRUMPF Technical Service.

1 Now (install immediately) 3 "Service package" (can only

2 On Reboot(installable at be installed by Technical
restart) Service)

Dialog: "Available updates" (available updates) Fig. 91414

4. If the update is to be installed immediately: Under "Install
Updates" (Install updates) Now, select (Now).
or
Ø If the update is to be installed at the next restart: Under
"Install Updates" (Install updates), On Reboot select (On
Reboot).

13.2 Switch off Online Update function

1. In the "TRUMPF Online Update" dialog, press the "Settings"

symbol.
2. Under "Settings" (Settings): Switch off "Automatic Online
Update" (Automatic Online Update).
3. Press Apply (Apply).

4‐84 Online Update Manager 2019-05-18 B876en

 14. Help in case of problems

14.1 Automatically calculated press force

too high

The press force automatically calculated by the machine is at

least 5% of the machine's maximum press force. The actual
press force during bending might be less, depending on the
process (e.g. during air bending or folding to). If a value lower
than 5% of the maximum press force is calculated, the value
will be rounded to this minimum value.

In the following cases, a message is output saying the calcu-

lated press force is too high for the selected tool:
■ The press force is actually too high for the selected tool
(e.g. when bottom bending or hemming).
■ For short bending lengths, the press force frequently falls
short of the minimum value. The press force is rounded to
the minimum value, although only a lower press force is
allowed for the selected tool. The calculated press force can
be checked.

Press force which is too high (e.g. when bottom bending

NOTICE or hemming).
The tool and/or the machine can be damaged.
Ø The result of the automatically calculated press force must
be taken into account.
Ø If the press force is too high for the specified tool, select a
different tool.

Checking the calculated press force

Condition
■ The message 'Presskraft zu hoch für Werkzeug' is displayed.

1. Increase the bending length of this bend by a factor of 10:

− e.g. enter 1000 mm instead of 100 mm.
The calculated press force is displayed.
2. Divide the displayed press force by 10:
− For example: If the displayed press force is 240 kN.
240 kN / 10 = 24 kN

B876en 2019-05-18 Help in case of problems 4‐85

 Note
The permissible press force of the tool is on the front of the
tool and in the tool catalog.
3. Compare the checked press force with the permissible press
force of the tool.
If the checked press force is less than or equal to the per-
missible press force of the tool, the bend can be carried out
despite the message on the user interface.

14.2 Activate remote support

Remote support is used to establish a connection between the

machine and Technical Service.
The service engineer can access the user interface to analyze
problems and in some cases to eliminate them directly.

Conditions
■ The machine must be configured via TCP-IP to enable
access to the customer network.
■ The machine must be able to connect to the TRUMPF Tele-
presence Portal via the customer network and the Internet.
The connection is made via IPSec using standard ports
UDP 500 and UDP 4500.
■ The firewall access rules should not be automatically deacti-
vated due to longer periods of non-use.

Activated remote support!

WARNING
Injury and damage to property.
Ø Only persons trained by TRUMPF may take part in a
remote support session.
Ø If doubts arise regarding the qualifications of the persons
involved or if comprehension issues arise, TRUMPF can
refuse remote support or terminate the remote support ses-
sion.

1. To change to TOSh (TRUMPF Operating Shell):

Ø Press (bottom left), Open TOSh.
or
Ø For a keyboard (option): Press the <Alt> + <Tab> keys.
TOSh (TRUMPF Operating Shell) appears.
2. Press Remote Support.
3. Press Connect.

4‐86 Help in case of problems 2019-05-18 B876en

 4. Wait until all 5 steps for the connection setup are completed.
Remote support is activated.
5. To end remote support, press Disconnect.
6. To return to the user interface:
Ø Press MMC-HMI.
or
Ø For a keyboard (option): Press the <Alt> + <Tab> keys.

14.3 The date and time are lost

Ø If the date and time need to be reset with each restart: dur-
ing the next service mission by Technical Service, have the
buffer battery replaced.

B876en 2019-05-18 Help in case of problems 4‐87

 15. ToolMaster (option)

15.1 Checking the tool inventory in the

ToolMaster

1. Press Programming, "Setup plan".

or
Ø Press Production, "Set up".
2. Press .
The tools which are not available in the ToolMaster are high-
lighted in color.

15.2 Transferring the setup plan to

ToolMaster

In the following cases, the press brake setup plan is automati-

cally transmitted to the ToolMaster:
■ When loading a program in the operation Production.
■ When changing from the operation Programming to the oper-
ation Production.

Ø To transfer the setup plan manually: press Production, "Set

up", .

15.3 Importing the tool inventory of the

ToolMaster onto the press brake

Means, Tools, Materials

■ USB flash drive

Exporting tool inventory to 1. Plug the USB flash drive into the operating panel on the
the ToolMaster ToolMaster.
2. Press (Configuration), "Import/Export".
3. In the "Export" area, press Tools.
4. Remove the USB flash drive.

Importing the tool inventory 5. Plug the USB flash drive into the operating panel on the
onto the press brake press brake.
6. Press Technology, "Tool management".

4‐88 ToolMaster (option) 2019-05-18 B876en

 7. Press .
"Load file" will appear.
8. Select the desired file.
9. Press Load.

15.4 Transferring the tool inventory of the

ToolMaster to the press brake

1. Press Technology, "Tool management".

2. Press .

15.5 Setting a tool inventory in the

ToolMaster

1. Press Technology, Tool management.

2. Select the tool.
3. Press Segmentation.
4. In the column "ToolMaster", indicate the number of tool seg-
ments in the specific length.

B876en 2019-05-18 ToolMaster (option) 4‐89

4‐90 ToolMaster (option) 2019-05-18 B876en
 Chapter 5

Setting work

1 Backgauge Finger 5‐2

1.1 4-axes backgauge (option): Positioning addi- 5‐2
tional backgauge fingers
1.2 With 2-axis backgauge: move backgauge fin- 5‐2
gers manually

2 Tooling 5‐4
2.1 For a manual tool clamp: set up upper tools 5‐4
2.2 Hydraulic tool clamp (option): Set up the 5‐5
upper tool
2.3 Hydraulic tool clamp (option): Set up lower 5‐6
tool

3 BendGuard (option) 5‐8

3.1 Checking and setting BendGuard 5‐8

4 Tactile ACB Wireless angle measuring 5‐17

system (option)
4.1 Calibrating the sensor tool 5‐17

B876en 2019-05-18 Setting work 5‐1

 1. Backgauge Finger

1.1 4-axes backgauge (option):

Positioning additional backgauge
fingers

Multiple backgauge fingers can be used simultaneously.

Unexpected movements of the axes.

WARNING
Risk of injury!
Ø Position backgauge fingers from the rear side of the
machine.

Risk of backgauge and additional backgauge fingers

NOTICE colliding!
Ø Before travelling the backgauge: Remove additional back-
gauge fingers.

1. Open the roller gate on the rear side of the machine.

2. Loosen the torque grip.

3. Position the backgauge finger at the desired point on the Z
axis.
4. Tighten the torque grip.

5. Close roller gate.

1.2 With 2-axis backgauge: move

backgauge fingers manually

Condition
■ The machine is ready for operation.

1. Press Manual.
or
Ø Press Production, "Run in".
2. Press Setting for the gauge finger.
Control stops.

5‐2 Backgauge Finger 2019-05-18 B876en

 Press beam moves to safety offset (depending on the
loaded tools).
The backgauge moves towards the front to a safe position
in front of the tool clamp.
Pneumatic fastening of gauge fingers is released.
3. Position gauge fingers.
4. Start the program to be run.
Gauge fingers are fastened pneumatically.
Backgauge moves to programmed position.

B876en 2019-05-18 Backgauge Finger 5‐3

 2. Tooling

2.1 For a manual tool clamp: set up

upper tools

Means, Tools, Materials

■ Allen wrench SW 8.

Note
Note the permissible upper tool height (see chapter 3, "Techni-
cal data").

Heavy tools!
CAUTION
Crushing!
Ø Wear safety shoes.

1 Socket head screw SW 8

Manual upper tool clamp Fig. 69033

1. Open the press beam with the PRESS BEAM UP foot

switch so that tools can be positioned easily.
2. To open the upper tool clamp: loosen the 8 mm Allen
screws.
3. For upper tool with Safety Click: Vertically insert upper tool
and position it.
4. For upper tool without Safety Click:

5‐4 Tooling 2019-05-18 B876en

 − Open the side safety door.
− If the manual BendGuard is set up, move the
BendGuard to the rear on the guide rail.
− Push in the upper tool from the side and position it.
− If the manual BendGuard is set up, move the
BendGuard forwards on the guide rail.
− Close the side safety door.
5. To close the upper tool clamp: tighten the 8 mm Allen
screws.
6. If manual BendGuard has been set up, set it to the working
height of the loaded upper tool (see chapter 4 "Operation").

2.2 Hydraulic tool clamp (option): Set up

the upper tool

Note
Note the permissible upper tool height (see chapter 3, "Techni-
cal data").

Heavy tools!
CAUTION
Crushing!
Ø Wear safety shoes.

Hydraulic upper tool clamp (option) Fig. 74291

1. Open the press beam with the PRESS BEAM UP foot

switch so that tools can be positioned easily.

B876en 2019-05-18 Tooling 5‐5

 2. On the operating panel or on the MobileControl unit, press
UPPER TOOL CLAMP.
3. For upper tool with Safety Click: Vertically insert upper tool
and position it.
4. For upper tool without Safety Click:
− Open the side safety door.
− If the manual BendGuard is set up, move the
BendGuard to the rear on the guide rail.
− Push in the upper tool from the side and position it.
− If the manual BendGuard is set up, move the
BendGuard forwards on the guide rail.
− Close the side safety door.
5. On the operating panel or on the MobileControl unit, press
UPPER TOOL CLAMP.
6. If manual BendGuard has been set up, set it to the working
height of the loaded upper tool (see chapter 4 "Operation").

2.3 Hydraulic tool clamp (option): Set up

lower tool

Heavy tools!
CAUTION
Crushing!
Ø Wear safety shoes.

Hydraulic lower tool clamp Fig. 69032

1. Open the press beam with the PRESS BEAM UP foot

switch so that tools can be positioned easily.

5‐6 Tooling 2019-05-18 B876en

 2. On the operating panel or on the MobileControl unit press
LOWER TOOL CLAMP.
3. Vertically insert and position lower tool.
4. On the operating panel or on the MobileControl unit press
LOWER TOOL CLAMP.

B876en 2019-05-18 Tooling 5‐7

 3. BendGuard (option)

3.1 Checking and setting BendGuard

Conditions
■ The user is logged on as an expert.
■ Manual operation is selected.
■ "BendGuard mode", "1: Profile mode" is selected.

Means, Tools, Materials

■ Transmitter setting template (mat. no. 2271789).
■ Receiver setting template (mat. no. 2271786).
■ 2 mm AF Allen key.
■ 3 mm AF Allen key.
■ 10 mm AF open-end wrench.

Beware of the risk of crushing between the BendGuard and

WARNING objects next to the machine table!
Ø Remove the tool from the transmitter when not in use to
avoid collisions when moving the Y axis.

Setting templates for the transmitter and receiver Fig. 86607

5‐8 BendGuard (option) 2019-05-18 B876en

 Setting the BendGuard needs to be done on two working
heights:
■ 120 mm.
■ 240 mm.

Note
The engraving on the setting templates must point in the
direction of the transmitter.
During set up, make sure that the setting templates are
exactly horizontal to the tool clamp. With the hydraulic tool
clamp (optional), make sure that the setting templates are
each exactly in the center of a clamp piston.

Transmitter setting template ("Transmitter") Fig. 97076

1. Set up the transmitter setting template on the left side of the
press beam about 10 cm from the edge.

Receiver setting template ("Receiver") Fig. 97077

2. Set up the receiver setting template on the right side of the
press beam about 10 cm from the edge.
3. Lower the transmitter as far as it will go.

B876en 2019-05-18 BendGuard (option) 5‐9

 Fig. 97956
4. Remove the cover using a 2 AF Allen key.
5. Set the transmitter and receiver to the working height of
120 mm.
6. On the operating panel or MobileControl unit, press START.

Transmitter light field Fig. 97040

7. At the transmitter setting template, check whether the light
field is within cut out contour and aligned to its lower edge.

5‐10 BendGuard (option) 2019-05-18 B876en

 Receiver light field Fig. 97041
8. At the receiver setting template, check if the engraved con-
tours are illuminated precisely.

Fig. 97966
9. If the light field has moved to the left/right: Adjust the trans-
mitter using a 3 AF Allen key.

B876en 2019-05-18 BendGuard (option) 5‐11

 Fig. 97961
10. If the light field has moved up/down: Adjust the transmitter
using a 10 AF open-end wrench.

Fig. 97959
11. Adjust the transmitter until the light field is oriented within
the engraving.
12. Run the Tool Align function and check the status display of
the BendGuard .
13. Set the transmitter and receiver to the working height of
240 mm and recheck light field.
14. Set up the upper tool to a height of 120 mm.
15. Remove the setting template.

5‐12 BendGuard (option) 2019-05-18 B876en

 1 Show status display 2 Calculate tool tip position
(black point)
Fig. 97963
16. Show status display: Press the BendGuard icon on the sta-
tus bar (right).
■ The black point indicates the position of the tool tip.

A Optimal tool tip position B BendGuard cannot operate

and must be adjusted
Fig. 97967
■ If the black point is in the green area, BendGuard has
been optimally set up. The black point should be in the
white area at minimum.
■ If the black point is on the edge and a red box appears,
BendGuard cannot operate and must be adjusted.
■ The button must be pressed after every adjustment to
recalculate the position of the point.

B876en 2019-05-18 BendGuard (option) 5‐13

 Fig. 97964
17. If the black point has moved up/down: Adjust the transmitter
using a 10 AF open-end wrench.
− Press the button after every adjustment to recalculate
the position of the point.
− Continue adjusting until the black point is on the horizon-
tal line.

Fig. 97968

5‐14 BendGuard (option) 2019-05-18 B876en

 Fig. 97965
18. If the black point has moved left/right: Adjust the transmitter
using a 3 AF Allen key.
− Press the button after every adjustment to recalculate
the position of the point.
− Continue adjusting until the black point is in the green
area.

Fig. 97968

19. Set up the upper tool to a height of 240 mm.

20. Set the transmitter and receiver to the working height of
240 mm.
21. Press the button on the user interface to recalculate the
position of the point.
22. Check the position of the black point. If necessary, continue
adjusting the transmitter until the black point is in the green
area.
23. Lower the transmitter as far as it will go.

B876en 2019-05-18 BendGuard (option) 5‐15

 Fig. 97956
24. Assemble the cover.

5‐16 BendGuard (option) 2019-05-18 B876en

 4. Tactile ACB Wireless angle
measuring system (option)

4.1 Calibrating the sensor tool

Calibrate all loaded sensor tools with the calibration die in the
following cases:
■ Before using the sensor tool for the first time.
■ After switching on the machine.
■ After replacing the sensor disks.
Production and assembly tolerances of the sensor disks are
compensated during calibration and the sensor tool is adjusted
to the respective working conditions.

Condition
■ The sensor tool is loaded according to the setup plan.

1. Move the press beam up to the mute point.

1 Replacement element 3 Guide body

2 2x guide rod/spring
Vertically adjustable calibration die Fig. 74303
2. Assemble calibration die:

B876en 2019-05-18 Tactile ACB Wireless angle measuring system 5‐17

(option)
 − Insert springs on the guide body.
− Insert replacement element for 90° calibration in the
guide body.
or
For sensor tool with a working height <140 mm and sen-
sor disks L12/L22: Insert replacement element for 120°
calibration (included in the scope of delivery of the sen-
sor tool) in the guide body.
3. Open the lower tool clamp.
4. Insert calibration under the sensor tool.
5. Close the lower tool clamp.

Note
Do not move the press beam up to the calibration die's stop.

Fig. 77377
6. Move the press beam down until the replacement element
moves down by about 10 mm.
7. Either
Ø Press Manual.
or
Ø Press Production, "Run in".
Ø Press Production settings.
8. Press Calibrate ACB.
9. Select a sensor tool.
10. Press Calibrate now.
or
Ø Press MobileControl UPPER TOOL CLAMP.
Once the calibration is completed, the LED on the sensor
tool lights up in green.

5‐18 Tactile ACB Wireless angle measuring system 2019-05-18 B876en

(option)
 The calibrated angle will be displayed.
Is the LED on the sensor tool red?

Ø Note message in the diagnostics.

B876en 2019-05-18 Tactile ACB Wireless angle measuring system 5‐19

(option)
5‐20 Tactile ACB Wireless angle measuring system 2019-05-18 B876en
(option)
 Chapter 6

Maintenance

1 Information on maintenance 6‐7

1.1 Replace safety-relevant parts of the controls 6‐9

2 Maintenance Overview 6‐10

3 Lubrication 6‐16
3.1 Overview 6‐16
3.2 Press Beam 6‐21
Clean and lubricate guide rails (Y axis) 6‐21
Lubricate (Y axis) guide rollers 6‐22
3.3 Backgauge 6‐24
For 2 axis backgauge: grease clamping 6‐24
plate on the backgauge finger
For 2, 4 and 5 axis backgauge: grease 6‐25
the rack (X axis)
Lubricate the ball screw (R axis) 6‐25
For 2, 4 and 5 axis backgauge: grease 6‐26
the guide carriage (R axis)

B876en 2019-05-18 Maintenance 6‐1

 For 6-axis backgauge: lubricate the guide 6‐27
carriage (R axis)
For 4-axis and 5-axis backgauge: Clean 6‐29
guide rail (Z axis)/Lubricate guide car-
riage (Z axis)
For 2-, 4- and 5-axis backgauge: Clean- 6‐30
ing guide rail (X axis)/Lubricating guide
carriage (X axis)
3.4 6 axes backgauge (option): central lubrication 6‐31
Check filling level 6‐31
3.5 Table plate for press table 6‐32
Cleaning and lubricating the table plate of 6‐32
the press table
3.6 Pneumatic I axis 6‐33
Clean and oil the contact surfaces 6‐33
Clean and oil the contact surfaces for the 6‐34
spacers
3.7 CNC controlled I axis (Option) 6‐35
Clean and grease the ball screw 6‐35
3.8 Crowning 6‐36
Cleaning and lubricating the wedge plate 6‐36
3.9 Bending aid (option) 6‐36
Lubricating the lift axis (H axis) 6‐36
Lubricating the guide carriage/rack (H 6‐36
axis) and the curved guide
Lubricating the brake's eccentric (Z axis) 6‐39
3.10 ACB laser optical angle measuring system 6‐41
(option)
Clean the guide rails/grease the guide car- 6‐41
riage

4 Mechanical elements 6‐43

4.1 Machine 6‐43
Check the machine alignment 6‐43
Check the mounting screw and floor 6‐43
anchors
Perform safety equipment test 6‐43
Check that covers are complete and 6‐44
firmly seated
Back up the data 6‐44
Machine data backup 6‐45
4.2 Tool clamping 6‐45
Cleaning the tool adapters 6‐45
Check tool clamping function 6‐46

6‐2 Maintenance 2019-05-18 B876en

 4.3 Support bracket (option) 6‐46
Cleaning the guide rails 6‐46
4.4 BendGuard (option) 6‐47
Clean guide rails 6‐47
BendGuard check and adjust 6‐48
Cleaning the transmitter and receiver 6‐48
4.5 Manual BendGuard (option) 6‐49
Replacing the roller spring 6‐49
4.6 Automatic BendGuard (option) 6‐50
Replacing the roller spring 6‐50
4.7 BendGuard (optional): Overtravel of the 6‐50
press beam
Check overtravel of the press beam with 6‐50
measuring device
4.8 Work area illumination (option) 6‐50
Cleaning work area illumination 6‐50
4.9 ACB laser optical angle measuring system 6‐51
(option)
Cleaning the glass panes 6‐51
Checking the gap in the cable carrier 6‐53
4.10 Part Indicator insertion aid (option) 6‐53
Cleaning the glass panes 6‐53
4.11 Press Beam 6‐54
Check guide rollers (Y axis) for fixed seat- 6‐54
ing
Check suspension (Y axis) for damage 6‐55
Check guide rails (Y axis) for wear 6‐55
Check the (Y axis) reference position 6‐56
Check distance measurement system (Y 6‐57
axis) for damage
Check limit switch (Y axis) functionality 6‐57
4.12 Backgauges 6‐57
2, 4 and 5 axis backgauge: Clean guide 6‐57
rail (Z axis)
Check the backgauge for wear/damage 6‐58
Checking the reference position (R, X 6‐58
and Z axis)
5 axis backgauge: Check the alignment 6‐59
of the backgauge finger (X5 axis)
Check the alignment of the backgauge fin- 6‐59
gers (Z-direction )
Checking the (X axis) backlash 6‐59
6 axis backgauge: check the alignment of 6‐59
the motion unit

B876en 2019-05-18 Maintenance 6‐3

 4.13 6 axes backgauge (option): central lubrication 6‐60
Check hoses for damage 6‐60
Check the film of grease at the lubrication 6‐61
points
4.14 Operating panel 6‐61
Cleaning the screen 6‐61
4.15 Lower tool displacement (I axis) 6‐62
Verifying the setting 6‐62
Check the play of the spherical plain bear- 6‐62
ing
4.16 Crowning 6‐62
Checking the reference position 6‐62
4.17 CNC-controlled wedge crowning (option) 6‐63
Check power consumption 6‐63
4.18 Heat sink (Cold Plate) 6‐63
Check the heat exchanger and fan for dirt 6‐63
Check the collecting tray for dirt 6‐64
Check filling level 6‐65
Checking the coolant quality 6‐66
Replace the coolant 6‐66
4.19 Bending aid (option) 6‐68
Cleaning the guide rail / sliding surfaces 6‐68
Checking the covers for stress marks 6‐69
Checking the brake function (Z axis) 6‐70
Performing a visual inspection within the 6‐70
bending aid

5 Electrics 6‐73
5.1 Side safety doors 6‐73
Checking the operation of the safety 6‐73
switch
5.2 Rear roller gate 6‐73
Checking the operation of the safety 6‐73
switch
5.3 Tool cabinet (option) 6‐74
5.4 Pneumatic I axis 6‐74
Checking the operation of the safety 6‐74
switch
5.5 EMERGENCY STOP push-button/PRESS 6‐75
BEAM DOWN foot switch with stop function
Check EMERGENCY STOP function 6‐75
5.6 Pilot lamps 6‐76
Checking the functioning of pilot lamps 6‐76

6‐4 Maintenance 2019-05-18 B876en

 5.7 Energy supply chains (press beam, back- 6‐77
gauge)
Checking lines for damage/deformation/ 6‐77
abrasion
5.8 Electrical supply lines 6‐79
Checking lines for damage/deformation/ 6‐79
abrasion
5.9 Encoder connector and proximity switch 6‐79
Check that the encoder connector and 6‐79
proximity switch are firmly seated
5.10 Electrical cabinet 6‐79
Cleaning the electrical cabinet 6‐79
5.11 Electrical cabinet (control cabinet) 6‐80
Check the voltage of the buffer battery in 6‐80
the IPC
Replace the buffer battery (BIOS battery) 6‐80
in the IPC
Check the function of the fan in the IPC 6‐80
5.12 Electrical cabinet (power cabinet) 6‐81
Clean the fan and the fan modules of the 6‐81
axis regulator
Check the input voltage/control voltage 6‐81
5.13 Air conditioning unit 6‐81
Check the air conditioning unit for dirt 6‐81
Cleaning the air conditioning unit 6‐83
5.14 MagicShoe (option)/Wireless foot switch 6‐83
(option)
Replace buffer battery 6‐83
5.15 Communications rail: 6‐83
Check the communications rail for dirt 6‐83

6 Hydraulics 6‐85
6.1 Hydraulic unit 6‐85
Refill oil 6‐85
Changing the oil filter 6‐86
Replace oil filter (first replacement) 6‐87
Replace oil filter (second replacement) 6‐88
Replace air filter 6‐88
Checking the hydraulic unit for leaks/ 6‐89
noise/vibrations
Analyze hydraulic oil (TruBend Fluid) 6‐89
Analyze hydraulic oil (all except 6‐90
TruBend Fluid)
Changing the hydraulic oil 6‐91

B876en 2019-05-18 Maintenance 6‐5

 Electrical cabinet air conditioning up to an 6‐91
ambient temperature of 45 °C (option):
Check the oil cooler for contamination
Check the main motors and fans of the 6‐92
servomotors for contamination
Check control block, valves, hoses and 6‐93
tube screw fittings for damage/tightness
6.2 Hydraulic hoses 6‐93
Check hoses for damage/tightness 6‐93
Replace the hoses 6‐94
6.3 Hydraulic cylinders 6‐95
Check hydraulic cylinder for damage/tight- 6‐95
ness
6.4 Diaphragm accumulator 6‐96
Determining initial pressure; refilling nitro- 6‐96
gen as needed
6.5 Press Beam 6‐98
Check the holding pressure (Y-axis) 6‐98

7 Pneumatic system 6‐99

7.1 Overview 6‐99
7.2 Maintenance unit 6‐99
Draining condensation water 6‐99
Check the system pressure 6‐100
Replace the filter cartridge 6‐100
7.3 6 axes backgauge (option): central lubrication 6‐101
Check the silencer on the pneumatic 6‐101
valve for dirt
7.4 Pneumatic I axis 6‐102
Check the hoses for deformation 6‐102
Check the silencer on the pneumatic 6‐103
valve for dirt

6‐6 Maintenance 2019-05-18 B876en

 1. Information on maintenance

Correct maintenance is essential for maintaining the quality of

the machine. It prevents operational malfunctions and their con-
sequences.

Risk of fatal injury during maintenance work with the

DANGER machine switched on!
Ø If not expressly described differently: Correctly switch off the
machine, switch off the MAIN SWITCH and secure with a
padlock.
Ø Strictly adhere to the safety regulations.

The leaning ladder could tip over!

CAUTION
Ø For maintenance work that requires climbing equipment,
use a stepladder.

Hot oil (up to 70 °C) during maintenance work immediately

WARNING after machine operation
Risk of burns.
Ø Apply appropriate safety measures.
Ø Wait until the oil has cooled down.

Maintenance personnel The user must authorize the maintenance personnel to perform
maintenance work on the machine.

B876en 2019-05-18 Information on maintenance 6‐7

 Depending upon the labeling, the maintenance work must be
done by the persons as specified in the following table:

Symbol Maintenance personnel

Machine operator

Trained maintenance personnel:

■ To train maintenance personnel, TRUMPF recommends that they participate in the mainte-
nance course for customers.
■ Work on the following assemblies requires specialist knowledge in the relevant area:
− Electrics.
− Hydraulics.
− Pneumatics.
− Mechanics.
− Laser.
■ The regulations of the relevant country are also applicable.
Technical Service:
This maintenance work may only be carried out by TRUMPF's Technical Service.
Maintenance personnel identification Tab. 6-1

Notes on cleaning ■ Clean the entire machine at regular intervals.

■ Brush off large particles of dirt or remove them with an
industrial vacuum cleaner.
■ Lightly grease the cylinder pistons when cleaning the
machine and whenever whistling noises occur:
− Remove the covers of the cylinders.
− Move the press beam all the way down.
− Lightly grease the cylinder pistons. Suitable grease can
be obtained from TRUMPF.

Notes on lubrication Refer to the lubrication schematic and maintenance instructions

for the lubrication of the machine. The following points should
also be observed:
■ Use only lint-free cleaning cloths and low-viscosity spindle
oil ("scavenge oil") to clean lubricating points. Do not use
cleaning wool, kerosene or benzene.
■ Do not mix synthetic lubricating oils with mineral oils or syn-
thetic oils from other manufacturers, even if the synthetic oil
in question has equivalent properties.
■ Pump out waste oil only at operating temperature.
■ Dispose of waste oil properly.
■ Do not leave filler and drainage caps open for longer than
necessary and keep them clean.

A safety harness for A safety harness for working on the machine can be purchased
working on the machine from TRUMPF (mat. no. 2349054).
The user must make sure that the safety harness is used
according to the local regulations.

6‐8 Information on maintenance 2019-05-18 B876en

 1.1 Replace safety-relevant parts of the
controls

To avoid dangerous situations, have the Technical Service

replace the following safety-relevant parts as a precaution:

Interval
Part Mat.-No. 1-shift operation 2-shift operation 3-shift operation 4-shift operation
(8 hours on 250 (16 hours on (24 hours on (24 hours on
days/year) 250 days/year) 250 days/year) 354 days/year)
PRESS BEAM 1875914 33 years 16 years 11 years 7 years
DOWN foot
switch with stop
function
Relay carrier 1822462 80 years 40 years 26 years 18 years
Tab. 6-2

B876en 2019-05-18 Information on maintenance 6‐9

 2. Maintenance Overview

Interval/ operating Maintenance Maintenance point Page

hours personnel
Ø Maintenance work
8 Bending aid (option) 6‐36
Ø Lubricating the lift axis (H axis)
40 Table plate for press table 6‐32
Ø Cleaning and lubricating the table plate of the press table
40 Tool clamping 6‐45
Ø Cleaning the tool adapters
40 Tool clamping 6‐46
Ø Check tool clamping function
40 Support bracket (option) 6‐46
Ø Cleaning the guide rails
40 Backgauges 6‐57
Ø 2, 4 and 5 axis backgauge: Clean guide rail (Z axis)
40 Bending aid (option) 6‐68
Ø Cleaning the guide rail / sliding surfaces
40 Maintenance unit 6‐99
Ø Draining condensation water
100 Heat sink (Cold Plate) 6‐64
Ø Check the collecting tray for dirt
160 Air conditioning unit 6‐81
Ø Check the air conditioning unit for dirt
160 Communications rail: 6‐83
Ø Check the communications rail for dirt
500 Press Beam 6‐21
Ø Clean and lubricate guide rails (Y axis)
500 Press Beam 6‐22
Ø Lubricate (Y axis) guide rollers
500 Backgauge 6‐24
Ø For 2 axis backgauge: grease clamping plate on the back-
gauge finger
500 Backgauge 6‐25
Ø For 2, 4 and 5 axis backgauge: grease the rack (X axis)
500 Backgauge 6‐25
Ø Lubricate the ball screw (R axis)
500 Backgauge 6‐26
Ø For 2, 4 and 5 axis backgauge: grease the guide carriage
(R axis)
500 Backgauge 6‐27
Ø For 6-axis backgauge: lubricate the guide carriage (R axis)
500 Pneumatic I axis 6‐34
Ø Clean and oil the contact surfaces for the spacers

6‐10 Maintenance Overview 2019-05-18 B876en

Interval/ operating Maintenance Maintenance point Page
hours personnel
Ø Maintenance work
500 6 axes backgauge (option): central lubrication 6‐60
Ø Check hoses for damage
500 6 axes backgauge (option): central lubrication 6‐61
Ø Check the film of grease at the lubrication points
500 Heat sink (Cold Plate) 6‐63
Ø Check the heat exchanger and fan for dirt
500 Hydraulic unit 6‐87
Ø Replace oil filter (first replacement)
500 Hydraulic unit 6‐89
Ø Checking the hydraulic unit for leaks/noise/vibrations
500 Hydraulic unit 6‐93
Ø Check control block, valves, hoses and tube screw fittings
for damage/tightness
500 Hydraulic cylinders 6‐95
Ø Check hydraulic cylinder for damage/tightness
500 Maintenance unit 6‐100
Ø Check the system pressure
500 6 axes backgauge (option): central lubrication 6‐101
Ø Check the silencer on the pneumatic valve for dirt
500 Pneumatic I axis 6‐103
Ø Check the silencer on the pneumatic valve for dirt
1000 Backgauge 6‐29
Ø For 4-axis and 5-axis backgauge: Clean guide rail (Z axis)/
Lubricate guide carriage (Z axis)
1000 Backgauge 6‐30
Ø For 2-, 4- and 5-axis backgauge: Cleaning guide rail (X
axis)/Lubricating guide carriage (X axis)
1000 Electrical cabinet 6‐79
Ø Cleaning the electrical cabinet
2000 ACB laser optical angle measuring system (option) 6‐41
Ø Clean the guide rails/grease the guide carriage
2000 BendGuard (option) 6‐47
Ø Clean guide rails
2000 Backgauges 6‐58
Ø Check the backgauge for wear/damage
2000 Hydraulic unit 6‐88
Ø Replace oil filter (second replacement)
5000 Crowning 6‐36
Ø Cleaning and lubricating the wedge plate
5000 Hydraulic unit 6‐86
Ø Changing the oil filter

B876en 2019-05-18 Maintenance Overview 6‐11

Interval/ operating Maintenance Maintenance point Page
hours personnel
Ø Maintenance work
5000 Hydraulic unit 6‐90
Ø Analyze hydraulic oil (all except TruBend Fluid)
20000 Hydraulic unit 6‐89
Ø Analyze hydraulic oil (TruBend Fluid)
Daily Side safety doors 6‐73
Ø Checking the operation of the safety switch
Daily Rear roller gate 6‐73
Ø Checking the operation of the safety switch
Daily Pneumatic I axis 6‐74
Ø Checking the operation of the safety switch
Daily EMERGENCY STOP push-button/PRESS BEAM DOWN foot 6‐75
switch with stop function
Ø Check EMERGENCY STOP function
Weekly Pneumatic I axis 6‐33
Ø Clean and oil the contact surfaces
Weekly Machine 6‐44
Ø Back up the data
Monthly Bending aid (option) 6‐69
Ø Checking the covers for stress marks
Monthly Pneumatic I axis 6‐102
Ø Check the hoses for deformation
Every 6 months Heat sink (Cold Plate) 6‐65
Ø Check filling level
Annually CNC controlled I axis (Option) 6‐35
Ø Clean and grease the ball screw
Annually Bending aid (option) 6‐36
Ø Lubricating the guide carriage/rack (H axis) and the curved
guide
Annually Bending aid (option) 6‐39
Ø Lubricating the brake's eccentric (Z axis)
Annually Machine 6‐43
Ø Check the machine alignment
Annually Machine 6‐43
Ø Check the mounting screw and floor anchors
Annually Machine 6‐43
Ø Perform safety equipment test
Annually Machine 6‐44
Ø Check that covers are complete and firmly seated
Annually Machine 6‐45
Ø Machine data backup
Annually BendGuard (option) 6‐48
Ø BendGuard check and adjust

6‐12 Maintenance Overview 2019-05-18 B876en

Interval/ operating Maintenance Maintenance point Page
hours personnel
Ø Maintenance work
Annually BendGuard (optional): Overtravel of the press beam 6‐50
Ø Check overtravel of the press beam with measuring device
Annually ACB laser optical angle measuring system (option) 6‐53
Ø Checking the gap in the cable carrier
Annually Press Beam 6‐54
Ø Check guide rollers (Y axis) for fixed seating
Annually Press Beam 6‐55
Ø Check suspension (Y axis) for damage
Annually Press Beam 6‐55
Ø Check guide rails (Y axis) for wear
Annually Press Beam 6‐56
Ø Check the (Y axis) reference position
Annually Press Beam 6‐57
Ø Check distance measurement system (Y axis) for damage
Annually Press Beam 6‐57
Ø Check limit switch (Y axis) functionality
Annually Backgauges 6‐58
Ø Checking the reference position (R, X and Z axis)
Annually Backgauges 6‐59
Ø 5 axis backgauge: Check the alignment of the backgauge
finger (X5 axis)
Annually Backgauges 6‐59
Ø Check the alignment of the backgauge fingers (Z-direction )
Annually Backgauges 6‐59
Ø Checking the (X axis) backlash
Annually Backgauges 6‐59
Ø 6 axis backgauge: check the alignment of the motion unit
Annually Lower tool displacement (I axis) 6‐62
Ø Verifying the setting
Annually Lower tool displacement (I axis) 6‐62
Ø Check the play of the spherical plain bearing
Annually Crowning 6‐62
Ø Checking the reference position
Annually CNC-controlled wedge crowning (option) 6‐63
Ø Check power consumption
Annually Heat sink (Cold Plate) 6‐66
Ø Checking the coolant quality
Annually Bending aid (option) 6‐70
Ø Checking the brake function (Z axis)
Annually Bending aid (option) 6‐70
Ø Performing a visual inspection within the bending aid

B876en 2019-05-18 Maintenance Overview 6‐13

Interval/ operating Maintenance Maintenance point Page
hours personnel
Ø Maintenance work
Annually Pilot lamps 6‐76
Ø Checking the functioning of pilot lamps
Annually Energy supply chains (press beam, backgauge) 6‐77
Ø Checking lines for damage/deformation/abrasion
Annually Electrical supply lines 6‐79
Ø Checking lines for damage/deformation/abrasion
Annually Encoder connector and proximity switch 6‐79
Ø Check that the encoder connector and proximity switch are
firmly seated
Annually Electrical cabinet (control cabinet) 6‐80
Ø Check the voltage of the buffer battery in the IPC
Annually Electrical cabinet (control cabinet) 6‐80
Ø Check the function of the fan in the IPC
Annually Electrical cabinet (power cabinet) 6‐81
Ø Clean the fan and the fan modules of the axis regulator
Annually Electrical cabinet (power cabinet) 6‐81
Ø Check the input voltage/control voltage
Annually Air conditioning unit 6‐83
Ø Cleaning the air conditioning unit
Annually MagicShoe (option)/Wireless foot switch (option) 6‐83
Ø Replace buffer battery
Annually Hydraulic unit 6‐88
Ø Replace air filter
Annually Hydraulic unit 6‐91
Ø Electrical cabinet air conditioning up to an ambient tempera-
ture of 45 °C (option): Check the oil cooler for contamination
Annually Hydraulic unit 6‐92
Ø Check the main motors and fans of the servomotors for
contamination
Annually Hydraulic hoses 6‐93
Ø Check hoses for damage/tightness
Annually Diaphragm accumulator 6‐96
Ø Determining initial pressure; refilling nitrogen as needed
Annually Press Beam 6‐98
Ø Check the holding pressure (Y-axis)
Every 2 years Manual BendGuard (option) 6‐49
Ø Replacing the roller spring
Every 4 years Electrical cabinet (control cabinet) 6‐80
Ø Replace the buffer battery (BIOS battery) in the IPC
Every 10 years Hydraulic hoses 6‐94
Ø Replace the hoses

6‐14 Maintenance Overview 2019-05-18 B876en

Interval/ operating Maintenance Maintenance point Page
hours personnel
Ø Maintenance work
As needed BendGuard (option) 6‐48
Ø Cleaning the transmitter and receiver
As needed Work area illumination (option) 6‐50
Ø Cleaning work area illumination
As needed ACB laser optical angle measuring system (option) 6‐51
Ø Cleaning the glass panes
As needed Part Indicator insertion aid (option) 6‐53
Ø Cleaning the glass panes
As needed Operating panel 6‐61
Ø Cleaning the screen
As needed Heat sink (Cold Plate) 6‐66
Ø Replace the coolant
As needed Hydraulic unit 6‐91
Ø Changing the hydraulic oil
As needed Maintenance unit 6‐100
Ø Replace the filter cartridge
When indicated by 6 axes backgauge (option): central lubrication 6‐31
the control system
Ø Check filling level
When indicated by Automatic BendGuard (option) 6‐50
the control system
Ø Replacing the roller spring
When indicated by Hydraulic unit 6‐85
the control system
Ø Refill oil

B876en 2019-05-18 Maintenance Overview 6‐15

 3. Lubrication

3.1 Overview

1 6 axes backgauge (option): cen- 4 Table plate for press table 7 Pneumatic I axis: Contact surfa-
tral lubrication 5 Press Beam: 4x Guide strip (Y ces
2 ACB laser optical angle measur- axis) 8 Pneumatic I axis: Contact surfa-
ing system (option): 2x guide 6 Press Beam: 8x Guide roller (Y ces for the spacers
carriage axis) w Weekly
3 2-axis backgauge: clamping
plate on the backgauge finger
Lubrication schematic for TruBend Series 5000 Fig. 75071

6‐16 Lubrication 2019-05-18 B876en

1 4 and 5 axis backgauge: 2x 3 4x Ball screw (R axis) 5 Rack (X axis)
Guide carriage (Z axis) 4 8x Guide carriage (X axis)
2 8x Guide carriage (R axis)
Lubrication plan 2-, 4- and 5-axis backgauge Fig. 69022

B876en 2019-05-18 Lubrication 6‐17

1 8x Guide carriage (R axis) 2 4x Ball screw (R axis)
Lubrication plan for 6-axis backgauge Fig. 69023

6‐18 Lubrication 2019-05-18 B876en

1 Guide carriage (H axis) 3 Brake (Z axis): Eccentric 5 Lift axis (H axis)
2 Sheet guide: Guide rail/guide 4 Rack (H axis) y Annually
roller
Bending aid lubrication plan (option) Fig. 78676

Symbol Explanation Symbol Explanation Symbol Explanation

Indication of Lubricate with a Lubricating with
lubrication inter- grease gun spray can
vals in hours
Read the main- Lubricating with Lubricate with
tenance instruc- the oil can brush
tions
Tab. 6-3

B876en 2019-05-18 Lubrication 6‐19

 Lubrication point Quantity Prescribed lubricant
Hydraulics ■ Recommended:TruBend Fluid (mat.
no. 1555678), initial filling
■ 5085 ■ 70 l
■ Castrol Hyspin AWH-M 46
■ 5085 (X) ■ 70 l
■ ARAL Vitam VF 46
■ 5085 (SX) ■ 70 l
■ ARAL Vitam VHF 46
■ 5130 ■ 120 l
■ BP Energol SHF-D 46
■ 5130 (X) ■ 120 l
■ BP Bartran HV-D 46
■ 5170 ■ 180 l
■ TOTAL AZOLLA ZS 46
■ 5170 (S) ■ 220 l
■ TOTAL EQUIVIS HE 46
■ 5230 ■ 180 l
■ ESSO Univis N 46
■ 5230 (S) ■ 220 l
■ FUCHS Renolin B 46 HVI
■ 5320 ■ 220 l
■ MOBIL DTE 10 Excel 46
■ SHELL Tellus S3 V
■ Guide strip (Y axis) – ■ KLÜBER Microlube GB 00 (mat.
■ Guide roller (Y axis) no. 0111780).
■ Guide carriage (R axis)
■ 2, 4 and 5 axis backgauge
− Guide carriage (X axis)
− Rack (X axis)
− Guide carriage (Z axis)
■ 6 axes backgauge (option): central lubri-
cation
− Guide carriage (X axis)
− Rack (X axis)
− Rack (Z axis)
− Guide carriage (Z axis)
■ Ball screw (R axis)
■ 2-axis backgauge: clamping plate on the
backgauge finger
■ ACB laser optical angle measuring sys-
tem (option): Guide carriage
■ Bending aid (option):
− Guide carriage (H axis)
− Rack (H axis)
− Sheet guide: Guide rail/guide roller
− Brake (Z axis): Eccentric
■ Table plate for press table – Bed track oil 68, 1 l (mat. no. 1838988)
■ Pneumatic I axis: Contact surfaces
■ Pneumatic I axis: Contact surfaces for
the spacers
Lubricants Tab. 6-4

6‐20 Lubrication 2019-05-18 B876en

 3.2 Press Beam

(see "Overview", pg. 6‐16)

Clean and lubricate guide rails (Y axis)

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).
■ Brush.
■ Slightly oiled cloth.

1. Move the press beam all the way down.

2. Open the roller gate on the rear side of the machine.
3. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

B876en 2019-05-18 Lubrication 6‐21

 1 Guide strip (Y axis)
Fig. 70839
4. Clean the guide strips with an oiled cloth and lubricate with
a brush.
5. Close roller gate.
6. Switch on the machine.
7. Move the press beam all the way upwards and downwards.

Lubricate (Y axis) guide rollers

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).

1. Move the press beam all the way down.

2. Open the roller gate on the rear side of the machine.

6‐22 Lubrication 2019-05-18 B876en

 3. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

1 Grease nipples
Fig. 71500
4. Lubricate guide rollers via grease nipple with a grease gun.
5. Close roller gate.
6. Switch on the machine.
7. Move the press beam all the way upwards and downwards.

B876en 2019-05-18 Lubrication 6‐23

 3.3 Backgauge

(see "Overview", pg. 6‐16)

For 2 axis backgauge: grease clamping

plate on the backgauge finger

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).
■ Brush.
■ Allen key size 5.
■ Insertion aids.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. Unscrew the white end stop of the backgauge on the right-
hand side.
3. Move the gauge fingers to the side and remove from the
guide strip.

1 Clamping plate
Fig. 72886
4. Carefully oil the clamping plate on all of the backgauge fin-
gers.
5. Mount the gauge fingers on the guide strip.
6. Screw on the end stop.

6‐24 Lubrication 2019-05-18 B876en

 For 2, 4 and 5 axis backgauge: grease the
rack (X axis)

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).
■ Brush.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

1 Rack (X axis)
Example: 4-axes backgauge (option) Fig. 69029
2. Clean the rack with a brush.
3. Move the backgauge a few times in the X direction. This will
clean the associated pinion.
4. Grease the rack with a brush.

Lubricate the ball screw (R axis)

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).

B876en 2019-05-18 Lubrication 6‐25

 1. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

Note
For each motion unit, there are two grease nipples, which
means a total of four grease nipples.

1 Grease nipples
Example: 6-axes backgauge (option) Fig. 70831
2. Lubricate the ball screw via the grease nipples using a
grease gun.
3. Switch on the machine.
4. Move R axis by at least 30 mm.
5. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.
6. Repeat steps 2 to 5 three times.

For 2, 4 and 5 axis backgauge: grease the

guide carriage (R axis)

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).

6‐26 Lubrication 2019-05-18 B876en

 1. Move the R axis right to the top.
2. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

Note
For each motion unit, there are two grease nipples on each
side, which means a total of eight grease nipples.

1 Grease nipples
Example: 4-axes backgauge (option) Fig. 69026
3. Lubricate the guide carriage via the grease nipples using a
grease gun.
4. Switch on the machine.
5. Move R axis by at least 30 mm.
6. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.
7. Repeat steps 3 to 6 three times.

For 6-axis backgauge: lubricate the guide

carriage (R axis)

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).

1. Move the R axis to position 0 mm.

B876en 2019-05-18 Lubrication 6‐27

 2. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

Note
For each motion unit, on each side there is a hole with two
grease nipples behind it, i.e. a total of eight grease nipples.

1 Grease nipples
6-axis backgauge Fig. 74948
3. Lubricate the guide carriage via the grease nipples using a
grease gun.
4. Switch on the machine.
5. Move the R axis to position +100 mm.
6. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.
7. Lubricate the guide carriage via the grease nipples using a
grease gun.

6‐28 Lubrication 2019-05-18 B876en

 For 4-axis and 5-axis backgauge: Clean
guide rail (Z axis)/Lubricate guide carriage
(Z axis)

Maintenance interval: 1000 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).
■ Slightly oiled cloth.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

Note
There is a grease nipple at each gauge finger.

1 Grease nipples 2 Guide rail

Example: 4-axes backgauge (option) Fig. 69025
2. Clean the guide rail with an oil-impregnated cloth.
3. Lubricate the guide carriage via the grease nipples using a
grease gun.
4. Switch on the machine.
5. Move Z axis by at least 500 mm.
6. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.
7. Repeat steps 3 to 6 three times.

B876en 2019-05-18 Lubrication 6‐29

 For 2-, 4- and 5-axis backgauge: Cleaning
guide rail (X axis)/Lubricating guide
carriage (X axis)

Maintenance interval: 1000 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).
■ Slightly oiled cloth.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

Note
For each motion unit, there are two grease nipples on each
side, which means a total of eight grease nipples.

1 Guide rail 2 Grease nipples

Example: 4-axes backgauge (option) Fig. 69024
2. Clean guide rails with an oil-impregnated cloth.
3. Lubricate the guide carriage via the grease nipples using a
grease gun.
4. Switch on the machine.
5. Traverse X axis by at least 30 mm.
6. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.
7. Repeat steps 3 to 6 three times.

6‐30 Lubrication 2019-05-18 B876en

 3.4 6 axes backgauge (option): central
lubrication

(see "Overview", pg. 6‐16)

Check filling level

Maintenance interval: When indicated by the control sys-

tem

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

1 Service door 2 Lubricant container

Fig. 71507
2. On the rear side of the machine, open the service door on
the right side.
3. Check the level on the lubricant container. Top up the lubri-
cant container if necessary.

B876en 2019-05-18 Lubrication 6‐31

 3.5 Table plate for press table

(see "Overview", pg. 6‐16)

Cleaning and lubricating the table plate of

the press table

Maintenance interval: 40 operating hours

The lower tool clamp lies on the table plate of the press table.
The lower tool holder is moved back and forth on the table plate
via the lower tool displacement (I axis).

Means, Tools, Materials

■ Bed track oil 68, 1 l (mat. no. 1838988)
■ Brush.
■ Slightly oiled cloth.

Cleaning with compressed air can cause dirt to reach the

NOTICE crowning wedges.
The function of the crowning is impaired.
Ø Clean the table plate and the lower tool clamp with a lightly
oiled cloth.

1. Move the I axis right to the back.

2. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

6‐32 Lubrication 2019-05-18 B876en

 1 Table plate of the press table
Fig. 71510
3. Clean and oil the front part of the table plate with an oil-
impregnated cloth.
4. Switch on the machine.
5. Move the I axis right to the front.
6. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.
7. Clean the back part of the table plate with an oil-impreg-
nated cloth and oil it.

3.6 Pneumatic I axis

(see "Overview", pg. 6‐16)

Clean and oil the contact surfaces

Maintenance interval: Weekly

Means, Tools, Materials

■ Bed track oil 68, 1 l (mat. no. 1838988)
■ Brush.
■ Slightly oiled cloth.

B876en 2019-05-18 Lubrication 6‐33

 1 Cover 3 Spacer for the position of
2 Spacer for the length of the the displacement path
translation path
Pneumatic I axis Fig. 69006

1. Push the cover to the rear.

2. Remove spacer (2).
3. Clean the contact surfaces with an oil-impregnated cloth.
4. Lightly oil the contact surfaces.
5. Fit the spacer.
6. Move the I axis.
7. Remove spacer (3).
8. Clean the contact surfaces with an oil-impregnated cloth.
9. Lightly oil the contact surfaces.
10. Fit the spacer.
11. Close the cover and acknowledge the message.

Clean and oil the contact surfaces for the

spacers

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ Bed track oil 68, 1 l (mat. no. 1838988)
■ Brush.
■ Slightly oiled cloth.

6‐34 Lubrication 2019-05-18 B876en

 1 Cover 2 Spacer
Fig. 73977

1. Push the cover to the rear.

2. Remove the spacer.
3. Clean the contact surfaces with an oil-impregnated cloth.
4. Lightly oil the contact surfaces.
5. Clean and oil other spacers in the same way.
6. Close the cover and acknowledge the message.

3.7 CNC controlled I axis (Option)

(see "Overview", pg. 6‐16)

Clean and grease the ball screw

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

B876en 2019-05-18 Lubrication 6‐35

 3.8 Crowning

(see "Overview", pg. 6‐16)

Cleaning and lubricating the wedge plate

Maintenance interval: 5000 operating hours

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

3.9 Bending aid (option)

(see "Overview", pg. 6‐16)

Lubricating the lift axis (H axis)

Maintenance interval: 8 operating hours

Ø Move lift axis (H axis) up and down completely 2x.

Lubricating the guide carriage/rack (H axis)

and the curved guide

Maintenance interval: Annually

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).
■ Brush.
■ Slightly oiled cloth.

1. Move the swivel axis (S axis) to the upper dead point.

2. Move the lift axis (H axis) to the upper dead point.
3. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

6‐36 Lubrication 2019-05-18 B876en

1 Screw 3 Cover 5 Telescopic cover
2 Screw 4 Screw 6 Cover
Example: Left-hand bending aid (option) Fig. 72217
4. Remove screws (1) and take off the cover (6).
5. Remove screw (2) and take off the cover (3).
6. Remove screws (4) to release the telescopic cover.

B876en 2019-05-18 Lubrication 6‐37

1 Bolt 2 Opening
Fig. 78677
7. Remove the bolt and insert it in the opening on the other
side to secure the swivel axis.

6‐38 Lubrication 2019-05-18 B876en

1 Guide rail 3 Rack (H axis) 4 Grease nipples
2 Guide roller
Example: Left-hand bending aid (option) Fig. 72218
8. Lubricate the guide carriage via the grease nipples using a
grease gun.
9. Cleaning the rack.
10. Grease the rack with a brush.
11. Clean guide rails with an oil-impregnated cloth.
12. Lubricate guide rollers with a brush.
13. Mount the telescopic cover.
14. Mount the covers.

Lubricating the brake's eccentric (Z axis)

Maintenance interval: Annually

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).
■ Brush.

B876en 2019-05-18 Lubrication 6‐39

 1. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

1 Brake (Z axis): Eccentric 2 Lever

Example: Left-hand bending aid (option) Fig. 72216
2. Lubricate eccentric slightly with brush.
3. Push lever up.
4. Lubricate eccentric slightly with brush.

6‐40 Lubrication 2019-05-18 B876en

 3.10 ACB laser optical angle measuring
system (option)

(see "Overview", pg. 6‐16)

Clean the guide rails/grease the guide

carriage

Maintenance interval: 2000 operating hours

Means, Tools, Materials

■ KLÜBER Microlube GB 00 (mat. no. 0111780).
■ Slightly oiled cloth.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

1 Cover 2 Screw
Fig. 73980
2. Remove the covers.

B876en 2019-05-18 Lubrication 6‐41

 1 Grease nipples 2 Guide rail
Fig. 72893
3. Clean guide rails with an oil-impregnated cloth.
4. Lubricate the guide carriage with a grease gun via the
grease nipples.

6‐42 Lubrication 2019-05-18 B876en

 4. Mechanical elements

4.1 Machine

Check the machine alignment

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Check the mounting screw and floor

anchors

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Perform safety equipment test

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

B876en 2019-05-18 Mechanical elements 6‐43

 Check that covers are complete and firmly
seated

Maintenance interval: Annually

Fig. 72890

Ø Check that covers are complete and firmly seated .

Back up the data

Maintenance interval: Weekly

Backup bending programs regularly on a USB flash drive or a

directory in the network.

Means, Tools, Materials

■ Use a USB flash drive, if required.

1. Insert USB flash drive at the side of the operating panel.

2. (lower left), press File management.
3. Select the 'DATA (F:)\programs' directory.
4. Press Select destination and select USB flash drive or direc-
tory in the network.
5. Either
Ø Mark the bending program and press Copy file to here.

6‐44 Mechanical elements 2019-05-18 B876en

 or
Ø To copy the entire data directory: press Copy data direc-
tory to here.

Machine data backup

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

4.2 Tool clamping

Cleaning the tool adapters

Maintenance interval: 40 operating hours

Means, Tools, Materials

■ Slightly oiled cloth.

1. Open tool clamps.

2. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

B876en 2019-05-18 Mechanical elements 6‐45

 1 Tool clamp: tool adapter
Example: Hydraulic tool clamp (option) Fig. 71509
3. Unload tools.
4. Clean the tool adapters.

Check tool clamping function

Maintenance interval: 40 operating hours

Ø Insert and clamp short tool at different positions and check

for fixed seating. If required: request Technical Service.

4.3 Support bracket (option)

Cleaning the guide rails

Maintenance interval: 40 operating hours

Means, Tools, Materials

■ Slightly oiled cloth.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

6‐46 Mechanical elements 2019-05-18 B876en

 1 Guide rail
Fig. 71508
2. Clean the guide rail with an oil-impregnated cloth.

4.4 BendGuard (option)

Clean guide rails

Maintenance interval: 2000 operating hours

Means, Tools, Materials

■ Slightly oiled cloth.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. Open the side safety doors.

B876en 2019-05-18 Mechanical elements 6‐47

 1 Guide rail
Fig. 70832
4. Clean guide rails with an oil-impregnated cloth.
5. Move the transmitter and receiver a few times forward and
back across the guide rails.
6. Close the side safety doors.

BendGuard check and adjust

Maintenance interval: Annually

Ø Check and adjust BendGuard (see chapter 5 "Setting work").

Cleaning the transmitter and receiver

Maintenance interval: As needed

Means, Tools, Materials

■ Clean, lint-free cloth.
■ Glass cleaner (mat. no. 1637606).

Note
Do not use any abrading or aggressive materials for cleaning.

6‐48 Mechanical elements 2019-05-18 B876en

 1. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

1 Transmitter 4 Upper tool

2 Light field 5 Receiver
3 Lower tool
Fig. 69001
2. Clean the glass pieces on the transmitter and receiver.

Note
Do not polish the glass pieces.
3. Dry the glass pieces.

4.5 Manual BendGuard (option)

Replacing the roller spring

Maintenance interval: Every 2 years

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

B876en 2019-05-18 Mechanical elements 6‐49

 4.6 Automatic BendGuard (option)

Replacing the roller spring

Maintenance interval: When indicated by the control sys-

tem

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

4.7 BendGuard (optional): Overtravel of

the press beam

Check overtravel of the press beam with

measuring device

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

4.8 Work area illumination (option)

Cleaning work area illumination

Maintenance interval: As needed

Means, Tools, Materials

■ Clean, lint-free cloth.
■ Anti-static plastic cleaner (mat. no. 1672922).

Note
Do not use any abrading or aggressive materials for cleaning.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

6‐50 Mechanical elements 2019-05-18 B876en

 1 Work area illumination (option)
Fig. 71512
2. Clean work area illumination.

Note
Do not polish the work area illumination.
3. Dry the work area illumination.

4.9 ACB laser optical angle measuring

system (option)

Cleaning the glass panes

Maintenance interval: As needed

Means, Tools, Materials

■ Clean, lint-free cloth.
■ Glass cleaner (mat. no. 1637606).

Note
Do not use any abrading or aggressive materials for cleaning.

1. If the angle measuring system in not in its parking position

(left side):

B876en 2019-05-18 Mechanical elements 6‐51

 − Press "Manual mode"or"Program", "Bending steps".
− Activate "ACB".
− Press / / .
− Press "ACB laser".
− Press Move to parking position.
2. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.
3. Open the side safety door.

1 Glass piece
Fig. 73979
4. Clean the glass pieces.

Note
Do not polish the glass pieces.
5. Dry the glass pieces.
6. Close the side safety door.

6‐52 Mechanical elements 2019-05-18 B876en

 Checking the gap in the cable carrier

Maintenance interval: Annually

Fig. 97683

1. Check the gap in the cable carrier.

2. If required: request Technical Service.

4.10 Part Indicator insertion aid (option)

Cleaning the glass panes

Maintenance interval: As needed

Means, Tools, Materials

■ Clean, lint-free cloth.
■ Glass cleaner (mat. no. 1637606).

Note
Do not use any abrading or aggressive materials for cleaning.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

B876en 2019-05-18 Mechanical elements 6‐53

 1 Front camera 2 Rear camera
Fig. 90681
2. Clean the panes on both cameras.

Note
Do not polish the panes.
3. Dry the panes.

4.11 Press Beam

Check guide rollers (Y axis) for fixed

seating

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

6‐54 Mechanical elements 2019-05-18 B876en

 Check suspension (Y axis) for damage

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Check guide rails (Y axis) for wear

Maintenance interval: Annually

1. Move the press beam all the way down.

2. Open the roller gate on the rear side of the machine.
3. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

B876en 2019-05-18 Mechanical elements 6‐55

 1 Guide strip (Y axis)
Fig. 70839
4. Check guide rails for wear. If required: request Technical
Service.
5. Close roller gate.

Check the (Y axis) reference position

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

6‐56 Mechanical elements 2019-05-18 B876en

 Check distance measurement system (Y
axis) for damage

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Check limit switch (Y axis) functionality

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

4.12 Backgauges

2, 4 and 5 axis backgauge: Clean guide rail

(Z axis)

Maintenance interval: 40 operating hours

Means, Tools, Materials

■ Slightly oiled cloth.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

B876en 2019-05-18 Mechanical elements 6‐57

 1 Guide rail
Example: 4-axes backgauge (option) Fig. 71513
2. Clean the guide rail with an oil-impregnated cloth.

Check the backgauge for wear/damage

Maintenance interval: 2000 operating hours

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. Check the covers for damage and abrasion.
3. Check the backgauge fingers for deformation.
4. If required: request Technical Service.

Checking the reference position (R, X and

Z axis)

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

6‐58 Mechanical elements 2019-05-18 B876en

 5 axis backgauge: Check the alignment of
the backgauge finger (X5 axis)

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Check the alignment of the backgauge

fingers (Z-direction )

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Checking the (X axis) backlash

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

6 axis backgauge: check the alignment of

the motion unit

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

B876en 2019-05-18 Mechanical elements 6‐59

 4.13 6 axes backgauge (option): central
lubrication

Check hoses for damage

Maintenance interval: 500 operating hours

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

1 Hose
Fig. 71514
2. Check lines for defects. Possible defects:
− Damaged lines.
− Deformed supply lines (e.g. kinks, crushed supply lines).
− Dirty lines
− Abrasion
If required: request Technical Service.

6‐60 Mechanical elements 2019-05-18 B876en

 Check the film of grease at the lubrication
points

Maintenance interval: 500 operating hours

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

1 Rack (X axis) 3 Rack (Z axis)

2 Guide rail 4 Guide rail
6-axis backgauge: Central lubrication lubrication points Fig. 71504
2. Check whether all of the lubrication points have been suffi-
ciently greased. If required: request Technical Service.

4.14 Operating panel

Cleaning the screen

Maintenance interval: As needed

Means, Tools, Materials

■ Clean, lint-free cloth.
■ Glass cleaner (mat. no. 1637606).

B876en 2019-05-18 Mechanical elements 6‐61

 Note
Do not use any abrading or aggressive materials for cleaning.

1. Press (bottom left), Clean screen.

2. Within 30 seconds, carefully clean the screen with a clean
cloth. Use some glass cleaner if necessary.

4.15 Lower tool displacement (I axis)

Verifying the setting

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Check the play of the spherical plain

bearing

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

4.16 Crowning

Checking the reference position

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

6‐62 Mechanical elements 2019-05-18 B876en

 4.17 CNC-controlled wedge crowning
(option)

Check power consumption

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

4.18 Heat sink (Cold Plate)

Check the heat exchanger and fan for dirt

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ Compressed air.

Effect on the eyes and lungs due to whirling dust and dirt!
CAUTION
Ø Wear suitable protective gear (safety glasses, dust protec-
tion glass).

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

B876en 2019-05-18 Mechanical elements 6‐63

 1 Screw joint 4 Heat exchangers
2 Fan 5 Electrical cabinet (power cab-
3 Plug connection inet)

Fig. 73981
2. Check the heat exchanger and fan for dirt. Clean with com-
pressed air if necessary.
3. Check that the screw joint and plug connection are firmly
seated.

Check the collecting tray for dirt

Maintenance interval: 100 operating hours

Means, Tools, Materials

■ Compressed air.

Effect on the eyes and lungs due to whirling dust and dirt!
CAUTION
Ø Wear suitable protective gear (safety glasses, dust protec-
tion glass).

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

6‐64 Mechanical elements 2019-05-18 B876en

 1 Collecting tray 2 Electrical cabinet (power cab-
inet)
Fig. 73982
2. Check the collecting tray for dirt. Clean with compressed air
if necessary.

Check filling level

Maintenance interval: Every 6 months

Means, Tools, Materials

■ Coolant Rifrost 1:4, 5 l (mat. no. 2044714)

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

B876en 2019-05-18 Mechanical elements 6‐65

 1 Level indicator
Fig. 73983
2. If the level has reached the minimum marking, add coolant
up to the maximum marking.

Checking the coolant quality

Maintenance interval: Annually

The customer service will check whether the coolant has to be

replaced. Inadequate quality of the coolant can cause damage
to seals or cause algae to grow.

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Replace the coolant

Maintenance interval: As needed

The customer service will check whether the coolant has to be

replaced. Inadequate quality of the coolant can cause damage
to seals or cause algae to grow.

6‐66 Mechanical elements 2019-05-18 B876en

 Means, Tools, Materials
■ Coolant Rifrost 1:4, 5 l (mat. no. 2044714)
■ Container (capacity > 5 l)

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

1 Electrical cabinet (power cab- 2 Cover

inet)
Fig. 76233
2. Remove cover (slide upwards).

1 Drain valve (red hose)

Fig. 76234
3. Take out the drain valve and and put it into the container.
4. Open the drain valve and drain off the coolant.
5. Close the drain valve.

B876en 2019-05-18 Mechanical elements 6‐67

 1 Cover
Fig. 76231
6. Screw off the cover.
7. Add coolant up to the maximum mark.

4.19 Bending aid (option)

Cleaning the guide rail / sliding surfaces

Maintenance interval: 40 operating hours

Means, Tools, Materials

■ Slightly oiled cloth.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

6‐68 Mechanical elements 2019-05-18 B876en

 1 Guide rail 2 Sliding surface
Bending aid (option) Fig. 76508
2. Clean the guide rail with an oil-impregnated cloth.
3. Clean the sliding surfaces with a cloth moistened with oil.

Checking the covers for stress marks

Maintenance interval: Monthly

1. Move the swivel axis (S axis) to the upper dead point.

2. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

1 Cover
Bending aid (option) Fig. 72220
3. Check covers for stress marks.

B876en 2019-05-18 Mechanical elements 6‐69

 4. If required: request Technical Service.

Checking the brake function (Z axis)

Maintenance interval: Annually

1 Lever
Example: Left-hand bending aid (option) Fig. 72221

1. Push the lever down to apply the brake (Z axis).

2. Check if the bending aid can be moved manually. If
required: request Technical Service.

Performing a visual inspection within the

bending aid

Maintenance interval: Annually

1. Move the swivel axis (S axis) to the upper dead point.

2. Move the lift axis (H axis) to the upper dead point.
3. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

6‐70 Mechanical elements 2019-05-18 B876en

1 Screw 3 Screw 5 Cover
2 Curved guide 4 Cover
Example: Left-hand bending aid (option) Fig. 72219
4. Remove screws (1) and take off the cover (5).
5. Remove screw (3) and take off the cover (4).
6. Check the curved guide for wear.
7. Check other parts for abrasion and wear.
8. Check that screws are tightened firmly.
9. Check lines for defects. Possible defects:
− Damaged or brittle insulation.
− Deformed supply lines (e.g. kinks, crushed supply lines).

B876en 2019-05-18 Mechanical elements 6‐71

 − Dirty lines
− Abrasion
10. If required: request Technical Service.
11. Mount the covers.

6‐72 Mechanical elements 2019-05-18 B876en

 5. Electrics

5.1 Side safety doors

Checking the operation of the safety switch

Maintenance interval: Daily

1. Trigger a stroke with the PRESS BEAM DOWN foot switch

and open one of the safety doors at the side.
2. Check that the press beam stops.
3. Confirm the error message with the PRESS BEAM DOWN
foot switch.
The press beam can be moved at reduced speed.
4. Trigger the stroke with PRESS BEAM DOWN foot switch.
5. Open both lateral safety doors.
6. Check if the following happens:
− Control stops.
− The press beam stops.
− Stop all axis motions of the backgauge.
− The hydraulic unit is switched off.
− For a 2-axis backgauge or 6-axis backgauge (option)
and/or pneumatic I axis (option) and/or BendMaster
(option): Pneumatics are shut off.
If required: request Technical Service.

5.2 Rear roller gate

Checking the operation of the safety switch

Maintenance interval: Daily

1. Open the roller gate on the rear side of the machine.

2. Check if the following happens:
− Control stops.
− The press beam stops.
− Stop all axis motions of the backgauge.

B876en 2019-05-18 Electrics 6‐73

 − The hydraulic unit is switched off.
− For a 2-axis backgauge or 6-axis backgauge (option)
and/or pneumatic I axis (option) and/or BendMaster
(option): Pneumatics are shut off.
If required: request Technical Service.

5.3 Tool cabinet (option)

5.4 Pneumatic I axis

Checking the operation of the safety switch

Maintenance interval: Daily

1 Cover
Fig. 73976

1. Push the cover to the rear.

2. Check if the following happens:
− Control stops.
− The press beam stops.
− Stop all axis motions of the backgauge.
− The hydraulic unit is switched off.
− For a 2-axis backgauge or 6-axis backgauge (option)
and/or pneumatic I axis (option) and/or BendMaster
(option): Pneumatics are shut off.
If required: request Technical Service.
3. Close the cover and acknowledge the message.

6‐74 Electrics 2019-05-18 B876en

 5.5 EMERGENCY STOP push-button/
PRESS BEAM DOWN foot switch
with stop function

Check EMERGENCY STOP function

Maintenance interval: Daily

Note
Check the EMERGENCY STOP push-button for damage during
the function check. If required: request Technical Service.

Check EMERGENCY STOP 1. Trigger the stroke with PRESS BEAM DOWN foot switch.
push-button function 2. Press the EMERGENCY STOP push-button on the operating
panel.
3. Check if the following happens:
− Control stops.
− The press beam stops.
− Stop all axis motions of the backgauge.
− The hydraulic unit is switched off.
− For a 2-axis backgauge or 6-axis backgauge (option)
and/or pneumatic I axis (option) and/or BendMaster
(option): Pneumatics are shut off.
If required: request Technical Service.
4. Check EMERGENCY STOP button on the foot switch in the
same way.

Check PRESS BEAM DOWN 5. Trigger the stroke with PRESS BEAM DOWN foot switch.
foot switch function 6. Push the PRESS BEAM DOWN foot switch through.
7. Check if the following happens:
− Control stops.
− The press beam stops.
− Stop all axis motions of the backgauge.
− The hydraulic unit is switched off.
− For a 2-axis backgauge or 6-axis backgauge (option)
and/or pneumatic I-axis (option) and/or BendMaster
(option): The pneumatic system is switched off.
If required: request Technical Service.

B876en 2019-05-18 Electrics 6‐75

 5.6 Pilot lamps

Checking the functioning of pilot lamps

Maintenance interval: Annually

Condition
■ The machine is ready for operation.

Checking the pilot lamp on 1. Switch the machine off.

the foot switch
2. Turn the MAIN SWITCH to I.
The control starts. This may take some time.
The start page of the user interface will appear.
"Log on" appears.

Note
If the user has not logged in after 60 seconds, the "user
group" "Standard" is logged in automatically.
3. Select "user group".
4. If necessary, enter "password".
or
Ø Unlock a machine with an ID card (RFID).
5. Press Log-on.
The user interface appears.
The symbol appears in the status bar.
STOP flashes.
6. Check if the following happens:
− The pilot lamp on foot switch 1 illuminates.
− The pilot lamps on the other foot switches flash for 16
seconds.
If pilot lamp is defective: have Technical Service replace the
foot switch.

Checking the START/STOP 7. Press START on the operating panel.

indicator lamp 8. Check whether or not the pilot lamp illuminates. If required:
request Technical Service.
9. Press STOP on the operating panel.
10. Check whether or not the pilot lamp illuminates. If required:
request Technical Service.

6‐76 Electrics 2019-05-18 B876en

Checking MobileControl and 11. Remove the operating element from the communications rail
MobileControl Pro (option) and put it back.
12. Check whether or not the pilot lamps are flashing. If neces-
sary, replace the operating element.

Checking MagicShoe 13. Remove the display element from the communications rail
Display (option) and put it back.
14. Check whether or not the pilot lamps are flashing. If neces-
sary, replace the operating element.

5.7 Energy supply chains (press beam,

backgauge)

Checking lines for damage/deformation/

abrasion

Maintenance interval: Annually

1. Move the press beam all the way down.

2. Open the roller gate on the rear side of the machine.

3. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

B876en 2019-05-18 Electrics 6‐77

 1 Press beam cable carrier 2 Backgauge cable carrier
Example: 6-axes backgauge (option) Fig. 72205
4. Check lines for defects. Possible defects:
− Damaged or brittle insulation.
− Deformed supply lines (e.g. kinks, crushed supply lines).
− Dirty lines.
− Abrasion.
− Improperly laid supply lines.
− Missing strain relief.
5. Check whether all lines are laid within the cable carrier.
6. If required: request Technical Service.

7. Close roller gate.

6‐78 Electrics 2019-05-18 B876en

 5.8 Electrical supply lines

Checking lines for damage/deformation/

abrasion

Maintenance interval: Annually

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. Check lines for defects. Possible defects:
− Damaged or brittle insulation.
− Deformed supply lines (e.g. kinks, crushed supply lines).
− Dirty lines.
− Abrasion.
− Improperly laid supply lines.
− Missing strain relief.

5.9 Encoder connector and proximity

switch

Check that the encoder connector and

proximity switch are firmly seated

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

5.10 Electrical cabinet

Cleaning the electrical cabinet

Maintenance interval: 1000 operating hours

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. Open the electrical cabinet door.

B876en 2019-05-18 Electrics 6‐79

 3. Keep the electrical cabinet free of dust.

5.11 Electrical cabinet (control cabinet)

Check the voltage of the buffer battery in

the IPC

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Replace the buffer battery (BIOS battery) in

the IPC

Maintenance interval: Every 4 years

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Check the function of the fan in the IPC

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

6‐80 Electrics 2019-05-18 B876en

 5.12 Electrical cabinet (power cabinet)

Clean the fan and the fan modules of the

axis regulator

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Check the input voltage/control voltage

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

5.13 Air conditioning unit

Check the air conditioning unit for dirt

Maintenance interval: 160 operating hours

Means, Tools, Materials

■ Clean, lint-free cloth.
■ Industrial vacuum cleaner.

Note
No filter mats may be used in the air conditioning unit since
they reduce the effectiveness of the air conditioning unit.

B876en 2019-05-18 Electrics 6‐81

 1 Air conditioning unit 2 Electrical cabinet air condition-
ing up to an ambient tempera-
ture of 45 °C (option): Air con-
ditioning unit
Fig. 72892

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

1 Covering 3 Fan wheel

2 Fins
Air conditioning unit Fig. 74300
2. Remove the covering.
3. Check the fins and fan wheel for dirt.

6‐82 Electrics 2019-05-18 B876en

 4. For strong contamination: wipe off coarse dirt with a cloth.
5. Vacuum off the fins and fan wheel.
6. Mount the covering.

Cleaning the air conditioning unit

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

5.14 MagicShoe (option)/Wireless foot

switch (option)

Replace buffer battery

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

5.15 Communications rail:

Check the communications rail for dirt

Maintenance interval: 160 operating hours

Means, Tools, Materials

■ Clean, lint-free cloth.

B876en 2019-05-18 Electrics 6‐83

 1 Communications rail
Fig. 73978

Ø Check the communications rail for dirt. Clean it, if necessary.

6‐84 Electrics 2019-05-18 B876en

 6. Hydraulics

6.1 Hydraulic unit

Refill oil

Maintenance interval: When indicated by the control sys-

tem

The control will output a message when the oil level is too low.
As soon as the minimum level is no longer covered, the control
will switch to disrupted and production will no longer be possible.

Means, Tools, Materials

■ Hydraulic oil TruBend Fluid, 20 l (mat. no. 1588452).
■ All oils except TruBend Fluid: filter with 3 μm filter fineness
■ Funnel.

Notes
■ If larger amounts of oil escape, there is a defect: request
Technical Service.
■ Observe the applicable national safety guidelines and acci-
dent prevention regulations (see "Safety" chapter).
■ Only use the same type of oil as before for topping up.

Unfiltered oil corrupts the hydraulic system.

CAUTION
Ø All oils except TruBend Fluid: Prefilter new oil with filter of
filter pore size 3 μm.
Ø TruBend Fluid: Prefilter new oil with filter of filter pore size
10 μm.

B876en 2019-05-18 Hydraulics 6‐85

 1 Oil filler port 3 Cover
2 Air filter
Fig. 74295

1. Screw off the cover.

2. Remove the air filter. No tool is used here.
3. Fill new hydraulic oil using a funnel. While doing so, prefilter
the oil with a filter.
4. Insert the air filter and screw on the cover.
5. Switch on the machine.
6. Program a single bend in manual operation.
7. On the operating panel or MobileControl unit, press START.
8. Carry out a 30-minute bending stroke and monitor the proc-
ess.

Changing the oil filter

Maintenance interval: 5000 operating hours

Means, Tools, Materials

■ Screw-on cartridge (mat. no. 1801553).
■ Strap wrench (mat. no. 0992482).

Notes
■ The oil filter needs to be changed more frequently with a
new machine.
First replacement after 500 operating hours.

6‐86 Hydraulics 2019-05-18 B876en

 Second replacement after 2000 operating hours.
After the third replacement, every 5000 operating hours.
■ With a corresponding message on the user interface:
Replace oil filter sooner.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

1 Hydraulic oil filter

Fig. 69031
2. Replace the filter insert of the hydraulic oil filter.

Replace oil filter (first replacement)

Maintenance interval: 500 operating hours

Notes
■ The oil filter needs to be changed more frequently with a
new machine.
First replacement after 500 operating hours.
Second replacement after 2000 operating hours.
After the third replacement, every 5000 operating hours.
■ With a corresponding message on the user interface:
Replace oil filter sooner.

Ø Changing the oil filter(see "Changing the oil filter", pg. 6‐86).

B876en 2019-05-18 Hydraulics 6‐87

 Replace oil filter (second replacement)

Maintenance interval: 2000 operating hours

Notes
■ The oil filter needs to be changed more frequently with a
new machine.
First replacement after 500 operating hours.
Second replacement after 2000 operating hours.
After the third replacement, every 5000 operating hours.
■ With a corresponding message on the user interface:
Replace oil filter sooner.

Ø Changing the oil filter(see "Changing the oil filter", pg. 6‐86).

Replace air filter

Maintenance interval: Annually

Means, Tools, Materials

■ Filter element (mat. no. 0826600).

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

6‐88 Hydraulics 2019-05-18 B876en

 1 Air filter 2 Cover
Fig. 70836
2. Screw off the cover.
3. Replace air filter. No tool is used here.
4. Screw the cover on.

Checking the hydraulic unit for leaks/noise/

vibrations

Maintenance interval: 500 operating hours

1. Check the hydraulic unit for noise/vibrations. If required:

request Technical Service.
2. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.
3. Checking the hydraulic unit for leaks (visual inspection). If
required: request Technical Service.

Analyze hydraulic oil (TruBend Fluid)

Maintenance interval: 20000 operating hours

1. Replace oil filter.

2. Have hydraulic oil analyzed by a lubricants laboratory. The
following analysis values are required:

B876en 2019-05-18 Hydraulics 6‐89

 − BN (base number).
− Viscosity.
− Water content.

If the water content is >1500 ppm, then damage to

WARNING components has probably already been caused!
Machine corrosion.
Ø Contact Technical Service.

3. If the analysis results in at least one of the following values:

Have the Technical Service change the hydraulic oil:
− BN (base number) <8.
− Viscosity < 41.4 mm2/s with ISO VG 46.
− Water content >1000 ppm (>0.1%).

Analyze hydraulic oil (all except

TruBend Fluid)

Maintenance interval: 5000 operating hours

1. Replace oil filter.

2. Have hydraulic oil analyzed by a lubricants laboratory. The
following analysis values are required:
− TAN (Total Acid Number).
− Viscosity.
− Water content.

If the water content is >1000 ppm, then damage to

WARNING components has probably already been caused!
Machine corrosion.
Ø Contact Technical Service.

3. If the analysis results in at least one of the following values:

Have the Technical Service change the hydraulic oil:
− TAN (Total Acid Number) >2.5.
− Viscosity <41.4 mm2/s or >50.6 mm2/s for ISO VG 46.
− Water content > 500 ppm.

6‐90 Hydraulics 2019-05-18 B876en

 Changing the hydraulic oil

Maintenance interval: As needed

The hydraulic oil must be replaced when the analysis of the

hydraulic oil results in impermissible values or at the latest after
50,000 operating hours.

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

Electrical cabinet air conditioning up to an

ambient temperature of 45 °C (option):
Check the oil cooler for contamination

Maintenance interval: Annually

Depending on the environment, the oil cooler will be covered in

dust after a particular time. If the oil cooler is contaminated, the
system will not be able to cool down the oil properly after great
heat generation.

Means, Tools, Materials

■ Compressed air.

Effect on the eyes and lungs due to whirling dust and dirt!
CAUTION
Ø Wear suitable protective gear (safety glasses, dust protec-
tion glass).

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

B876en 2019-05-18 Hydraulics 6‐91

 1 Oil cooler
Fig. 72887
2. Check the oil cooler for contamination. Clean with com-
pressed air if necessary.

Check the main motors and fans of the

servomotors for contamination

Maintenance interval: Annually

Depending on the environment, the motor will be covered in

dust after a certain time. The dust functions as an insulator. The
unwanted build up of heat may damage the bearings.

Means, Tools, Materials

■ Compressed air.

Effect on the eyes and lungs due to whirling dust and dirt!
CAUTION
Ø Wear suitable protective gear (safety glasses, dust protec-
tion glass).

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

6‐92 Hydraulics 2019-05-18 B876en

 1 Main motor 2 Fan for the servo motor
Fig. 70837
2. Check the main motors for contamination. Clean with com-
pressed air if necessary.
3. For TruBend 5130 – 5320: check the fans for dirt. Clean
with compressed air if necessary.

Check control block, valves, hoses and

tube screw fittings for damage/tightness

Maintenance interval: 500 operating hours

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. Check control block, valves, hoses and tube screw fittings
for damage/tightness (visual inspection).

6.2 Hydraulic hoses

Check hoses for damage/tightness

Maintenance interval: Annually

Possible defect at the hydraulic system hoses:

■ Damage in the outer layer extending to the inner lining
(chafe marks, cuts, cracks).
■ Brittle outer layer (cracks in the hose).

B876en 2019-05-18 Hydraulics 6‐93

 ■ Deformations that do not correspond to the natural form of
the hose; in the depressurized or pressurized status or when
bending (layer separation, bubble formation, crush areas,
kinks).
■ Leaks.
■ The hose dislodging itself from the fittings.
■ Damage or distortion of the fittings which diminishes the
function and tensile strength of the fitting or impairs the con-
nection between hose and fittings.
■ Corrosion of the fittings that impairs the function and tensile
strength.

Note
The safety rules for hydraulic system hoses (for Germany, see
DGUV Regel 113-020, former number was BGR 237) and the
national safety regulations must be complied with.

Injury due to a hydraulic system hose bursting and

DANGER thrashing around!
Ø Check all hydraulic system hoses in accordance with these
maintenance instructions.
Ø In case of doubt, replace the hydraulic system hose.

Ø Have the hydraulic hoses inspected by an expert to assure

safe operating standards. Check the hydraulic hoses before
the initial commissioning of the machine.
An expert is a person who has completed the appropriate
course of studies.

Replace the hoses

Maintenance interval: Every 10 years

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

6‐94 Hydraulics 2019-05-18 B876en

 6.3 Hydraulic cylinders

Check hydraulic cylinder for damage/

tightness

Maintenance interval: 500 operating hours

The surface of the cylinders must not exhibit any damage (e.g.
notches). Leaks may form and oil drip out. If a flow of oil is visi-
ble below the cylinders, the surface of the cylinder is already
damaged or the seal is faulty.

1. Move the press beam all the way down.

2. Open the roller gate on the rear side of the machine.
3. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

1 Hydraulic cylinder
Fig. 73973

B876en 2019-05-18 Hydraulics 6‐95

 4. Check hydraulic cylinder for damage/[Link] required:
request Technical Service.

6.4 Diaphragm accumulator

Determining initial pressure; refilling

nitrogen as needed

Maintenance interval: Annually

Means, Tools, Materials

■ Diaphragm accumulator check set (mat. no. 0346973).
■ Adapter (see "Tab. 6-5", pg. 6‐97).
■ 2nd person, who uses the EMERGENCY STOP to switch
the hydraulics off.

Notes
■ Diaphragm accumulators may only be serviced by corre-
spondingly trained persons. The equipment's operator is
responsible for the training (see the health & safety at work
law for the Federal Republic of Germany). National regula-
tions for checking the diaphragm accumulators must be
adhered to.
■ The gas chamber may be filled only with nitrogen. The pro-
cedure is documented in the separate operator's manual sup-
plied with the diaphragm accumulator check set.

Explosion of the diaphragm accumulator!

DANGER
This leads to severe injuries.
Ø When filling the diaphragm accumulator, a pressure reducer
with pressure relief valve must be used.
Ø The pressure reducer must be set to the prescribed initial
pressure (see hydraulic plan).
Ø The stop valve on the nitrogen cylinder must be opened
carefully to allow the gas to escape slowly.

6‐96 Hydraulics 2019-05-18 B876en

 Due to fluids and gases being expelled under high
WARNING pressure!
This can result in injuries.
Ø Before working on the hydraulics: Switch the machine off
properly, turn the MAIN SWITCH off and lock it with a pad-
lock.

Adapter Countries Mat.-No.

Nitrogen 300 bar (DIN) Europe 354499
Nitrogen 300 bar Europe 036288
(CEN)
Nitrogen France 357401
Nitrogen Great Britain 357404
Nitrogen USA 357405
Nitrogen Korea 357403
Nitrogen Japan 357402
Nitrogen CIS 357406
Available adapters Tab. 6-5

1 Oil pressure gauge 2 Diaphragm accumulator

Fig. 74296

1. Switch the hydraulics on (release the EMERGENCY STOP

or press START).
After 1 to 2 seconds, the value on the pressure gauge will
be approx. 55 bar.
2. Have a 2nd person switch the hydraulics off via the EMER-
GENCY STOP.
3. At the pressure gauge, check at which value the pressure
suddenly drops. This value corresponds to the charging pres-
sure in the gas chamber.
The needle on the pressure gauge falls continuously
(approx. 7 s) to a value (standard value 30 bar at 20 °C)
and then drops suddenly to 0 bar.

B876en 2019-05-18 Hydraulics 6‐97

 4. For a charging pressure of < 22 bar:
− Shut down the machine properly, secure the MAIN
SWITCH and secure with a padlock.
− Fill the diaphragm accumulator with nitrogen, until the
preliminary charging pressure in the gas chamber
reaches 30 bar (see diaphragm accumulator check set
operator's manual for the procedure).

6.5 Press Beam

Check the holding pressure (Y-axis)

Maintenance interval: Annually

Ø To perform this maintenance work: Have TRUMPF's Techni-

cal Service do this.

6‐98 Hydraulics 2019-05-18 B876en

 7. Pneumatic system

7.1 Overview

1 Maintenance unit 3 6-axes backgauge (option):

2 Pneumatic I axis: compressed Silencer
air hose 4 Pneumatic I axis: Silencer
Fig. 73984

The machine must have a compressed air supply if the machine

contains at least one of the following components:
■ 2-axis backgauge.
■ 6-axes backgauge (option)
■ Pneumatic I-axis.
■ Tool changer ToolMaster (option)
■ Pneumatically operated special option.

7.2 Maintenance unit

(see "Overview", pg. 6‐99)

Draining condensation water

Maintenance interval: 40 operating hours

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

B876en 2019-05-18 Pneumatic system 6‐99

 1 Filter cartridge 3 Drain
2 Inspection glass
Draining condensation water Fig. 2109
2. Push drain upward.

Check the system pressure

Maintenance interval: 500 operating hours

Ø Check the system pressure at the pressure gauge. Target

value: 6±1 bar (87±15 psi). Correct the pressure, if neces-
sary.

Replace the filter cartridge

Maintenance interval: As needed

If too much pressure is lost on the maintenance unit, the filter

cartridge must be replaced.

Means, Tools, Materials

■ Filter cartridge (material no. 1957686)

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. Close the air supply at the ball cock and secure it with a
padlock.

6‐100 Pneumatic system 2019-05-18 B876en

 1 Filter cartridge 3 Drain
2 Inspection glass
Draining condensation water Fig. 2109
3. Screw off the sight glass.
4. Clean the sight glass with water.
5. Remove the filter cartridge.
6. Install a new filter cartridge.
7. Install the sight glass.
8. Open air supply.

7.3 6 axes backgauge (option): central

lubrication

(see "Overview", pg. 6‐99)

Check the silencer on the pneumatic valve

for dirt

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ Silencer (material no. 0357397).

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

B876en 2019-05-18 Pneumatic system 6‐101

 1 Service door 3 Screw
2 Silencer 4 Pneumatic valve
Fig. 73986
2. On the rear side of the machine, open the service door on
the right side.
3. Remove the screws and take off the pneumatic valve.
4. Check the silencer on the pneumatic valve for dirt. Replace
if necessary.
5. If required: request Technical Service.

7.4 Pneumatic I axis

(see "Overview", pg. 6‐99)

Check the hoses for deformation

Maintenance interval: Monthly

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. On the rear side of the machine, open the service door on
the right side.
3. Ensure that the compressed air hoses are not kinked. If
required: request Technical Service.

6‐102 Pneumatic system 2019-05-18 B876en

 Check the silencer on the pneumatic valve
for dirt

Maintenance interval: 500 operating hours

Means, Tools, Materials

■ Silencer (material no. 1625031).

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. On the rear side of the machine, open the service door on
the right side.

1 Screw 3 Silencer
2 Pneumatic valve
Fig. 73985
3. Remove the screws and take off the pneumatic valve.
4. Check the silencer on the pneumatic valve for dirt. Replace
if necessary.
5. If required: request Technical Service.

B876en 2019-05-18 Pneumatic system 6‐103

6‐104 Pneumatic system 2019-05-18 B876en
 Chapter 7

Angle measuring system

ACB (option)

1 Structure 7‐3

2 Measuring principle 7‐5

2.1 Automatic bending angle correction sequence 7‐7

3 Technical Data 7‐8

4 Sensor tools and sensor disks 7‐9

4.1 Select sensor tool and sensor disks 7‐9

5 Changing sensor disks 7‐12

5.1 Bending installation device 7‐12
5.2 Removing sensor disks 7‐13
5.3 Installing sensor disks 7‐15
5.4 Cleaning the sensor tool 7‐16

B876en 2019-05-18 Angle measuring system ACB (option) 7‐1

 6 Programming 7‐18
6.1 ACB Methods 7‐18
6.2 Programming a bend with ACB (option) 7‐19

7 Calibration 7‐21
7.1 Calibrating the sensor tool 7‐21

8 Production 7‐23
8.1 Producing a part with ACB Speed 7‐23

7‐2 Angle measuring system ACB (option) 2019-05-18 B876en

 1. Structure

Fig. 81146

The ACB angle measuring system consists of a sensor tool and

an ACB module for connecting to the control.

ACB module The ACB module is used in the communications rail on the
press beam. The sensor tool is connected to the ACB module
by means of a cable. The ACB module transmits the data to the
control via the contacts in the communications rail.

B876en 2019-05-18 Structure 7‐3

 1 Calibration button 3 Connection for sensor tool
2 Display: number of the ACB
module
ACB module Fig. 36473

Notes
■ Only use modules starting from serial number 5035 on the
machine (see front side of the module).
■ The operating element can be freely positioned in the com-
munications rail.A maximum of 8 items can be operated
simultaneously in the communications rail (e.g.
MobileControl, MobileControl Pro, MagicShoe Display).
■ The operating element may not be moved along the commu-
nications rail since this could lead to damage to the electri-
cal contacts. To select another position: Remove the operat-
ing element and insert it at the desired place.

7‐4 Structure 2019-05-18 B876en

 2. Measuring principle

Angle measurement with The system for angle measurement is integrated in the upper
upper tool tool. The sensor tool is set up with the normal upper tools.

Angle measurement with sensor disks Fig. 56837

4 point angle measurement

with sensor disks

1 Contact points on the insides 2 Distance of the centers of the

of the bending sides sensor disks
Four-point angle measurement principle with sensor disks Fig. 45857

In the sensor tool there are two sensor disks with different diam-
eters. During bending, the two sensor disks register four contact
points on the inner sides of the bend.
Depending upon the plunging depth of the sensor disks, the dis-
tance between their center points changes. The linear displace-
ment of the sensor disks is measured electronically and the
angle is determined.

B876en 2019-05-18 Measuring principle 7‐5

 Two-dimensional angle Intelligent signal processing evaluates the distance between the
measurement centers of the sensor disks in two dimensions.
The current bending angle as well as a possible tilt angle of the
workpiece are recorded in the X direction.
The characteristic curves of the various sensor disk pairs and all
relevant tool data is stored In a memory chip integrated in the
tool.

Checking the bending Depending on the setting, the control evaluates the measured
operation signals of the sensor tool. It calculates the bending angle as
well as the springback and tilt angle of the workpiece. The
control assumes control over the bending operation.

7‐6 Measuring principle 2019-05-18 B876en

 2.1 Automatic bending angle correction
sequence

t Time
Schematic sequence of automatic bending angle correction Fig. 39961

Springback iden- Phase A From angle α1, the angle measurement system intervenes and controls
tification the bending. α1 is calculated as follows:
■ Measuring is possible when both sensor disks come into contact with
the sheet. The measured angle is compared to a (calculated) reference
angle, in relation to the plunge depth of the press beam. The reference
angle depends on the die width, sheet thickness, material, and working
radius on the upper tool, for example.
■ Identification starts once the difference between the calculated refer-
ence angle and actually measured angle is less than 20° (confidence
range) or once the reference angle differs by 10° from the programmed
angle (ACB measurement range).
Overbending by half the expected springback angle to α2 (value from
TRUMPF technology database).
Phase B Decompressing to α3 (= max. springback) and measurement of the spring-
back angle. The maximum springback angle depends on the tool and
material data.
The tilt is checked within the decompression path (α3 to α2). The operator
corrects the tilting manually.
Regulation Phase C Post bend at α4 ("controlled opera- From the springback angle (α3 -
tion") α2), the data for bending angle cor-
rection is calculated and immedi-
■ α4 is calculated from the pro-
ately converted into post-bending
grammed required angle minus
form (phases C to E).
the springback angle measured
in phase B.
Phase D Decompression to the point of the
programmed required angle α5. Tilt-
ing is measured.
Phase E Measuring the actual angle α5
Automatic bending angle correction sequence Tab. 7-1

B876en 2019-05-18 Measuring principle 7‐7

 3. Technical Data

Technical data Value

Sensor tools All normal standard
upper tools. Special
tools on request.
Tool width 25 mm and 35 mm
for sensor tools for
thick sheet.
Max. number of sensor tools per machine 8
Max. number of sensor tools per bend 2
Measurement range (dependent on the sensor 45° – 135°
tool)
Precision ±0.3°
Measurements per second 250
(125 values per sec-
ond are processed by
the control unit.)
Tab. 7-2

Scope of delivery Initial equipment:

■ Sensor tool with the corresponding sensor disks (and installa-
tion aids).
■ 2 ACB modules.
■ Calibration die with replaceable element for 90° calibration.
■ Accessories.

7‐8 Technical Data 2019-05-18 B876en

 4. Sensor tools and sensor disks

4.1 Select sensor tool and sensor disks

1. Select the sensor tool and sensor disks depending on the

material, the sheet thickness and the desired radius and
bending angle. Unsuitable materials include, for example:
− Materials without springback (e. g. special aluminum
alloys).
− Materials with excessive springback (e. g. spring steel).
− Structured sheet metal (e. g. perforated sheet, checker
plate).
− Parts with a sheet thickness >15 mm.

Tip
For relevant data about the sensor disks, see the informa-
tion printed on the sensor disk packaging or see the tool cat-
alog.

2. To determine the minimum side length Li:

− Subtract the estimated springback angle from the
required bending angle (example: 90° - 4° = 86°).
− In the following table, find the side length Li for the calcu-
lated angle (in the example: 86°). The side length Li
which is closest to the corrected angle is relevant here
(in the example: 85°).
The values have been established in test sequences.
The values are independent of the material as the spring-
back angle is not taken into account.

Minimum side length Li Fig. 65149

B876en 2019-05-18 Sensor tools and sensor disks 7‐9

 Tip
In the case of sensor disks with radii (R series), the side
length Li can also be calculated using the following rule of
thumb: Li = radius of the larger sensor disk + sheet thick-
ness + 0.5 mm.

3. If the minimum side length is not reached:

Ø Select the smaller sensor disk pair for the same sensor
tool. Here, make sure that these are suitable for the
sheet thickness, the material and the desired bending
angle.
or
Ø If no smaller sensor disk pair is available: change the
bending sequence and use ACB method "Copy of inser-
tion depth".
4. Select the lower tool. Take into account the following rules
of thumb for the calculation of the die width.

Upper tool radius R Sheet thickness s Die width W

R ≤1 mm s = 0.5 - 2.5 mm W = s x 6
s = 3.0 - 6.0 mm W = s x 8
s = 8.0 - 10 mm/15 mm19 W = s x 8 - 10 mm/15 mm19
1 mm < R < 10 mm Calculate the die width depending on the sheet thickness and minimum die width.
Use the greatest calculated die width.
All sheet thicknesses s. Minimum die width
W = (s x 4) + (R x 2)
s = 0.5 - 2.5 mm W = s x 6
s = 3.0 - 6.0 mm W = s x 8
s = 8.0 - 10 mm/15 mm19 W = s x 8 - 10 mm/15 mm19
10 mm ≤ R < 40 mm All sheet thicknesses s. Minimum die width W = (s + R) x 2
(insert for radius tool)
Rule of thumb for the calculation of the die width Tab. 7-3

The calculated die width can be fallen short of or exceeded by

the respectively next smaller or next larger die width.

Calculated die width Possible die width

W = 12 mm W = 10, 12 and 16 mm
W = 32 mm W = 30 and 40 mm
Examples for the selection of the die width Tab. 7-4

19 Sheet thickness up to 15 mm only possible with sensor tool for thick

sheet

7‐10 Sensor tools and sensor disks 2019-05-18 B876en

 Examples for the calculation and selection of die width:

Upper tool radius Sheet thickness s Calculation of die width W

R
R = 1 s = 2 mm W = s x 6
W = 2 mm x 6 = 12
R = 2 s = 4 mm Calculation according to sheet thickness:
■ W = s x 8
■ W = 4 mm x 8 = 32

Calculation of the minimum die width:

■ W = (s x 4) + (R x 2)
■ W = (4 mm x 4) + (2 x 4)
■ W = 16 + 4 = 20
⇒ Select tool with die width 30.
R = 12 s = 4 mm Calculation of the minimum die width:
■ W = (s + R) x 2
■ W = (4 mm + 12) x 2
■ W = 16 x 2= 32
⇒ Select tool with die width 30 or 40.
Examples for the calculation and selection of die width Tab. 7-5

5. Mount sensor disks in the sensor tool.

B876en 2019-05-18 Sensor tools and sensor disks 7‐11

 5. Changing sensor disks

5.1 Bending installation device

On initial equipment, a finished blank is delivered with the instal-

lation device. Sensor disks can be more easily installed and
removed with this installation device.

Ø Bend the blank according to the following drawing (all bend-

ings 90°):

a 1st upward bend c 3rd downward bend d 4th upward bend

b 2nd upward bend
Installation device drawing Fig. 20523

7‐12 Changing sensor disks 2019-05-18 B876en

 Example: Sensor tool in the installation device Fig. 74304

5.2 Removing sensor disks

Condition
■ The work area is clean. Contamination in the sensor tool
results in measurement errors.

Means, Tools, Materials

■ Installation device (included in the scope of delivery).
■ Locking pin (included in the scope of delivery).
■ Screwdriver 2.5 (included in the scope of delivery).

B876en 2019-05-18 Changing sensor disks 7‐13

 1 Screw (max. 4x) 3 Mounting position of sensor
2 Locking pin disk with narrow bracket
4 Mounting position of sensor
disk with wide bracket
Example: Changing the sensor disks Fig. 74305

1. Place sensor tool in the installation device. While doing so,

observe the following:
− The label on the installation device indicates where each
sensor tool needs to be loaded.
− The screws must be at the top.
− The sensor tool must lie in a well-aligned position on the
installation device.
2. Insert locking pin without undue force into the bore hole pro-
vided.
3. Press the sensor disks in the direction of the tool head until
the locking pin can be pressed without force through both
sensor disk brackets. The brackets should now no longer
move.
4. Loosen the screws, but do not remove them.
5. Carefully remove the sensor disks.

7‐14 Changing sensor disks 2019-05-18 B876en

 5.3 Installing sensor disks

Conditions
■ The sensor tool lies in the installation device. The locking
pin is inserted in the hole provided.
■ The sensor tool is clean.
■ The work area is clean.

Means, Tools, Materials

■ Installation device (included in the scope of delivery).
■ Locking pin (included in the scope of delivery).
■ Screwdriver 2.5 (included in the scope of delivery).
■ Flat precision ribbon (0.1 mm) (included in the scope of
delivery).
■ Torque wrench (for torque 0.16 Nm).
■ If required: impression aid (included in the scope of delivery).

Notes
■ Note the different bracket widths of the sensor disks and
corresponding symbols on the sensor tool.
■ Note the mounting position of the sensor disks: labelling
must face outwards.

B876en 2019-05-18 Changing sensor disks 7‐15

 1 Screw (max. 4x) 3 Mounting position of sensor
2 Locking pin disk with narrow bracket
4 Mounting position of sensor
disk with wide bracket
Example: Changing the sensor disks Fig. 74305
1. Slide the sensor disk with the wide bracket into the mount-
ing device for the wide bracket.
2. Push in the sensor disk with the narrow bracket.
3. Push the flat precision ribbon between the two sensor disks.
4. Slide in the sensor disks as far as they go.

Tip
Use the impression aid for small sensor disks.

5. Tighten screws to max. 0.16 Nm.

6. Remove the flat precision ribbon.
7. Remove the locking pin.
8. Check the ease of movement of the sensor disks.

5.4 Cleaning the sensor tool

Contamination in the sensor tool results in measurement errors

and must be removed before use.

Means, Tools, Materials

■ Clean, lint-free cloth.

7‐16 Changing sensor disks 2019-05-18 B876en

 Notes
■ Do not use liquid cleaning agent for cleaning.
■ Lubricants must not get into the bracket and the electronics
of the sensor tool.

1. Remove sensor disks.

2. Clean sensor disks and sensor tool with a dry cloth.

B876en 2019-05-18 Changing sensor disks 7‐17

 6. Programming

6.1 ACB Methods

The following ACB methods are available:

ACB Method Description

"Springback identification" "Springback identification" (identification of the springback angle and regulation with
and without tilt angle monitoring):
■ Application: For a material with unknown properties.
■ Description: For the ACB method "Springback identification", the following
phases are run through:
− Phase A: Pre-bending and overbending to the overbending angle.
− Phase B: Decompression until maximum springback, tilting is checked (if tilt
angle monitoring is active) and the springback angle is measured.
− Phase C: Post-bending by the springback angle measured in phase B.
− Phase D: Decompression to the programmed required angle and measure-
ment of the tilt. If the workpiece is not tilted, then the measured springback
angle is used. If the workpiece is tilted, then a calculated angle is displayed.
− Phase E: Measuring the actual angle.

t: time

Tip
■ To optimize the processing time, the measured springback angle can be used for
subsequent ACB bending operations (see Production, "Run in", Production set-
tings, "ACB Speed").
Tab. 7-6

7‐18 Programming 2019-05-18 B876en

ACB Method Description
"Springback entry" "Springback entry" (manual input of the springback angle, angle-controlled):
■ Application: If the determination of the material characteristics (springback) is
uncertain:
− For rough surfaces.
− When bending at the upper limit of the measuring range.
− When bending with bending aid (option).
■ Description:
− For the ACB method "Springback entry", the estimated or manually meas-
ured springback angle is input. The sheet is overbent by the amount of this
springback angle during the bending operation.
− Example: For a programmed bending angle of 90°, the springback angle is –
2°, i.e. an angle of 88° is bent (the angle measuring system measures until
88° is reached).
"Plunging depth copy" "Plunging depth copy" (position-controlled, i. e. the pressing depth of the upper tool
is applied from a previous bend):
■ Only possible in the Programming operation.
■ Application:
− If the angle measuring system cannot directly measure a bend angle (e.g.
measuring in a recess or on an elevation, short side, large bend radius).
− For time optimization in the event of similar bending operations in the same
rolling direction.
■ Description: The bend with ACB method "Plunging depth copy" applies the press-
ing depth of a previous ACB bending operation. The angle measuring system is
active here.
■ Prerequisite:
− The bend with ACB method "Plunging depth copy" precedes by at least one
bend, from which the pressing depth of the upper tool can be applied (basic
bend).
− For the bend with the ACB method "Plunging depth copy", the "Bending posi-
tion" should be the same.
■ Note: If a clamping point correction is programmed for the basic bend, a clamp-
ing point correction must also be programmed for the bend with ACB method
"Plunging depth copy".
Tab. 7-7

6.2 Programming a bend with ACB

(option)

Notes
■ Within a program, the ACB angle measuring systems can be
combined (example: 1. Bend with ACB, 2. Bend with ACB
Laser, 3. Bend with ACB Wireless).
■ The program allows the TCB sheet thickness detection and
the angle measuring system ACB to be combined (example:
1. bending with ACB, 2. bending with TCB).
The bending program does not allow TCB sheet thickness
detection and ACB angle measuring system to be combined
as ACB bends in an angle-controlled manner and therefore
already takes sheet thickness deviations into consideration.

B876en 2019-05-18 Programming 7‐19

 Choosing Manual mode/ 1. Press Manual operation.
Program
or
Ø Press Program, "Bending steps".

Setting up tools 2. Set up the sensor tool and module, and the lower tool.
3. Close the tool clamp.

Specify the parameters for 4. "Bending method" Select "Air bending".

the bend 5. Define the desired parameters.

Tip
For further information, see the contextual help. The contex-
tual help can be called by tapping with 2 fingers on the oper-
ating element.

Specifying the parameters 6. Activate "ACB".

for ACB 7. Press / / .

8. Press "ACB".
9. Define the desired parameters.
10. Press Confirm.

7‐20 Programming 2019-05-18 B876en

 7. Calibration

7.1 Calibrating the sensor tool

Calibrate all loaded sensor tools with the calibration die in the
following cases:
■ Before using the sensor tool for the first time.
■ After switching on the machine.
■ After replacing the sensor disks.
Production and assembly tolerances of the sensor disks are
compensated during calibration and the sensor tool is adjusted
to the respective working conditions.

Condition
■ The sensor tool is loaded according to the setup plan.

1. Move the press beam up to the mute point.

1 Replacement element 3 Guide body

2 2x guide rod/spring
Vertically adjustable calibration die Fig. 74303
2. Assemble calibration die:
− Insert springs on the guide body.
− Insert replacement element for 90° calibration in the
guide body.
or
For sensor tool with a working height <140 mm and sen-
sor disks L12/L22: Insert replacement element for 120°

B876en 2019-05-18 Calibration 7‐21

 calibration (included in the scope of delivery of the sen-
sor tool) in the guide body.
3. Open the lower tool clamp.
4. Insert calibration under the sensor tool.
5. Close the lower tool clamp.

Note
Do not move the press beam up to the calibration die's stop.

Fig. 77377
6. Move the press beam down until the replacement element
moves down by about 10 mm.
7. Either
Ø Press Manual.
or
Ø Press Production, "Run in".
Ø Press Production settings.
8. Press Calibrate ACB.
9. Select a sensor tool.
10. Press Calibrate now.
or
Ø Press MobileControl UPPER TOOL CLAMP.
Once the calibration is completed, the LED on the sensor
tool lights up in green.
The calibrated angle will be displayed.
Is the LED on the sensor tool red?

Ø Note message in the diagnostics.

7‐22 Calibration 2019-05-18 B876en

 8. Production

8.1 Producing a part with ACB Speed

When using the ACB Speed function, the springback angle is

only measured once for each bending angle (applies to all com-
ponents). All other bends refer to these bends.
Reactivating the ACB Speed checkbox initiates new springback
angle measurements.
If the deviation of the measured springback angle is greater
than 0.5° for an identification bend, identification must be per-
formed again the next time the bend is carried out.
In the Manual mode operation, no bending parameters are
saved.

The bending parameters are reset in the following cases:

■ When the ACB Speed checkbox is activated/deactivated.
The next time the bending part is processed, an identifica-
tion bend is performed for each bend with the ACB method
"Identification of spring-back".
■ If another program is loaded.
■ If the bending angle, the bending angle correction, the sheet
thickness or a tool is modified.

The bending parameters are retained in the following cases:

■ When changing from a program in the Programming or Pro-
duction operation to the Manual mode operation. This allows
bends to be carried out in Manual mode in the interim. Bend-
ing parameters are retained when the Production operation
is resumed.

Conditions
■ The desired program is loaded.
■ The programmed tool is loaded.
■ The sensor tools are calibrated.
■ Every bend will be done in the program at least once with
the ACB method "Springback identification", which means
that the springback angle will be measured.

1. Press Production, "Run in".

2. Press Production settings.
3. Activate "ACB speed".
4. Press Close.
5. On the operating panel or MobileControl unit, press START.
6. Place workpiece between the upper and the lower tool and
bring it against the backgauge.

B876en 2019-05-18 Production 7‐23

 7. To move the press beam downwards: Press the PRESS
BEAM DOWN foot switch.

7‐24 Production 2019-05-18 B876en

 Chapter 8

Tactile ACB Wireless angle

measuring system (option)

1 Measuring principle 8‐3

1.1 Automatic bending angle correction sequence 8‐5

2 Technical Data 8‐6

3 Bending with the angle measuring system 8‐7

ACB Wireless (overview)
3.1 Procedure 8‐7

4 Sensor tools and sensor disks 8‐8

4.1 Select sensor tool and sensor disks 8‐8

5 Changing sensor disks 8‐11

5.1 Bending installation device 8‐11
5.2 Removing sensor disks 8‐12

B876en 2019-05-18 Tactile ACB Wireless angle measuring system 8‐1

(option)
 5.3 Installing sensor disks 8‐14
5.4 Cleaning the sensor tool 8‐15

6 Programming 8‐17
6.1 ACB Methods 8‐17
6.2 Programming a bend with ACB Wireless 8‐18
(option)

7 Calibration 8‐20
7.1 Calibrating the sensor tool 8‐20

8 Production 8‐22
8.1 Producing a part with ACB Speed 8‐22

8‐2 Tactile ACB Wireless angle measuring system 2019-05-18 B876en

(option)
 1. Measuring principle

Angle measurement with The system for angle measurement is integrated in the upper
upper tool tool. The sensor tool is set up with the normal upper tools.

Angle measurement with sensor disks Fig. 56837

4 point angle measurement

with sensor disks

1 Contact points on the insides 2 Distance of the centers of the

of the bending sides sensor disks
Four-point angle measurement principle with sensor disks Fig. 45857

In the sensor tool there are two sensor disks with different diam-
eters. During bending, the two sensor disks register four contact
points on the inner sides of the bend.
Depending upon the plunging depth of the sensor disks, the dis-
tance between their center points changes. The linear displace-
ment of the sensor disks is measured electronically and the
angle is determined.

B876en 2019-05-18 Measuring principle 8‐3

 Two-dimensional angle Intelligent signal processing evaluates the distance between the
measurement centers of the sensor disks in two dimensions.
The current bending angle as well as a possible tilt angle of the
workpiece are recorded in the X direction.
The characteristic curves of the various sensor disk pairs and all
relevant tool data is stored In a memory chip integrated in the
tool.

Checking the bending Depending on the setting, the control evaluates the measured
operation signals of the sensor tool. It calculates the bending angle as
well as the springback and tilt angle of the workpiece. The
control assumes control over the bending operation.

8‐4 Measuring principle 2019-05-18 B876en

 1.1 Automatic bending angle correction
sequence

t Time
Schematic sequence of automatic bending angle correction Fig. 39961

Springback iden- Phase A From angle α1, the angle measurement system intervenes and controls
tification the bending. α1 is calculated as follows:
■ Measuring is possible when both sensor disks come into contact with
the sheet. The measured angle is compared to a (calculated) reference
angle, in relation to the plunge depth of the press beam. The reference
angle depends on the die width, sheet thickness, material, and working
radius on the upper tool, for example.
■ Identification starts once the difference between the calculated refer-
ence angle and actually measured angle is less than 20° (confidence
range) or once the reference angle differs by 10° from the programmed
angle (ACB measurement range).
Overbending by half the expected springback angle to α2 (value from
TRUMPF technology database).
Phase B Decompressing to α3 (= max. springback) and measurement of the spring-
back angle. The maximum springback angle depends on the tool and
material data.
The tilt is checked within the decompression path (α3 to α2). The operator
corrects the tilting manually.
Regulation Phase C Post bend at α4 ("controlled opera- From the springback angle (α3 -
tion") α2), the data for bending angle cor-
rection is calculated and immedi-
■ α4 is calculated from the pro-
ately converted into post-bending
grammed required angle minus
form (phases C to E).
the springback angle measured
in phase B.
Phase D Decompression to the point of the
programmed required angle α5. Tilt-
ing is measured.
Phase E Measuring the actual angle α5
Automatic bending angle correction sequence Tab. 8-1

B876en 2019-05-18 Measuring principle 8‐5

 2. Technical Data

Technical data Value

The minimum side length (depending on the (see "Fig. 65149",
sensor disks and sheet thickness) pg. 7‐9)
Tool width 25 mm and 35 mm
for sensor tools for
thick sheet.
Max. number of sensor tools per machine 8
Max. number of sensor tools per bend 3
Measurement range (dependent on the sensor 45° – 135°
tool)
Precision ±0.3°
Measurements per second 250
(125 values per sec-
ond are processed by
the control unit.)
Tab. 8-2

Technical data Value

The minimum flange length (depending on the (see "Fig. 65149",
sensor disks and sheet thickness) pg. 7‐9)
Tool width 25 mm and 35 mm
for sensor tools for
thick sheet.
Max. number of sensor tools per machine 8
Max. number of sensor tools per bend 2
Measurement range (dependent on the sensor 45° – 135°
tool)
Precision ±0.3°
Measurements per second 250
(125 values per sec-
ond are processed by
the control unit.)
Tab. 8-3

Delivery contents Initial equipment:

■ Sensor tool with the corresponding sensor disks (and installa-
tion aids).
■ Calibration die with replaceable element for 90° calibration.
■ Accessories.

8‐6 Technical Data 2019-05-18 B876en

 3. Bending with the angle measuring
system ACB Wireless (overview)

3.1 Procedure

1. Select the sensor tool and sensor disks.

2. Mount sensor disks in the sensor tool.
3. Either
Ø Program the bending program with ACB.
or
Ø Load the bending program and all data relevant to the
ACB.
4. Calibrate the sensor tool.
5. Produce part/bend.

B876en 2019-05-18 Bending with the angle measuring system ACB 8‐7
Wireless (overview)
 4. Sensor tools and sensor disks

4.1 Select sensor tool and sensor disks

1. Select the sensor tool and sensor disks depending on the

material, the sheet thickness and the desired radius and
bending angle. Unsuitable materials include, for example:
− Materials without springback (e. g. special aluminum
alloys).
− Materials with excessive springback (e. g. spring steel).
− Structured sheet metal (e. g. perforated sheet, checker
plate).
− Parts with a sheet thickness >15 mm.

Tip
For relevant data about the sensor disks, see the informa-
tion printed on the sensor disk packaging or see the tool cat-
alog.

2. To determine the minimum side length Li:

− Subtract the estimated springback angle from the
required bending angle (example: 90° - 4° = 86°).
− In the following table, find the side length Li for the calcu-
lated angle (in the example: 86°). The side length Li
which is closest to the corrected angle is relevant here
(in the example: 85°).
The values have been established in test sequences.
The values are independent of the material as the spring-
back angle is not taken into account.

Minimum side length Li Fig. 65149

8‐8 Sensor tools and sensor disks 2019-05-18 B876en

 Tip
In the case of sensor disks with radii (R series), the side
length Li can also be calculated using the following rule of
thumb: Li = radius of the larger sensor disk + sheet thick-
ness + 0.5 mm.

3. If the minimum side length is not reached:

Ø Select the smaller sensor disk pair for the same sensor
tool. Here, make sure that these are suitable for the
sheet thickness, the material and the desired bending
angle.
or
Ø If no smaller sensor disk pair is available: change the
bending sequence and use ACB method "Copy of inser-
tion depth".
4. Select the lower tool. Take into account the following rules
of thumb for the calculation of the die width.

Upper tool radius R Sheet thickness s Die width W

R ≤1 mm s = 0.5 - 2.5 mm W = s x 6
s = 3.0 - 6.0 mm W = s x 8
s = 8.0 - 10 mm/15 mm20 W = s x 8 - 10 mm/15 mm20
1 mm < R < 10 mm Calculate the die width depending on the sheet thickness and minimum die width.
Use the greatest calculated die width.
All sheet thicknesses s. Minimum die width
W = (s x 4) + (R x 2)
s = 0.5 - 2.5 mm W = s x 6
s = 3.0 - 6.0 mm W = s x 8
s = 8.0 - 10 mm/15 mm20 W = s x 8 - 10 mm/15 mm20
10 mm ≤ R < 40 mm All sheet thicknesses s. Minimum die width W = (s + R) x 2
(insert for radius tool)
Rule of thumb for the calculation of the die width Tab. 8-4

The calculated die width can be fallen short of or exceeded by

the respectively next smaller or next larger die width.

Calculated die width Possible die width

W = 12 mm W = 10, 12 and 16 mm
W = 32 mm W = 30 and 40 mm
Examples for the selection of the die width Tab. 8-5

20 Sheet thickness up to 15 mm only possible with sensor tool for thick

sheet

B876en 2019-05-18 Sensor tools and sensor disks 8‐9

 Examples for the calculation and selection of die width:

Upper tool radius Sheet thickness s Calculation of die width W

R
R = 1 s = 2 mm W = s x 6
W = 2 mm x 6 = 12
R = 2 s = 4 mm Calculation according to sheet thickness:
■ W = s x 8
■ W = 4 mm x 8 = 32

Calculation of the minimum die width:

■ W = (s x 4) + (R x 2)
■ W = (4 mm x 4) + (2 x 4)
■ W = 16 + 4 = 20
⇒ Select tool with die width 30.
R = 12 s = 4 mm Calculation of the minimum die width:
■ W = (s + R) x 2
■ W = (4 mm + 12) x 2
■ W = 16 x 2= 32
⇒ Select tool with die width 30 or 40.
Examples for the calculation and selection of die width Tab. 8-6

5. Mount sensor disks in the sensor tool.

8‐10 Sensor tools and sensor disks 2019-05-18 B876en

 5. Changing sensor disks

5.1 Bending installation device

On initial equipment, a finished blank is delivered with the instal-

lation device. Sensor disks can be more easily installed and
removed with this installation device.

Ø Bend the blank according to the following drawing (all bend-

ings 90°):

a 1st upward bend c 3rd downward bend d 4th upward bend

b 2nd upward bend
Installation device drawing Fig. 20523

B876en 2019-05-18 Changing sensor disks 8‐11

 Example: Sensor tool in the installation device Fig. 74304

5.2 Removing sensor disks

Condition
■ The work area is clean. Contamination in the sensor tool
results in measurement errors.

Means, Tools, Materials

■ Installation device (included in the scope of delivery).
■ Locking pin (included in the scope of delivery).
■ Screwdriver 2.5 (included in the scope of delivery).

8‐12 Changing sensor disks 2019-05-18 B876en

 1 Screw (max. 4x) 3 Mounting position of sensor
2 Locking pin disk with narrow bracket
4 Mounting position of sensor
disk with wide bracket
Example: Changing the sensor disks Fig. 74305

1. Place sensor tool in the installation device. While doing so,

observe the following:
− The label on the installation device indicates where each
sensor tool needs to be loaded.
− The screws must be at the top.
− The sensor tool must lie in a well-aligned position on the
installation device.
2. Insert locking pin without undue force into the bore hole pro-
vided.
3. Press the sensor disks in the direction of the tool head until
the locking pin can be pressed without force through both
sensor disk brackets. The brackets should now no longer
move.
4. Loosen the screws, but do not remove them.
5. Carefully remove the sensor disks.

B876en 2019-05-18 Changing sensor disks 8‐13

 5.3 Installing sensor disks

Conditions
■ The sensor tool lies in the installation device. The locking
pin is inserted in the hole provided.
■ The sensor tool is clean.
■ The work area is clean.

Means, Tools, Materials

■ Installation device (included in the scope of delivery).
■ Locking pin (included in the scope of delivery).
■ Screwdriver 2.5 (included in the scope of delivery).
■ Flat precision ribbon (0.1 mm) (included in the scope of
delivery).
■ Torque wrench (for torque 0.16 Nm).
■ If required: impression aid (included in the scope of delivery).

Notes
■ Note the different bracket widths of the sensor disks and
corresponding symbols on the sensor tool.
■ Note the mounting position of the sensor disks: labelling
must face outwards.

8‐14 Changing sensor disks 2019-05-18 B876en

 1 Screw (max. 4x) 3 Mounting position of sensor
2 Locking pin disk with narrow bracket
4 Mounting position of sensor
disk with wide bracket
Example: Changing the sensor disks Fig. 74305
1. Slide the sensor disk with the wide bracket into the mount-
ing device for the wide bracket.
2. Push in the sensor disk with the narrow bracket.
3. Push the flat precision ribbon between the two sensor disks.
4. Slide in the sensor disks as far as they go.

Tip
Use the impression aid for small sensor disks.

5. Tighten screws to max. 0.16 Nm.

6. Remove the flat precision ribbon.
7. Remove the locking pin.
8. Check the ease of movement of the sensor disks.

5.4 Cleaning the sensor tool

Contamination in the sensor tool results in measurement errors

and must be removed before use.

Means, Tools, Materials

■ Clean, lint-free cloth.

B876en 2019-05-18 Changing sensor disks 8‐15

 Notes
■ Do not use liquid cleaning agent for cleaning.
■ Lubricants must not get into the bracket and the electronics
of the sensor tool.

1. Remove sensor disks.

2. Clean sensor disks and sensor tool with a dry cloth.

8‐16 Changing sensor disks 2019-05-18 B876en

 6. Programming

6.1 ACB Methods

The following ACB methods are available:

ACB Method Description

"Springback identification" "Springback identification" (identification of the springback angle and regulation with
and without tilt angle monitoring):
■ Application: For a material with unknown properties.
■ Description: For the ACB method "Springback identification", the following
phases are run through:
− Phase A: Pre-bending and overbending to the overbending angle.
− Phase B: Decompression until maximum springback, tilting is checked (if tilt
angle monitoring is active) and the springback angle is measured.
− Phase C: Post-bending by the springback angle measured in phase B.
− Phase D: Decompression to the programmed required angle and measure-
ment of the tilt. If the workpiece is not tilted, then the measured springback
angle is used. If the workpiece is tilted, then a calculated angle is displayed.
− Phase E: Measuring the actual angle.

t: time

Tip
■ To optimize the processing time, the measured springback angle can be used for
subsequent ACB bending operations (see Production, "Run in", Production set-
tings, "ACB Speed").
Tab. 8-7

B876en 2019-05-18 Programming 8‐17

ACB Method Description
"Springback entry" "Springback entry" (manual input of the springback angle, angle-controlled):
■ Application: If the determination of the material characteristics (springback) is
uncertain:
− For rough surfaces.
− When bending at the upper limit of the measuring range.
− When bending with bending aid (option).
■ Description:
− For the ACB method "Springback entry", the estimated or manually meas-
ured springback angle is input. The sheet is overbent by the amount of this
springback angle during the bending operation.
− Example: For a programmed bending angle of 90°, the springback angle is –
2°, i.e. an angle of 88° is bent (the angle measuring system measures until
88° is reached).
"Plunging depth copy" "Plunging depth copy" (position-controlled, i. e. the pressing depth of the upper tool
is applied from a previous bend):
■ Only possible in the Programming operation.
■ Application:
− If the angle measuring system cannot directly measure a bend angle (e.g.
measuring in a recess or on an elevation, short side, large bend radius).
− For time optimization in the event of similar bending operations in the same
rolling direction.
■ Description: The bend with ACB method "Plunging depth copy" applies the press-
ing depth of a previous ACB bending operation. The angle measuring system is
active here.
■ Prerequisite:
− The bend with ACB method "Plunging depth copy" precedes by at least one
bend, from which the pressing depth of the upper tool can be applied (basic
bend).
− For the bend with the ACB method "Plunging depth copy", the "Bending posi-
tion" should be the same.
■ Note: If a clamping point correction is programmed for the basic bend, a clamp-
ing point correction must also be programmed for the bend with ACB method
"Plunging depth copy".
Tab. 8-8

6.2 Programming a bend with ACB

Wireless (option)

Notes
■ Within a program, the ACB angle measuring systems can be
combined (example: 1. Bend with ACB, 2. Bend with ACB
Laser, 3. Bend with ACB Wireless).
■ The program allows the TCB sheet thickness detection and
the angle measuring system ACB to be combined (example:
1. bending with ACB, 2. bending with TCB).
The bending program does not allow TCB sheet thickness
detection and ACB angle measuring system to be combined
as ACB bends in an angle-controlled manner and therefore
already takes sheet thickness deviations into consideration.

8‐18 Programming 2019-05-18 B876en

 Choosing Manual mode/ 1. Press Manual operation.
Program
or
Ø Press Program, "Bending steps".

Setting up tools 2. Set up the ACB sensor tool and lower tool.
3. Close the tool clamp.
Once the position of the tool has been automatically
detected, the LED lights up in blue on the sensor tool.

Specify the parameters for 4. "Bending method" Select "Air bending".

the bend 5. Define the desired parameters.

Tip
For further information, see the contextual help. The contex-
tual help can be called by tapping with 2 fingers on the oper-
ating element.

Specifying the parameters 6. Activate "ACB".

for ACB 7. Press / / .

8. Press "ACB Wireless".

9. Define the desired parameters.
10. Press Confirm.

B876en 2019-05-18 Programming 8‐19

 7. Calibration

7.1 Calibrating the sensor tool

Calibrate all loaded sensor tools with the calibration die in the
following cases:
■ Before using the sensor tool for the first time.
■ After switching on the machine.
■ After replacing the sensor disks.
Production and assembly tolerances of the sensor disks are
compensated during calibration and the sensor tool is adjusted
to the respective working conditions.

Condition
■ The sensor tool is loaded according to the setup plan.

1. Move the press beam up to the mute point.

1 Replacement element 3 Guide body

2 2x guide rod/spring
Vertically adjustable calibration die Fig. 74303
2. Assemble calibration die:
− Insert springs on the guide body.
− Insert replacement element for 90° calibration in the
guide body.
or
For sensor tool with a working height <140 mm and sen-
sor disks L12/L22: Insert replacement element for 120°

8‐20 Calibration 2019-05-18 B876en

 calibration (included in the scope of delivery of the sen-
sor tool) in the guide body.
3. Open the lower tool clamp.
4. Insert calibration under the sensor tool.
5. Close the lower tool clamp.

Note
Do not move the press beam up to the calibration die's stop.

Fig. 77377
6. Move the press beam down until the replacement element
moves down by about 10 mm.
7. Either
Ø Press Manual.
or
Ø Press Production, "Run in".
Ø Press Production settings.
8. Press Calibrate ACB.
9. Select a sensor tool.
10. Press Calibrate now.
or
Ø Press MobileControl UPPER TOOL CLAMP.
Once the calibration is completed, the LED on the sensor
tool lights up in green.
The calibrated angle will be displayed.
Is the LED on the sensor tool red?

Ø Note message in the diagnostics.

B876en 2019-05-18 Calibration 8‐21

 8. Production

8.1 Producing a part with ACB Speed

When using the ACB Speed function, the springback angles are
only measured once for each bending angle (applies to all
parts). All other bends refer to these bends.
Reactivating the "ACB Speed" checkbox initiates new spring-
back angle measurements.
If the deviation of the measured springback angle is greater
than 0.5° for an identification bend, identification must be per-
formed again the next time the bend is carried out.
In the Manual mode operation, no bending parameters are
saved.

The bending parameters are reset in the following cases:

■ When the "ACB Speed" checkbox is activated/deactivated.
The next time the bending part is processed, an identifica-
tion bend is performed for each bend with the ACB method
"Identification of spring-back".
■ If another program is loaded.
■ If the bending angle, the bending angle correction, the sheet
thickness or a tool is modified.

The bending parameters are retained in the following cases:

■ When changing from a program in the Programming or Pro-
duction operation to the Manual mode operation. This allows
bends to be carried out in Manual mode in the interim. Bend-
ing parameters are retained when the Production operation
is resumed.

Conditions
■ The desired program is loaded.
■ The programmed tool is loaded.
■ The sensor tools are calibrated.
■ Each bending angle is run through in the program at least
once with the ACB method "Springback identification", i.e.
the springback angle is measured.

1. Press Production, "Run in".

2. Press Production settings.
3. Activate "ACB speed".
4. Press Close.
5. On the operating panel or MobileControl unit, press START.
6. Place workpiece between the upper and the lower tool and
bring it against the backgauge.

8‐22 Production 2019-05-18 B876en

 7. To move the beam downwards: press the PRESS BEAM
DOWN foot switch.

B876en 2019-05-18 Production 8‐23

8‐24 Production 2019-05-18 B876en
 Chapter 9

2D code scanner (option)

1 Description 9‐2
1.1 Code syntax 9‐3

2 Installing the device 9‐5

2.1 Attaching the holder 9‐5
2.2 For version with cable: Connecting the device 9‐6

3 Loading program 9‐7

3.1 Loading a program by using a code 9‐7

4 Possible errors when scanning codes 9‐8

B876en 2019-05-18 2D code scanner (option) 9‐1

 1. Description

2D code scanner (option) Fig. 74290

Programs can be assigned and called up at the machine using

a data matrix code or bar code.

■ For versions with cables, the code can be a sticker on the

pre-cut part or in the printout of the setup plan.
■ For wireless versions with Bluetooth, the code directly on
the sheet can be a sticker on the pre-cut part or in the print-
out of the setup plan.
The code is read with the scanner and the relevant program is
called up automatically on the operating panel.
The program of the selected product needs to be contained in
the memory of the control system or be loadable using the net-
work.

Code types The device is designed for Data Matrix Code and code 128, but
it also supports all common 2D codes and bar codes.
■ Alphanumeric code.
■ Complete scope of functions (unrestricted length of network
name).

Generating Data Matrix Code The codes can be generated on corresponding web pages (e.g.
'[Link]

9‐2 Description 2019-05-18 B876en

 Creating a bar code Bar codes can be created by using a bar code printer or appro-
priate software (e.g. TruTops Bend or demo versions, for exam-
ple at [Link]).

1.1 Code syntax

Important information about Comply with the following when creating a code:
the codes ■ Do not use any ASCII characters < 32 or > 127.
■ When specifying paths, use '\'. Spaces are not permitted.
■ A program from the network can only be selected if the cor-
responding file is available in the network.

Possible shortcuts in the The following types of shortcuts can be displayed in the code
code depending on the storage location.

Shortcut in the code Description Example

Programs ■ State the program name in the code: 'test(.bnc)'
− The file extension does not have to be listed.
− After a dot, the file extension automatically
appears.
− Separations with a dot are not permissible
■ The program is searched for directly in the local
bending program folder.
Drawing number ■ List the drawing number with the prefix $ in the '$123456(.bnc)'
code.
■ The program is searched for directly in the local
bending program folder.
Program name with local ■ In the code, specify the entire local path. 'D:\Programs\customer
path ■ The program is searched for under the specified \test(.bnc)'
local path and in the bending program folder.
■ If the program is not found under the specified
path, the path will be treated as a network path.
■ The program can be copied into the local bending
program folder before loading.
Drawing number with ■ In the code, specify the entire local path and the 'D:\Programs\customer\
local path drawing number with prefix $. $123456(.bnc)'
■ The program with the specified drawing number is
searched for under the specified local path and in
the bending program folder.
■ If the program is not found under the specified
path, the path will be treated as a network path.
■ The program can be copied into the local bending
program folder before loading.

B876en 2019-05-18 Description 9‐3

 Shortcut in the code Description Example
Program name with net- ■ State the entire network path and the program '\\pc071417\Programs
work path name in the code. \test(.bnc)'
■ The computer searches for the program under the
specified network path.
■ The machine needs to have read access at the
specified network path.
■ The program can be copied into the local bending
program folder before loading.
Drawing number with net- ■ List the entire network path and the drawing num- '\\pc071417\Programs\
work path ber with the prefix $ in the code. $123456(.bnc)'
■ The computer searches for the program under the
specified network path.
■ The machine needs to have read access at the
specified network path.
■ The program can be copied into the local bending
program folder before loading.
Possible shortcuts in the code Tab. 9-1

9‐4 Description 2019-05-18 B876en

 2. Installing the device

2.1 Attaching the holder

Means, Tools, Materials

■ Torx wrench T25.

1 Screw 2 Mounting device

Fig. 81081

1. Screw out the screws from the operating panel.

2. Screw in the mounting device with the screws.

B876en 2019-05-18 Installing the device 9‐5

 2.2 For version with cable: Connecting
the device

Fig. 81082

Ø Plug the device cable into the USB socket on the operating
panel.

9‐6 Installing the device 2019-05-18 B876en

 3. Loading program

3.1 Loading a program by using a code

The appropriate bending program is activated on the operating

panel via the code of a program and can be executed.

Condition
■ The device is installed.

Note
The code can only be read in the operations Production and
Programming.
1. Press Production.
or
Ø Press Programming.
2. Scan code.
If the device acknowledges the code, a green point lights up
and the device beeps.
Data of the detected programs are displayed.
3. Press Yes.
or
Ø Scan in the confirmation code again.

B876en 2019-05-18 Loading program 9‐7

 4. Possible errors when scanning codes

Wrong program is loaded The following explains what caused the wrong program to be
loaded:
■ Several programs have the same drawing number in the
specified folder (the program found first is displayed).
■ Several programs have the same program name in different
directories for the bending program folder.

An error message appears If a program is identified that can not be loaded, an error
message appears. This can have the following reasons:
■ Special characters are listed in the code that are not permis-
sible for file names on a Windows operating system.
■ The program could not be found because it does not exist.
■ The machine does not have access to the specified directory.
■ The device is not programmed correctly.

No program identified in the If no program is identified and no error message appears, the
code following may be the cause:
■ The code contains ASCII characters < 32 or > 127.
■ Production/programming is not selected.
■ The device is not programmed correctly.
■ The path specified in the code is not available.
■ The code contains start and/or stop characters.
■ There is a dot in the program name or network path of the
program, without having the file extension directly after it.

9‐8 Possible errors when scanning codes 2019-05-18 B876en