Operator's manual

TruLaser 5030 (L41)

TruLaser 5040 (L47)
Operator's manual

TruLaser 5030 (L41)

TruLaser 5040 (L47)

Original operator's manual

Edition 2011-10-07
 Order Information Please specify when ordering this document:
Operator's manual
TruLaser 5030 (L41) TruLaser 5040 (L47)
Edition 2011-10-07
Document number B743en

TRUMPF Werkzeugmaschinen GmbH + Co. KG

Address for orders Technische Redaktion
Johann-Maus-Straße 2
D-71254 Ditzingen
Fon: +49 7156 303 - 0
Fax: +49 7156 303 - 930540
Internet: http://www.trumpf.com
E-Mail: [email protected]

For "partly completed machinery" in accordance with the EC

Machinery Directive, this document corresponds to the
assembly instructions.

© TRUMPF Werkzeugmaschinen GmbH + Co. KG

 Before you proceed ...

Operator's manual for This operator's manual documents the TruLaser 5030 (L41), Tru-
TruLaser 5030 (L41), Laser 5030 (L47) laser cutting machine with TRUMPF CNC path
TruLaser 5040 (L47) control system on the basis of SIEMENS SINUMERIK 840D sl.
The operator's manual is intended not only for the user (owner)
and the operator of the machine, but also for the maintenance
personnel. It should be made accessible to all of these people.

The entire machine documentation contains important safety

information on the prevention of injuries and potential hazards to
life and health. Such information is marked by the symbol shown
here. Read the Safety chapter!

Documentation for further The User's Guide like the spare parts catalog, control system
reference documentation and procurement documents is a separate part of
the complete system documentation. The documentation must be
accessible to all persons involved with operation, programming,
and maintenance.
The regulations and instructions of the documentation must be
observed to prevent unnecessary downtime and as a condition
for the recognition of warranty claims. The safety instructions
should be strictly adhered to in order to avoid accidents.

B743en 2011-10-07 Before you proceed ... I

II Before you proceed ... 2011-10-07 B743en
 Table of contents

Chapter 1 Safety

1 Safety regulations 1-3

2 Terms 1-5

3 Operating safety 1-6

3.1 Intended use 1-6
3.2 Authorized personnel 1-7

4 Hazards 1-8
4.1 Overview of laser classes 1-8
Laser classes of the machine 1-8
Laser classes of laser device and compo- 1-9
nents
4.2 Hazards due to laser radiation 1-9
4.3 Hazards due to secondary radiation 1-10
4.4 Fire hazard 1-11
Machining highly reactive materials 1-12
4.5 Dangers from magnetic fields 1-12
Linear drives 1-12
4.6 Dangers due to the switch cabinet 1-13
4.7 Live parts 1-14
4.8 Hazards when dealing with workpieces 1-14
Sharp-edged workpieces 1-14
Dangers due to accessing the pallet 1-15
4.9 Danger due to Teleservice 1-15
4.10 Hazardous substances 1-16
Dusts, aerosols and gases 1-16
Hazardous materials due to cutting oils 1-17
Hazardous substances derived from poly- 1-17
ethylene films

5 Measures to be taken by the manufacturer 1-18

5.1 Danger zones and safeguarding device 1-18
5.2 Danger signs on the machine 1-20

B743en 2011-10-07 Table of contents 0-1

 6 Measures to be taken by the owner 1-23
6.1 Observing warnings and danger signs 1-23
6.2 Training and instructing operators 1-23
Measures applicable worldwide 1-23
Protection against radiation: Additional 1-24
measures in the Federal Republic of Ger-
many
Protection against radiation: Additional 1-25
measures in the USA
6.3 Adhering to the duty of care when handling 1-25
the machine
6.4 Pay attention to water protection 1-26
6.5 Using spare parts, accessories, software and 1-27
operating materials
6.6 Fire in the compact dust extractor 1-28
Extinguishing the fire in the compact dust 1-28
extractor (Handte) without the CO2 fire
extinguishing system

7 Overview of residual risks 1-30

8 Disassembly and disposal 1-32

Chapter 2 Installation conditions for TruLaser

5030 (L41); TruLaser 5040 (L47)

To what does this apply? 2-4

1 Planning aid 2-5

2 Installation site 2-7

2.1 Space requirements 2-7
2.2 Floor requirements 2-7
Machine without LoadMaster or LiftMaster. 2-8
Machine with LoadMaster or LiftMaster 2-9
and prepared machines
2.3 Weight load 2-10
2.4 Ambient conditions 2-12
2.5 Cabe racks for laser light cables 2-14

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 2.6 Exhaust air system of the compact dust 2-14
extractor
2.7 Installation of the cooling unit 2-15

3 Gas supply 2-16

3.1 Cutting gases 2-16
Purity 2-16
Cutting gas consumption 2-17
Supply lines for cutting gas supply 2-19
Requirements on the connection point of 2-21
the machine
Cutting gas supply with cylinders or bun- 2-21
dles
Cutting gas supply with gas tank 2-22
3.2 Nitrogen for cutting unit ventilation 2-23

4 Electrical supply 2-25

4.1 Electrical connection 2-25
4.2 Power supply 2-26
Uninterruptible Power Supply (UPS) 2-27
Residual current device (RCD) 2-27
NEC conditions 2-28
Isolating transformer 2-28
4.3 Connected loads, fuse protection and fre- 2-30
quency
4.4 Electrical power input 2-31
4.5 Network connection 2-31
4.6 Teleservice 2-31
4.7 Enhanced shop floor programming 2-32

5 Compressed air supply 2-34

6 Operating materials 2-36

6.1 Gases 2-36
6.2 Cooling water. 2-36

7 Transportation of the machine 2-38

7.1 Measures to be taken by the customer 2-39
7.2 TRUMPF service work 2-40

B743en 2011-10-07 Table of contents 0-3

 Chapter 3 Description

1 The most important assemblies 3-3

1.1 Closed machine frame 3-4
1.2 Motion unit 3-5
1.3 TruDisk Laser 3-6
1.4 Fiber optic laser cable 3-7
1.5 Cutting unit 3-8
1.6 Multi-chamber suction system 3-9
1.7 Compact dust extractor 3-10
1.8 Longitudinal conveyor belt 3-10
1.9 Partitioned slag container 3-10
1.10 Automatic pallet changer 3-11
1.11 Spraying equipment 3-11
1.12 Cleaning brush 3-12
1.13 Laser pointer diode 3-12
1.14 Electrical rolling roof 3-12

2 Control system 3-13

2.1 Integrated E-shop 3-14
2.2 Teleservice 3-15
2.3 Shop floor programming 3-15

3 The most important functions 3-17

3.1 One-cutting-head strategy 3-17
3.2 FocusLine 3-17
3.3 FastLine 3-17
3.4 FlyLine 3-18
3.5 PierceLine 3-19
3.6 Laser power control 3-20
3.7 NitroLine 3-20
3.8 ControlLine 3-20
3.9 ContourLine 3-21
3.10 Compressed-air cutting 3-21
3.11 Auto-shutdown 3-21

4 Safety 3-22
4.1 CE marking 3-22

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 4.2 Closed safety cabin with rolling roof 3-23

5 The most important options 3-24

5.1 Nozzle changer 3-24
5.2 Clamps 3-25
5.3 TruTops Laser complete package 3-26
5.4 TruTops Message 3-27
5.5 Camera for process monitoring 3-28

6 Automation 3-29
6.1 Example 3-30

7 Technical data 3-31

Chapter 4 Operating

Auxiliary systems at the user interface 4-4

1 Description of the operating elements 4-5

1.1 User interface 4-10
User interface layout 4-10
1.2 USB connection 4-13
1.3 Keyboard 4-13

2 Switch on the machine 4-14

2.1 Unlock EMERGENCY STOP 4-14
2.2 Switch on the machine 4-14

3 Switch the machine off 4-16

3.1 Switch the machine off 4-16

4 User interface: Basic settings 4-17

4.1 Calibrate the touchscreen 4-17
4.2 Set language, measuring system, date and 4-18
time
4.3 Switching off the user interface (MMC) 4-18

5 Production 4-19
5.1 Prepare program 4-19

B743en 2011-10-07 Table of contents 0-5

 5.2 Executing a program automatically 4-20
5.3 Displaying program 4-21
5.4 Pause program 4-21
5.5 Aborting a program 4-22
5.6 Performing post-production 4-22

6 Flexible entry into the program 4-23

6.1 Restarting the program after an interruption 4-24
Entry at the point of interruption 4-24
Entry at a piercing 4-26
Entering at a specific part 4-27

7 Modifying technology parameters man- 4-29

ually
7.1 Modifying loading modes 4-29
7.2 Lasertechnologie anpassen 4-29
7.3 Modifying microjoints 4-30
7.4 Modifying sheet technology 4-31
7.5 Modifying the sheet measurement 4-31

8 Manual functions 4-32

8.1 Using manual functions 4-34

9 Working with the production plan 4-35

9.1 Manually creating a production plan 4-36
9.2 Deleting a job 4-36
9.3 Modifying the sequence of the jobs 4-37
9.4 Starting the production plan 4-37
9.5 Resume production plan after an interruption 4-37
9.6 Displaying production overview 4-38
9.7 Displaying the machine or component status 4-38
during re-entry

10 Setup 4-39
10.1 Moving the axes manually 4-39
10.2 Releasing brakes for the Z axis drive 4-39
10.3 MDA 4-40
Creating programs block-by-block 4-40

11 Programming 4-41
11.1 Process Part 4-41

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 Add a part to the partlist 4-41
Process part 4-41
11.2 Create Program 4-43
Create a program 4-43
11.3 Management Part Files 4-44
Manage files 4-44
Delete files or clear folder 4-44

12 Program management 4-45

12.1 Displaying program 4-45
12.2 Edit program 4-45
12.3 Modifying technology parameters in the Edi- 4-46
tor
12.4 Finding and replacing in the NC program 4-47
12.5 Renumbering the program 4-48
12.6 Delete program 4-49
12.7 Exporting program 4-49
12.8 Editing a program 4-49
12.9 Copying a program 4-50

13 Help in the case of problems 4-51

13.1 Switch off the machine if malfunctions occur 4-51
13.2 Activating remote diagnostics 4-51

Chapter 5 Setting work

1 Safety information 5-3

2 Luminous displays on the cutting unit 5-4

2.1 Luminous displays on the upper cutting unit 5-4
2.2 Luminous displays on the lower cutting unit 5-5

3 Center the beam to the nozzle 5-6

3.1 Procedure with adhesive strips 5-6

4 Determining the focal position 5-9

4.1 Procedure 5-9
4.2 CP_FOCUS_COMB focus search program 5-9

B743en 2011-10-07 Table of contents 0-7

 5 Setting work on the pallet conveyor 5-10
5.1 Replace cam assembly 5-10
5.2 Replacing pallet conveyor chain 5-11
Procedure 5-12
Case differentiation 5-12
Procedure in case 1 5-13
Procedure in case 2 5-14

6 Further utility programs and files 5-15

6.1 CP_TRIM_OFF parting cut program 5-15
6.2 CP_CUTTING_TOOLS - utility program for 5-15
the optimization of the parameters
6.3 Files on cutting wear parts of the workpiece 5-15
support

Chapter 6 Maintenance

1 General guidelines 6-4

2 Maintenance Overview 6-6

3 Lubrication 6-9
3.1 Overview 6-9
3.2 Maintenance Instructions 6-10
Central lubrication 6-10
Guide rails on the pallet 6-13
Longitudinal conveyor belt brush lubrica- 6-13
tion
Chain and cam assembly of the pallet 6-14
transport and pallet index

4 Hydraulic unit 6-15

4.1 Maintenance Instructions 6-15
Hydraulic unit 6-15
Hydraulic hoses 6-16

5 Mechanics 6-18
5.1 Overview 6-18

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 5.2 Maintenance Instructions 6-18
Z axis bellows 6-18
Slats, copper installation and slat support, 6-19
area under the pallet changer
X and Z energy chain 6-19
Bulkheads, grid sheets and flaps 6-19
Storage bin for slag and dust, scrap car- 6-20
riage
Pallet conveyor cam assembly 6-20
Disposable container of the compact dust 6-21
extractor
Compact dust extractor purging valves 6-22
CO2 fire extinguishing system in the com- 6-22
pact dust extractor (option)
Tube bend and suction tube of the suction 6-22
system
Longitudinal conveyor belt 6-23
Track rollers of pallets, brass brushes and 6-23
guide rails for the pallet
Calibration plate and nozzle-cleaning 6-23
brushes

6 Pneumatics 6-25
6.1 Overview 6-25
6.2 Maintenance Instructions 6-26
Input controller operating pressure 6-26
40 μm filter for compressed air supply 6-26
Filter B compressed air supply 6-26
Filter A compressed air supply 6-27
Activated carbon filter compressed air 6-27
supply
Cutting gas filter for oxygen and nitrogen 6-28
Filter elements in the compact dust 6-28
extractor
Differential pressure indicator at the com- 6-29
pact dust extractor
Filter-lubricator unit on compact dust 6-30
extractor
Filter (only with the compressed-air cutting 6-31
option)
Microfilter (only with the compressed-air 6-31
cutting option)
Activated carbon filter 1 (only for the com- 6-32
pressed-air cutting option)

B743en 2011-10-07 Table of contents 0-9

 Activated carbon filter 2 (only for the com- 6-32
pressed-air cutting option)
Spraying equipment 6-34

7 Machine cooling circuit 6-36

7.1 Maintenance Instructions 6-36
Process cooler 6-36

8 External cooling circuit laser 6-42

8.1 Maintenance Instructions 6-42
External laser process cooler 6-42

9 Electrics 6-44
9.1 Maintenance Instructions 6-44
Switch cabinet 6-44
Safety light barrier 6-49

10 Optic 6-50
10.1 Overview 6-50
10.2 Maintenance Instructions 6-50
Cartridge in the cutting unit 6-50

Chapter 7 Safety light barrier

1 Safety light barrier SICK M 4000 7-2

2 Installation of safety light barrier 7-3

2.1 Installing mirror columns 7-3
2.2 Aligning mirror columns 7-3

0-10 Table of contents 2011-10-07 B743en

 Chapter 8 Test certificate on the noise level
of the TruLaser 5030 (L41)

1 Test certificate 8-2

2 Measurement result 8-4

3 Position of the measuring points 8-5

Chapter 9 Nozzle changer

 

B743en 2011-10-07 Table of contents 0-11

0-12 Table of contents 2011-10-07 B743en
 Chapter 1

Safety

1 Safety regulations 1-3

2 Terms 1-5

3 Operating safety 1-6

3.1 Intended use 1-6
3.2 Authorized personnel 1-7

4 Hazards 1-8
4.1 Overview of laser classes 1-8
Laser classes of the machine 1-8
Laser classes of laser device and compo- 1-9
nents
4.2 Hazards due to laser radiation 1-9
4.3 Hazards due to secondary radiation 1-10
4.4 Fire hazard 1-11
Machining highly reactive materials 1-12
4.5 Dangers from magnetic fields 1-12

B743en 2011-10-07 Safety 1-1

 Linear drives 1-12
4.6 Dangers due to the switch cabinet 1-13
4.7 Live parts 1-14
4.8 Hazards when dealing with workpieces 1-14
Sharp-edged workpieces 1-14
Dangers due to accessing the pallet 1-15
4.9 Danger due to Teleservice 1-15
4.10 Hazardous substances 1-16
Dusts, aerosols and gases 1-16
Hazardous materials due to cutting oils 1-17
Hazardous substances derived from poly- 1-17
ethylene films

5 Measures to be taken by the manufacturer 1-18

5.1 Danger zones and safeguarding device 1-18
5.2 Danger signs on the machine 1-20

6 Measures to be taken by the owner 1-23

6.1 Observing warnings and danger signs 1-23
6.2 Training and instructing operators 1-23
Measures applicable worldwide 1-23
Protection against radiation: Additional 1-24
measures in the Federal Republic of Ger-
many
Protection against radiation: Additional 1-25
measures in the USA
6.3 Adhering to the duty of care when handling 1-25
the machine
6.4 Pay attention to water protection 1-26
6.5 Using spare parts, accessories, software and 1-27
operating materials
6.6 Fire in the compact dust extractor 1-28
Extinguishing the fire in the compact dust 1-28
extractor (Handte) without the CO2 fire
extinguishing system

7 Overview of residual risks 1-30

8 Disassembly and disposal 1-32

1-2 Safety 2011-10-07 B743en

 1. Safety regulations

Regulations and guidelines With the CE marking and the EC Declaration of Conformity,
TRUMPF confirms that the machine corresponds to the basic
safety and health-related requirements of the EC Machinery
Directive.
This TRUMPF machine was registered and certified for North
America by the US Food and Drug Administration (FDA), Center
for Devices and Radiological Health (CDRH), as per the Federal
Performance Standard Title 21 Chapter 1 Section 1040.
The CE marking is located on the nameplate of the machine.
The EC Declaration of Conformity is delivered along with the
machine.

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

Note
The operator must adhere to the valid safety and accident pre-
vention regulations of the respective country and the safety laws
of the state and of the region!

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

A warning contains signaling words that have been explained in

the following table:

Signaling word Description

DANGER ... refers to great dangers. Death an If not avoided, it
can result in death and serious injuries.
WARNING ... indicates a potentially dangerous situation. Very
serious injury or considerable material damage can be
the result if it is not avoided.
CAUTION ... indicates a potentially dangerous situation. Minor
injury or material damage can be the result if it is not
avoided.
Tab. 1-1

B743en 2011-10-07 Safety regulations 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 Safety regulations 2011-10-07 B743en

 2. Terms

Term Meaning
Laser Device for generating laser radiation. Lasers consist of a resonator that comprises a
laser active medium and mostly a reflective and translucent mirror.
Laser device Laser plus components for operating the laser such as control technology, energy sup-
ply, cooling system, gas system etc.
Laser system Machine, to which a laser device is connected or should be connected later. The
terms machine and laser system are used as synonyms in this document.
Laser network A laser network is comprised of several processing systems which are connected to a
laser device via laser light cable. The processing systems can use the laser radiation
in alteration.
Processing optics Processing optics is a generic term. It can mean either a laser cutting head, a laser
welding head or a combination head depending on the machine.
Terms Tab. 1-2

B743en 2011-10-07 Terms 1-5

 3. Operating safety

The machine can become a source of danger if it is used inap-

propriately or for purposes other than those intended:
■ Dangers to the safety of the operator.
■ Damage to the machine and other material assets of the
operator.
■ Negative effect on the effective functioning of the machine.

Area of application in the USA:

■ Notice: Use of controls or adjustments or performance of pro-
cedures other than those specified herein may result in haz-
ardous radiation exposure.

3.1 Intended use

Machine The operator may use the machine only in the industrial sector.
The installation, operating and transport conditions prescribed by
TRUMPF must be adhered to and the maintenance work must
be performed. The installation and operation must comply with
the relevant national regulations that are valid in the country of
operation. The operator must adhere to the national regulations.
The operator may laser cut the materials described in the data
collection. The operator may process other materials only after
consulting TRUMPF.

Note
Standard values for the evenness of metallic materials for hot
rolled sheets are DIN EN ISO 9444-2 and DIN EN 10051 and for
cold rolled sheets DIN EN 10131.

The laser device may be operated, only if all protective and

safety devices are in place and working.
In case of malfunctions, the laser device must be switched off
immediately and prevented from being switched on again.

The following is not allowed:

■ Unauthorized alteration or conversion of the machine by the
operator or personnel.
■ Operating the machine with a laser device that TRUMPF has
not supplied with this machine, without consulting TRUMPF.

1-6 Operating safety 2011-10-07 B743en

 ■ Any working procedure that impairs the safety.
■ Laser cutting
− of plastics.
− of wood.
− of sheets layered with PVC foil.
− of magnesium.

Laser protection device The machine's laser protection devices, for example the window
of the safety cabin, are designed for the wavelength and the
power of the laser device delivered with the machine. If a laser
device is connected with a different wavelength or power, or if
the machine was supplied without a laser, then the user is
obliged to check the effectiveness and suitability of the existing
laser protection devices. The user is responsible for safe opera-
tion.

Laser network If a product from a different manufacturer is connected to a

TRUMPF laser device or if a TRUMPF product is connected to
the laser device of a different manufacturer, then the user is
responsible for the safe operation of the laser network.

Exemption from liability Any other form of use is considered unauthorized use. TRUMPF
is not liable for any damage, especially personnel injuries and
production failures resulting from this. The risk is borne solely by
the operator. The machine warranty will be voided.

3.2 Authorized personnel

■ Operation, setting and maintenance work may only be carried

out by authorized, trained and instructed personnel.
■ Qualified personnel may:
− Transporting the machine to the installation site.
− Carry out work at the laser-specific, hydraulic, pneumatic
and electrical modules.
− Disassembling the machine.

B743en 2011-10-07 Authorized personnel 1-7

 4. Hazards

4.1 Overview of laser classes

Laser systems are classified 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.

Laser class Description

1 The accessible laser radiation is not dangerous under sensibly predictable
conditions.
2 The accessible laser radiation lies in the visible spectral range (400 nm to
700 nm). It is not dangerous for the eyes when the exposure time is limi-
ted (up to 0.25 s). 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 clos-
ing the eyelids.
4 The accessible laser radiation is very dangerous to the eyes and danger-
ous to the skin. Diffused radiation can also be dangerous. The laser radia-
tion can lead to a risk of fire and explosion.
Safety precautions must be implemented for laser devices of class 4; ade-
quate eye protection is primarily important.
Laser systems of class 4 are usually sufficiently powerful in order to burn
the skin, extinguish the fire and ionize the atmosphere during focussing.
Thus, a series of additional safety measures is required.
Overview of laser classes Tab. 1-3

Laser classes of the machine

Operation Description Laser class

mode
Normal mode Normal mode is the mode of Characteristics: 1
the machine in the entire ■ The machine is controlled by a program or
scope of function including the
by hand.
maintenance work that has
been described in the opera- ■ The protective devices are activated.
tor's manual. ■ The processing optics is in working position
above the workpiece when the laser beam
is switched on.
■ The personnel is located outside the danger
zone.
Service mode Service mode is the mode of Service work includes the following: 4
the machine for service work. ■ Setting up optical assemblies of the
machine.
■ Adjustment and checking of the laser beam.
Laser classes of the machine Tab. 1-4

1-8 Hazards 2011-10-07 B743en

 Laser classes of laser device and
components

Laser device, component Laser class

■ Laser device with open hood. 4
■ Pilot laser at the emission opening of the laser 3R
device.
■ Pilot laser upon leaving the focusing lens. 2
■ Laser device with closed hood. 1
■ Laser light cable.
Laser classes of laser device and components Tab. 1-5

4.2 Hazards due to laser radiation

Solid-state laser TruDisk The TruDisk is a laser class 4 solid-state laser.

Solid-state lasers generate intensive light in the invisible near-
infrared spectral range with a wave length of 1030 nm.
Biological tissue absorbs light in different ways. It is usually con-
verted into heat and causes thermal damage (e.g. burns,
destruction of protein) and permanent retina damage.
Eyes and skin are especially at risk due to direct and reflective
laser radiation.

Invisible, high-energy laser radiation!

DANGER
Severe skin burns and eye injuries may occur. Effect on the
sight and blindness!
Ø Operate machines only with active safety devices.

Invisible, high energy laser radiation in the service mode!

DANGER
Severe skin burns and eye injuries may occur. Effect on the
sight and blindness!
Ø All setting work in the service mode may be carried out only
by specially trained service and technical personnel.
Ø Protective gloves and laser safety glasses must be worn
during setting work with the laser switched on.
Ø Pay attention to the danger signs and warning symbols.

B743en 2011-10-07 Hazards due to laser radiation 1-9

 Incorrect laser safety glasses!
WARNING
Serious eye injuries. Impairment to sight and blindness!
Ø Do not mix up laser safety glasses for lasers with differing
wavelengths.
Ø Before using laser safety glasses, check whether they are
approved for the wavelength of the laser radiation.

Pilot laser TruDisk The laser device can contain laser diodes of laser class 3R. The
red light of the laser diodes is used for adjustment work on the
machine.

Eye injury due to laser radiation!

WARNING
Laser radiation damages the eyes permanently.
Ø Do not look directly into the beam.

Wavelength 635 nm to 650 nm

Max. power output ≤5 mW
Pilot laser laser class 3R
Pilot laser technical data Tab. 1-6

4.3 Hazards due to secondary radiation

There is secondary radiation (wavelength range: 100 nm to

1 mm) during laser machining. It is composed of ultraviolet
(<400 nm), infrared (> 780 nm) and visible radiation. The safety
cabin and the viewing window screen the ultraviolet radiation
effectively. The part of the infrared radiation is negligible.
A possible hazard for the operator exists in connection with pro-
longed eye contact with the machining point caused by the visi-
ble radiation in the wave range of 380 nm to 780 nm. A bright
intensive light that can cause permanent damage to the retina is
generated as a result of plasma formation particularly during
high-speed cutting, the piercing or machining of, e.g., galvanized
sheet steel, titanium, aluminum and stainless steel.
The high-speed cutting of galvanized sheet steel is particularly
critical. Depending on national legislation, the acceptable exposi-
tion time (time that the operator may look directly into the
machining point without special eye protection) is a few minutes
per workday.

1-10 Hazards due to secondary radiation 2011-10-07 B743en

 Danger due to secondary radiation during laser machining
WARNING
Intense visible radiation irreversibly damages the retina.
Ø Never look directly into the machining point without proper
eye protection.
Ø If necessary, wear eye protection: hold tinted glasses in front
of your eyes.
Ø Operate machines only with closed safety cabins.
Ø Do not operate a machine with damaged viewing windows.

4.4 Fire hazard

The following fire extinguishers should be kept ready at the

machine for fire protection:
■ Powder extinguisher (Fire Classification A, B, C) due to the
danger of ignition of the hot slag created during laser
machining.
■ CO2 fire extinguisher (fire class B) for fires in the compact
dust extractor.

Combustible objects in the machine's work area; formation

CAUTION of foil lint when cutting foil-coated aluminum; changes of
material.
Fire in the compact dust extractor.
Ø Do not throw any combustible objects, such as cigarettes or
paper, into the machine's work area.
Ø When cutting foil-coated aluminum: monitor the cutting proc-
ess. If foil lint is produced, cancel the cutting process and
modify the cutting parameters in consultation with TRUMPF.
Ø When changing from aluminum/aluminum alloys to other
metal materials or vice versa: wait until the end of the
exhaust system's lag time and change the container in the
compact dust extractor. Use a separate, marked container
for each material group.
Ø Service the compact dust extractor on a regular basis. Reg-
ularly empty and clean the container or drawer.
Ø Replace the container when the filling level is as indicated.
Ø Ensure that the gasket on the upper edge of the container
forms an airtight seal. Use an original container from the
manufacturer.
Ø The manufacturer must be informed immediately if there is a
fire in the compact dust extractor. The compact dust extrac-
tor may not be repaired after a fire by anyone except the
manufacturer.

B743en 2011-10-07 Fire hazard 1-11

 Machining highly reactive materials

Titanium Titanium is a highly reactive material. In the event of a fire, met-

allic titanium reacts with conventional extinguishing agents, such
as water, N2, CO2, which is why they are not permitted as
extinguishing agents.

Fire hazard due to titanium reacting with other substances!

CAUTION
Ø Only use fire extinguishing systems of fire class D to extin-
guish fires.
Ø Do not extinguish fires with water, N2 or CO2.
Ø Process titanium only with the required safety devices.

Required safety devices The laser cutting machine may be used to cut titanium only in
combination with the following safety devices:
■ Precoating system with sorpexin dosing unit. The precoating
system enables the continuous addition of sorpexin (378651).
Sorpexin reduces the fire load of dust.
■ Automatic inert gas extinguisher system with argon as extin-
guishing gas.

4.5 Dangers from magnetic fields

Linear drives

The machine is equipped with linear motors (drives in Y and Z

direction). The installed permanently magnets generate a strong
magnetic field and a high ferromagnetic attraction force (attrac-
tion force secondary part 20 kN).
The magnetic field and the attraction force are always effective
when the main switch is switched off.

Notes
■ Operation, as well as maintenance and service work may be
carried out only by properly instructed personnel.
■ The entire length of the linear drives is covered with bellows.

Malfunction of a pacemaker due to strong magnetic fields

DANGER of the linear drives!
Ø Keep a minimum distance of 30 cm from the linear drives.
Ø Notify personnel, visitors, or visiting personnel of the dan-
gers for persons with a pacemaker.

1-12 Dangers from magnetic fields 2011-10-07 B743en

 Magnetic flux density The magnetic flux density is greatest on the surface of the linear
motors, approx. 360 mT (milli tesla). If the distance is 30 cm, the
value is approx. 30 μT (micro tesla).
According to modern medical standards, values up to 100 μT
with a permanent load and a frequency of 50 Hz, are medically
harmless for persons in good health (DIN VDE 0848, Part 4).

High attractive force Due to the high force of attraction, be particularly careful in the
immediate proximity (distance <50 mm) of the secondary parts
(moveable upper parts). The magnetic attraction forces are effec-
tive in the nearby area and can increase to >1 kN in case of
medium objects.
Heavy (>1 kg) or flat (>10 cm2) objects made out of steel or iron
should not be carried by hand in this area.

Risk of injury due to strong magnetic fields of the linear

WARNING drives!
Ø Do not carry any heavy ferromagnetic parts (metal sheets,
tools) in the hands near the drives.
Ø Do not remove the bellows from the linear drives.
Ø Keep watches and magnetic storage mediums (diskettes,
credit cards) away from the drives.
Ø If body parts still get caught between a linear drive and a
ferromagnetic part, separate the parts stuck together away
from each other using a pointed key (10–15°) made of non-
magnetic material (e.g. V2A) or drive them apart using a
non-magnetic hammer and key.

4.6 Dangers due to the switch cabinet

The switch cabinet may be opened only by a specialist electri-

cian.

Electrical voltage!
DANGER
Electric shock!
Ø Keep the switch cabinet closed.
Ø Every time before opening the control cabinet: switch off the
machine and wait for the cooling phase (minimum
5 minutes).

B743en 2011-10-07 Dangers due to the switch cabinet 1-13

 Hot components!
CAUTION
Risk of burns!
Ø Keep the switch cabinet closed.
Ø Each time before opening the control cabinet, switch off the
machine and wait for the cooling phase (minimum
5 minutes).

4.7 Live parts

Live parts!
DANGER
Risk of electric shock!
Ø Only an electrician may work on electrical devices.
Ø Before repair work: Switch off the laser device and secure it
against being switched on again.
Ø Before touching: check whether the parts are de-energized.

4.8 Hazards when dealing with

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 protective gear.

1-14 Live parts 2011-10-07 B743en

 Dangers due to accessing the pallet

Risk of injury due to a fall.

WARNING
When climbing onto or standing on the pallet while it is in
the pallet changer or the machine, there is a risk of slipping
on an oily sheet and twisting one's ankle, for example, or
falling between the carrier slats, especially when if the
distance between them is to large.
Ø Do not climb onto or stand on the pallet.
Ø Unload the pallet always outside the machine; separate the
scrap skeleton with separating cuts first.
Ø Use additional equipment, such as magnet grippers, hooks,
grippers or suction cups to remove parts from the outside.
Ø If necessary, resort to using automation solutions such as
the LiftMaster, auxiliary pallets etc.

4.9 Danger due to Teleservice

Teleservice establishes a connection (Internet or modem)

between the machine and a service technician at TRUMPF.
The service technician can access the user interface to analyze
problems and in some cases to eliminate them directly.
For some errors it can be necessary for an operator to trigger
machine movements while another person is in the danger zone.
In such cases the TRUMPF service technician will expressly
inform you of this during the Teleservice session.

Entering the danger zone when Teleservice is active!

WARNING
Injury and damage to property due to machine movements.
Ø Only persons trained by TRUMPF may take part in a Tele-
service session.
Ø If doubts arise regarding the qualifications of the persons
involved or if comprehension issues arise, TRUMPF can
refuse Teleservice or terminate the Teleservice session.
Ø If the danger zone has to be entered e.g. to eliminate faults,
a second person must be present.
Ø The speed of dangerous movements should be reduced as
far as possible.

B743en 2011-10-07 Danger due to Teleservice 1-15

 4.10 Hazardous substances

Processing generates smoke and particles. Heavy metal vapors

can arise during metal processing. They can damage body tis-
sues and organs.
In the case of hazardous substances, TRUMPF indicates the
sources of danger. The user must estimate the danger caused
by a processed material. The user must check and initiate the
required measures.

Non-functioning suction system!

WARNING
Gasses and particles that are hazardous to health enter the
respiratory tract during laser machining.
Ø Only work with an exhaust system which is working order.

Insufficient suction power!

CAUTION
During laser machining, dust can contaminate the machine
and possible get into the airways.
Ø When machining small sheets, the unused areas of the pal-
let must be covered. This is the only way to ensure that the
suction power is used optimally.

Dusts, aerosols and gases

Laser machining of metals leads to the emission of the following

materials:
■ Dusts with a particle size >1 μm.
■ Aerosols with a particle size <1 μm.
An aerosol is a gas with finely distributed solid or liquid
materials.
■ Gases.

Emission when processing The emission depends on the following:

metallic workpieces ■ Cutting and welding speed.
■ Cutting gas pressure.
■ Raw material.

Note
If there is a danger of hazardous emissions (e.g. during the pro-
cessing of stainless steel), the operator must carry out measure-
ments and implement safety measures.

1-16 Hazardous substances 2011-10-07 B743en

 In the Federal Republic of Germany, the "Technische Regel für
Gefahrstoffe TRGS 560 (Technical Regulation for Hazardous
Substances TRGS 560)" regulates the air recycling for vacuum
disposals and filtering in case of hazardous substances leading
to cancer.

Examples from the Technical Regulation for Metallic Hazardous

Substances leading to cancer:
■ Beryllium compounds.
■ Chrome/nickel compounds.
■ Zinc chromates.

Hazardous materials due to cutting oils

If metallic materials are processed with cutting oils, this might

lead to organic compounds (liquid or gaseous) during laser cut-
ting or welding.

Note
If there is a danger of dangerous emissions, the operator must
carry out measurements and implement safety measures.

Hazardous substances derived from

polyethylene films

Certain materials are covered with a polyethylene film in order to

protect the surface. Polyethylene film is vaporized during laser
cutting. The resulting organic compounds (e.g. alcane) do not
exceed the exhaust air limit values.
However some of the resulting organic compounds lead to smell
load in very small concentrations (ppb area) in the exhaust air.

B743en 2011-10-07 Hazardous substances 1-17

 5. 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.

5.1 Danger zones and safeguarding

device

1 EMERGENCY STOP impact 5 Mirror posts

button 6 Mirror posts
2 Main switch 7 Start posts with receivers and
3 EMERGENCY STOP impact EMERGENCY STOP impact
button on standard installation buttons
laser 8 Safety cabin
4 Mirror posts with transmitters
Danger zone of the TruLaser 5030 (L41) Fig. 58578

Safety light barrier The standard scope of delivery of the machine includes a dual-
beam light barrier for securing the danger zone. The beams of
the safety light barrier run 400 mm and 900 mm above the floor.

Notes
■ In the normal mode, the danger zone of the machine is
secured with the safety light barrier.
■ An interrupted light beam triggers a Feed Hold during opera-
tion: All movements of the machine are automatically stop-
ped.

1-18 Measures to be taken by the manufacturer 2011-10-07 B743en

 Safety cabin The machine with a completely closed safety cabin is supplied,
as a standard, with one or more safety doors. The safety doors
are electrically secured and monitored by the control system.
The safety cabin is equipped with a roll-back roof which prevents
reflected laser radiation or stray radiation from escaping upward
during machining.
The laser beam is ignited only when the safety cabin is closed;
i.e. safety door, roll-back roof and flap in the area where the pal-
lets are inserted must be closed.
If the safety door is opened during machining, then a FEED
HOLD is triggered.
The safety cabin is made of steel sheet. The viewing area is fit-
ted with laser protective windows.
Do not access the roof of the safety cabin.

Main switch The machine is switched on and off via the main switch. The
main switch can be prevented from being switched on again
using a lock.
The main switch has two positions:

Switch setting 0 The machine is switched off and the voltage

supply of the machine is interrupted .
Switch setting 1 The machine is switched on.
Tab. 1-7

Emergency stop impact An EMERGENCY STOP leads to the following:

button ■ The laser beam is switched off. In the event of a deviation
from the standard installation, or in the case of laser devices
which have more than one outlet, the laser is not switched
off; the beam is directed towards the absorber instead.
■ The shutter switch of the installed light path is disabled in the
laser device.
■ The gas supply of the processing gas is interrupted.
■ All axis motions are stopped.
■ All drives are switched off electrically.
■ The hydraulic unit, the compact dust extractor and the
lengthwise and/or transverse conveyor, respectively, are
switched off.

Feed hold A Feed hold leads to the following:

■ All axis motions are stopped.
■ No beam enable for the installed light path.
■ The lengthwise and transverse conveyor belts are switched
off.

B743en 2011-10-07 Danger zones and safeguarding device 1-19

 Beam block key switch The BEAM BLOCK key switch is on the control panel. It can be
turned to two positions. In the right switch setting, the key must
be removed and safely kept.

Left switch setting Beam block not active: the shutter switch of the
installed light path is released.
Right switch setting Beam block active: the shutter switch of the
installed light path is disabled.
Tab. 1-8

Key switch on the laser The key switch on the laser device can be turned into the posi-
device. tions 0 and 1.

Switch setting 0 The key can be removed in this setting. The

unauthorized activation of the laser is preven-
ted.
Switch setting 1 The laser is in the operating state.
Tab. 1-9

Laser warning lamp, laser Laser warning lamps show that the laser light is being emitted at
device the machining point and that the laser is ready to emit laser light
even when laser light is no longer being emitted (in the "Laser is
on" status).

5.2 Danger signs on the machine

Danger signs indicate dangers when operating the machine.

Location of signs Fig. 58618

1-20 Danger signs on the machine 2011-10-07 B743en

 Danger signs indicate dangers when operating the machine.

Sign no. Danger signs

1

Identification of the laser system in normal mode

2 and 3

Laser warning symbol and information plate on covers with safety lock
2 and 4

Laser warning symbol and information plate on covers without safety lock (detachable only with
tools)
5

Laser class identification on the alignment or pilot laser on the beam emission opening.
-

Danger due to laser radiation

-

Danger due to electrical voltage

B743en 2011-10-07 Danger signs on the machine 1-21

 Sign no. Danger signs
-

Risk due to electromagnetic fields

-

Danger due to hot surfaces

-

Persons with pacemakers prohibited

Danger signs on the machine Tab. 1-10

1-22 Danger signs on the machine 2011-10-07 B743en

 6. Measures to be taken by the owner

6.1 Observing warnings and danger

signs

Certain activities can be a source of danger during the operation.

The documentation contains warnings before the instructions for
these activities and danger signs are provided on the machine
(see "Measures to be taken by the manufacturer", pg. 1-18).

6.2 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.
■ Keep personal protective gear ready.
■ As far as possible, ensure personnel wear protective gear
(e.g. gloves, safety shoes, hearing protection, safety
glasses...).
■ Define responsibilities for safety, operation, maintenance, set-
ting work and service.
■ Make it mandatory for the personnel to read the technical
documentation of the machine. Recommendation: ask for a
written confirmation from the personnel.
■ Inform the personnel about the measures for protection
against radiation:
− Inform the personnel about the operating processes of
the laser.
− Use protection against radiation correctly, e.g. wear laser
safety glasses.
− Instruct the personnel about the accident prevention pro-
cedures.
− Explain the biological effects of laser radiation on eyes
and skin.
■ Remove hot workpieces using an appropriate tool.
■ For fault diagnosis and error correction, teleservice estab-
lishes a connection between the machine and a service
employee at TRUMPF. As part of the commissioning of the
machine, the user is informed of the sequence and possible
risks of the teleservice. The operator has to teach safety to
operators who are involved in the teleservice.

B743en 2011-10-07 Measures to be taken by the owner 1-23

Protection against radiation: Only personnel trained and appropriately instructed about in laser
measures for adjusting and radiation may carry out adjusting and setting work in the service
setting work mode. In service mode, the machine corresponds to Laser
Class 4.
■ The personnel must wear laser safety glasses that conform
to the requirements of the European Standards EN 60825-1
or EN 207 (USA: ANSI Z87.1).
■ If necessary, the danger zone must also be secured by the
customer (e.g. with portable barriers made of sheet steel
and/or laser safety glass).

Protection against radiation: Additional

measures in the Federal Republic of
Germany

Observe the accident For the jurisdiction of laws in the Federal Republic of Germany,
prevention regulations the accident prevention regulation "Laser radiation" (BGV B2) of
the employer's liability insurance association is to be strictly
observed.

Appointing a laser safety The user of the machine must appoint a laser safety officer in
officer writing, unless the operator proves that he/she has the expertise
required to monitor the operation of the laser system himself/her-
self. Responsibilities of the laser safety officer are defined by
BGV B 2 and by the guidelines of this accident prevention regu-
lation.

Training facilities in the Federal Republic of Germany include:

■ Berufsgenossenschaft für Feinmechanik und Elektrotechnik
(German Employer's Liability Insurance Association for Preci-
sion Mechanics and Electrical Engineering), Postfach 510580,
Gustav Heinemann Ufer, D-50968 Cologne, Germany.
■ Physikalisch-Technische Bundesanstalt (Physical-technical
Federal Agency), Bundesallee 100, D-38116 Braunschweig.
■ TÜV Akademie Bayern/Hessen GmbH (Technical Inspection
Academy of Bavaria/Hesse Ltd), Postfach 210420, Westend-
straße 199, D-80686 München, Germany.
■ Technische Akademie Esslingen, Postfach 1265, In den Anla-
gen 5, 73760 Esslingen, Germany

1-24 Training and instructing operators 2011-10-07 B743en

 Protection against radiation: Additional
measures in the USA

Appointing a laser safety The following instances, the user must appoint a laser safety offi-
officer cer:
■ For class 3B or 4 laser systems.
■ The user operates in the machin in service mode.
The area of responsibility of the laser safety officer is defined in
the ANSI Standard Z136.1. ANSI Z136.1 can be obtained from
the American Laser Institute.
Laser Institute of America (LIA)
13501 Ingenuity Drive, Suite 128
Orlando, FL 32826
www.laserinstitute.org
LIA also offers training courses for laser safety officers.

6.3 Adhering to the duty of care when

handling the machine

Checking the danger zone The operator must always make sure that nobody is within the
and safety devices danger zone before starting up the machine.
The operator may only operate the machine using safety devi-
ces. Safety devices may not be removed or put out of operation,
except when performing maintenance and service work. The
operator must replace and put the safety devices into operation
after completing work.

Once per shift, preferably before starting the production:

■ Check the safety light barriers and the light grids for proper
function.
■ Check the safety cabin, especially viewing window, safety
fencing and service door to ensure that there is no damage:
do not operate the machine if a viewing window is damaged
(deep scorching, hole, crack, bubble formation etc.)

After all work on safety light barriers and light grids, particularly
when the layout has changed:
■ Check the safety light barriers and the light grids for proper
function.

Ensuring the perfect working User:

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.

B743en 2011-10-07 Adhering to the duty of care when handling the 1-25
machine
 ■ 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 immediately press EMERGENCY STOP if
a viewing window is damaged while the laser is in operation.
Machining may not be resumed until the window is replaced
properly.

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

Observe EU Pressure The EC pressure device guideline 97/23/EC and the European
devices guideline Standard EN 378, part 1-4 for the cooling device. The national
regulations in the individual countries must be respected.

The operator must initiate the following measures:

■ Get the cooling unit regularly checked by an expert.
■ A small list of instructions should be attached to the machine
such that it is easily visible and durable.
− A sample with the required data in accordance with EN
378 is contained in the operator's manual of the cooling
unit.
■ A system log should be maintained.
− The operating manual of the cooling unit contains a sam-
ple.

6.4 Pay attention to water protection

Water-pollutant substances (e.g. oil) should not enter the ground

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

The Federal Republic of The principle of precaution is applicable for machines in the Fed-
Germany eral Republic of Germany: water should not become contamina-
ted when using water-pollutant substances (Federal Water Act
WHG).

1-26 Pay attention to water protection 2011-10-07 B743en

 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 and lubri-

cants
Water Hazard Class WHC 2
Hydraulic oil operating pressure 150 bar
Volume of water-pollutant materials ≤1000 l
Hazard level of the machine A
Water protection specifications Tab. 1-11

6.5 Using spare parts, accessories,

software and 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
accessories are used or if spare parts and accessories
approved by TRUMPF are not installed or replaced properly.
■ TRUMPF cannot be held liable for damages resulting from
the installation or operation of software which is not approved
by TRUMPF.

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 safety
regulations data sheet has been prescribed for the manufacturer of the oper-
ating material (European Directive 1907/2006 REACH), the
instructions in it must be followed, such as:
■ Chemical properties.
■ Physical and safety-related specifications.
■ transport.
■ Regulations
■ Safety measures, storage, and handling.
■ Procedures in the event of accidents or fires.
■ Specifications for toxicology and ecology.
■ Waste code with prescribed disposal method for the operat-
ing materials.

B743en 2011-10-07 Using spare parts, accessories, software and 1-27

operating materials
 Note
Safety data sheets can be obtained from the manufacturers of
the respective operating materials.

6.6 Fire in the compact dust extractor

Extinguishing the fire in the compact dust

extractor (Handte) without the CO2 fire
extinguishing system

Means, Tools, Materials

■ CO2 fire extinguisher (fire classification B) for fires in the
compact dust extractor and smaller fires at the machine.
■ Powder extinguisher (Fire classification A, B, C) for fires,
which cannot be extinguished with the CO2 fire extinguisher
and/or as a backup for when the CO2 fire extinguisher is
exhausted.

Burns due to flames and hot components!

WARNING
Ø Open the door of the compact dust extractor only with
someone else standing by to cover you.
Ø Hold the fire extinguisher ready.
Ø Only touch hot components with protective gloves.

Note
The extinguishing openings at the compact dust extractor are
marked with a label.
1. Press the EMERGENCY STOP impact button.
2. Switch off the MAIN SWITCH.
3. Wear work gloves.
4. Provide CO2-fire extinguishers.
5. Remove the cover of the spray opening for the CO2 fire
extinguisher. The spray opening is marked with a sign.

Note
To ensure that the extinguishing agent is not suctioned off
immediately, wait for the end of the 30 s lag time of the fan
in the compact dust extractor.
6. Push the foam tube of the CO2 fire extinguisher all the way
into the extinguisher opening.

1-28 Fire in the compact dust extractor 2011-10-07 B743en

 7. Insert the extinguishing agent intermittently into the compact
dust extractor.
8. Close the spray opening again with the cover.
9. If flames appear again, reextinguish them with a powder
extinguisher.
− Remove the cover of the spray opening for the powder
extinguisher. The spray opening is marked with a sign.
− Push the nozzle of the powder extinguisher into the
spray-in opening.
− Insert the extinguishing agent intermittently into the com-
pact dust extractor.
10. Do not open the door of the housing until smoke has ceased
to develop and the device has cooled down noticeably.

B743en 2011-10-07 Fire in the compact dust extractor 1-29

 7. Overview of residual risks

The machine has residual risks in spite of its safety devices and
construction type.
The following overview of residual risks is a summary of the
main potential threats to life and limb posed by the machine.
Any additional precautions that can be taken by the machine
owner to reduce residual risks are specified in the overview of
residual risks.

Residual risks Hazard area Type of danger Measure to be taken by

the user
Mechanics
Squeezing or impact Motion of the X, Y and Z Risk of injury -
axes, of the pallet, con-
veyor belts.
LiftMaster (Option), Load- Risk of injury -
Master (Option).
Loading and unloading Risk of injury --
cart (option).
Storage system (option). Risk of injury -
Roll-back roof Risk of injury Do not grasp or use the
upper edge of the safety
cabin in the area around
the guide or the back stop
of roll-back roof as a sup-
port.
Shearing Raising, lowering, and Risk of injury -
traveling of the pallet
Cutting and cutting to size Sharp-edged workpieces Risk of injury ■ Wearing protective
clothing and gloves.
■ Use of tools to remove
workpieces.
By interception or coiling Chain drive of the pallet Risk of injury -
changer.
Due to being drawn in or Pallet movement on upper Risk of injury -
caught track.
Due to fluids and gases Cutting gas Risk of injury -
being expelled under high
Hydraulic oil Risk of injury -
pressure
Electrics
Electrical contact and Directly with parts that are Risk of fatal injury -
proximity to parts under normally live.
high voltage
Indirectly with parts that Risk of fatal injury -
are live due to defects.
Contact with parts storing Risk of fatal injury -
electrical charges.
Heat
Due to thermal radiation Ejected slag spatters Risk of injury -
or spurting, melted parts.
Due to touching Hot workpieces Risk of injury -

1-30 Overview of residual risks 2011-10-07 B743en

 Residual risks Hazard area Type of danger Measure to be taken by
the user
Due to flames or explo- Fires/detonations due to Risk of injury -
sion concentration of oxygen
Radiation
Laser Radiation during service Risk of injury Wear protective clothing
work. and laser safety glasses.
Secondary radiation (extremely bright and intensive light at the machining point)
Eye contact Due to plasma formation, Risk of injury ■ Personal eye protec-
intense, visible radiation at tion: wear glasses with
Permanent damage to the
the machining point darkened lenses or
retina
hold a darkened plate
in front of your eyes.
■ Observe national regu-
lations.
Magnetic fields
Strong magnetic field due Linear drives Danger to life of persons ■ Persons with pacemak-
to permanent magnet with pacemakers ers must keep a mini-
Expanding magnets on
regardless of the switch- mum distance of 30
the LoadMaster (optional)
on condition of the cm.
machine ■ Have a key and ham-
mer of non-magnetic
material available.
Materials
Through contact with or Cutting gas, dust, aero- Health hazard ■ Ventilate the workplace
by inhaling toxic fluids, sols, cutting oils, PE- sufficiently.
gases, mist, vapors, and coated profiles ■ Observe the notes in
dust. the operating manual.
Thermally decomposed Health hazard ■ Observe prescribed
lenses or mirrors measures in the event
of an accident.
■ Dispose of corrupted
lenses properly.
Fire and explosion
Fire hazard Entire system Risk of injury Estimate danger of fire as
part of the operational
hazard analysis. Imple-
ment appropriate fire pro-
tection measures in
accordance with valid
national regulations.
Beam guidance Risk of injury -
Reflection of laser radia- Risk of injury -
tion
Compact dust extractor Risk of injury ■ Keep a CO2 hand-held
fire extinguisher ready
(fire classification B).
■ Keep a powder hand-
held fire extinguisher
ready (fire classification
A,B,C).
Malfunction or incorrect function
Malfunction of energy sup- Drives Risk of injury -
ply
Control voltage Risk of injury -
Residual risks Tab. 1-12

B743en 2011-10-07 Overview of residual risks 1-31

 8. Disassembly and disposal

TRUMPF recommends that TRUMPF machine tools be disas-

sembled and disposed of by TRUMPF customer service or a
specialist disposal company. The following notes are to be
passed on to the specialist disposal company executing the dis-
posal work, to guarantee fast, environmentally friendly and safe
disposal.
The following points should be observed when disposing of a
TRUMPF machine tool.

Preparing disassembly ■ Contamination, in particular types of dust which can be stir-

red up or which be hazardous during disassembly are to be
removed.
■ Close off the disassembly and storage area over a wide
area.
■ Move down movable parts and suspended loads as far as
possible. Secure or support suspended loads in the event of
a defective machine.
■ Have the machine disconnected from the mains by a trained
electrician and earth the laser RF generator with a grounding
rod if necessary.
■ If necessary, close the compressed air supply and gas sup-
ply and disconnect them from the machine.
■ Depressurize components under pressure (e. g. diaphragm
accumulators).
■ Wait at least an hour to allow any residual voltage in the
machine to dissipate and hot components to cool down. All
assemblies/components can then be touched.

Overview of hazardous ■ The following hazardous substances are to be disposed of

substances according to applicable legislation prior to disassembly:

Hazardous substance Installed in assembly

Arsenic Diodes (Solid-state laser)
Refrigerant
Lubricant container Basic machine
(e. g. central lubrica-
tion)
Cooling water with bio- Process cooler
cides
Filter plates Compact dust extractor
Metal dust Compact dust extractor
Batteries Switch cabinet, APC, control system, ...
Possible hazardous substances Tab. 1-13

1-32 Disassembly and disposal 2011-10-07 B743en

 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 and are to be carefully brought
into a good transport position(center of gravity down).
■ Movable assemblies can be unbraked after being disconnec-
ted from the mains!
− Fix movable assemblies prior to disassembly/transport, so
that the center of gravity cannot move in an uncontrolled
manner.
■ Mechanical stresses can be released when undoing chains,
ropes and steel constructions!
− Wear suitable protective gear and close off the area over
a wide area.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 can still be under pressure!

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

B743en 2011-10-07 Disassembly and disposal 1-33

1-34 Disassembly and disposal 2011-10-07 B743en
 Chapter 2

Installation conditions for

TruLaser 5030 (L41);
TruLaser 5040 (L47)
Material number 1627817
Graphic number 93735-5-20.en

B743en Installation conditions for TruLaser 5030 (L41); 2-1

TruLaser 5040 (L47) - Version 2
 To what does this apply? 2-4

1 Planning aid 2-5

2 Installation site 2-7

2.1 Space requirements 2-7
2.2 Floor requirements 2-7
Machine without LoadMaster or LiftMaster. 2-8
Machine with LoadMaster or LiftMaster 2-9
and prepared machines
2.3 Weight load 2-10
2.4 Ambient conditions 2-12
2.5 Cabe racks for laser light cables 2-14
2.6 Exhaust air system of the compact dust 2-14
extractor
2.7 Installation of the cooling unit 2-15

3 Gas supply 2-16

3.1 Cutting gases 2-16
Purity 2-16
Cutting gas consumption 2-17
Supply lines for cutting gas supply 2-19
Requirements on the connection point of 2-21
the machine
Cutting gas supply with cylinders or bun- 2-21
dles
Cutting gas supply with gas tank 2-22
3.2 Nitrogen for cutting unit ventilation 2-23

4 Electrical supply 2-25

4.1 Electrical connection 2-25
4.2 Power supply 2-26
Uninterruptible Power Supply (UPS) 2-27
Residual current device (RCD) 2-27
NEC conditions 2-28
Isolating transformer 2-28
4.3 Connected loads, fuse protection and fre- 2-30
quency
4.4 Electrical power input 2-31
4.5 Network connection 2-31
4.6 Teleservice 2-31
4.7 Enhanced shop floor programming 2-32

2-2 Installation conditions for TruLaser 5030 (L41); B743en

TruLaser 5040 (L47) - Version 2
 5 Compressed air supply 2-34

6 Operating materials 2-36

6.1 Gases 2-36
6.2 Cooling water. 2-36

7 Transportation of the machine 2-38

7.1 Measures to be taken by the customer 2-39
7.2 TRUMPF service work 2-40

B743en Installation conditions for TruLaser 5030 (L41); 2-3

TruLaser 5040 (L47) - Version 2
 To what does this apply?
The installation conditions contain all information for preparing
the installation and start-up of the machine including the laser.

Note
The TruLaser 5030 / 5040 is a system for laser cutting metal
materials. The machine is designed for machining flat sheets.
The TruLaser 5030 / 5040 may not be used for laser cutting
plastic material!

Who does what? Customer: All the conditions described in this chapter must be
fulfilled before the machine is delivered.
If this is not the case, the TRUMPF service technicians will not
be able to put the machine into service.
Pass along the respective subsections in accordance with the
following planning aid to the specialist companies/plants (e.g.
electrical installer, specialist plant for industrial gases...) in a
timely manner.

Note
During commissioning, the main switch on the machine may only
be switched on by TRUMPF service personnel.

TRUMPF Service: start-up of the machine is performed by

TRUMPF service technicians.

This includes:
■ Installing, aligning, leveling and securing the machine.
■ Laying laser light cables.
■ Filling up the process cooler.
■ Connecting the machine to the supplies (with the exception
of the electrical power supply).
■ Performing a functional test.
■ Instructing personnel

Note
The machine needs to be topped up with oil if it was shipped by
air freight. An oil pump is supplied as part of the standard equip-
ment. Oil is already in the hydraulic oil tank in all other cases.

2-4 Installation conditions for TruLaser 5030 (L41); B743en

TruLaser 5040 (L47) - Version 2
 1. Planning aid

The planning aid provides an overview of the measures to be

taken and preparations to be carried out.
For details, refer to the corresponding subchapters of these
installation conditions.

Time before the delivery Planning criterion Action required

of the machine
15 weeks Personnel and training ■ Appoint a member of staff to be responsible for
course preparations for the delivery of the machine.
■ Appoint operating and service personnel and pro-
grammers.
■ Arrange training schedules for specialist personnel.
■ Designate laser safety officer in accordance with EN
60825-1 (VBG 93).
14 weeks, but no later Installation site ■ Determine the installation site of the machine, taking
than week... into account the space requirements according to
See point 2: Installation
the installation plan.
site
■ Check the floor requirements:
− Floor quality.
− Evenness.
− 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 the transport route:
− Gateway openings
− Header heights.
− Cable rack heights.
− Room to negotiate around corners etc.
12 weeks but no later Gas supply ■ Install supply lines for the cutting gas supply to the
than week .... installation site.
See point 3: Gas supply
■ Decide about the gas supply method (cylinders, cyl-
inder bundles, gas tank).
■ Observe the required fittings.
■ Plan the gas supply lines in cooperation with the
gas supplier.
12 weeks but no later Electrical supply ■ Install electrical connections at the installation site.
than week .... ■ Lay the conductor cross-section and fuse protection
See point 4: Electrical
supply according to the legal requirements.
Please observe: there can be a different number of
connections depending on the system.
Please note: In some installation versions, e.g. when
the laser unit is set up rather far from the machine, the
basic machine, laser device, and process cooler of the
laser each need a separate electrical connection.

B743en Planning aid - Version 2 2-5

Time before the delivery Planning criterion Action required
of the machine
12 weeks, but no later Compressed air supply ■ Arrange for the installation of the compressed air
than week ... supply at the installation site.
See point 5: Compressed
air supply
4 weeks but no later than Operating materials ■ Stock up on operating materials
week .... − Laser gases (not valid for TruDisk lasers).
See point 6: Operating
materials − Cutting gases.
− Operating materials for the cooling unit.
4 weeks, but no later than Cable racks Mount cable racks for laying the laser light cable.
calendar week....
See point 2: Installation
site
4 weeks, but no later than Teleservice Valid for Teleservice via modem: Install a telephone
calendar week.... socket for the Teleservice modem
See point 4: Electrical
supply Note: Modem is omitted with Teleservice via Internet.
4 weeks, but no later than Network connection The network connection requires a separate power
calendar week.... supply.
See point 4: Electrical
supply Return the network questionnaire to TRUMPF.
4 weeks but no later than Transport Only if the customer performs "machine conveyance"
week .... himself:
See point 7: Transporting
the machine ■ Ensure the required transport aids are available.
4 weeks but no later than Laser safety Valid for Germany:
week ....
Register the laser machining system with the employ-
er's liability insurance association and with the trade
board.
Observe the regulations applicable in the country of
operation.
Make laser safety glasses available for service work,
safety glasses for laser light with a wavelength of
1030 nm.
During installation and Allocate qualified electri- Establish electrical connections to the system.
commissioning cians
Tab. 2-1

2-6 Planning aid - Version 2 B743en

 2. Installation site

What does the customer Please consult a structural analyst for professional support, par-
need to do? ticularly in connection with the topic of "floor requirements", and
give him a copy of the pertinent section.

2.1 Space requirements

The arrangement of the individual components and the space

requirements for the system should be taken from the installation
plan that applies in each case. The space required for opening
the doors of the control cabinets, suction system, cooling unit,
and laser unit is included in the plan.
A special foundation plan or installation plan is required in the
event of deviations from the standard installation plan. The instal-
lation plan delivered with the system is always valid.

2.2 Floor requirements

Evenness ■ The floor on which the system is installed should be as even

as possible.
■ No height differential greater than 12 mm per 10 m /
0.5 inches per 33 ft is permitted across the entire surface
that the system will be set up on.
■ Minor unevenness can be compensated for using adjustable
legs or wedge mounts.

Installation surface ■ The entire installation surface for the basic machine and the
two front legs of the pallet changer must consist of one con-
tinuous base plate with a smooth surface in the area of the
load-bearing points. This applies in particular to the area of
the wedge mounts.
■ Steel fiber concrete without reinforcement is generally not
permissible.
■ If there is a floor heater in the area of the installation sur-
face, it must not be positioned less than 150 mm / 6 inches
below the upper edge of the floor.
■ For newly laid floor/ceiling plates, it is imperative to avoid
setting effects (e.g. during the drying process) which would
exceed the values indicated above and in the following.
■ The maximum position shift permitted for the height of the
two rear legs of the pallet changer is ±1.5 mm /±0.06 inches.

B743en Installation site - Version 2 2-7

 External influences Any changes that result from the machine being tilted should not
move the laser beam on the lens by more than ±0.5 mm /±0.02
inches.

Note
External influences due to changing loads in the immediate vicin-
ity of the system can affect the cut quality of the workpieces.

These include:
■ Fork lifts, industrial trucks, etc.
■ The installation or removal of other machines in the immedi-
ate vicinity of the system.
■ Machines which excite vibrations during operation, such as
punch presses etc.
■ The maximum permissible acceleration at the support points
of the laser (or basic machine) is 0.1x the acceleration due
to gravity.
Exact inspections must be conducted in individual cases.

Case differentiation of the A distinction must be made between two different cases for the
floor quality specifications regarding the requirements for the floor or ceiling
plates:

■ Machine without LoadMaster or LiftMaster

■ Machine + LoadMaster or LiftMaster, as well as prepared
machines which are to be retrofitted with a LoadMaster or a
LiftMaster.

Machine without LoadMaster or LiftMaster.

Elastically cushioned base ■ Effective load 15 kN/m2 / 2.2 psi..

plate ■ Minimum thickness 200 mm / 8 in..
■ Concrete quality (corresponding to a tensile strength of C
25/30):
− Cylinder compressive strength fck ≥ 25 N/mm2 / 3750 psi..
− Cube compressive strength fck, cube ≥30 N/mm2 / 4500
psi..
■ Concrete steel reinforcement with:
− characteristic rated value fy ≥435 N/mm2.
− an elasticity module for which Es ≥200000 N/mm2.
− crosswise upper reinforcement, 3.7 cm2/m / 0.175 in²/ft.
each.

2-8 Floor requirements - Version 2 B743en

 − crosswise lower reinforcement, 3.7 cm2/m / 0.175 in²/ft.
each.
− US specification: reinforced with two layers of #5 reinforc-
ing bars 12 in on center and hookes each way.
■ Elastic cushioning of the floor plate on foundation with a min-
imum ballast number of C ≥5000 kN/m3 (loess loam).
■ The following stipulations apply with respect to joints in the
area of the machine:
− No expansion joints are permitted to be within a minimum
area around the machine legs of 750 mm / 30 inches.
− No dummy joints (i.e. the lower reinforcement is active)
are permitted within a minimum area around the machine
legs of 200 mm / 8 inches.
− A structural analyst must be consulted for all other joints
and for distances less than the specified minimum clear-
ances.

Ceiling plate / free span ■ Effective load 15 kN/m2 / 2.2 psi..

base plate ■ Minimum thickness 200 mm / 6 inches (for load capacity 15
kN/m2 / 2.2 psi.).
■ Plates as multiple span girders.

Note
Calculations must be made by a structural analyst if these
requirements are not met or bearing technology is used!

Machine with LoadMaster or LiftMaster and

prepared machines

Elastically cushioned base ■ Effective load 15 kN/m2 / 2.2 psi..

plate ■ Minimum thickness of 200 mm / 8 inches.
■ Concrete quality (corresponding to a tensile strength of C
25/30):
− Cylinder compressive strength fck ≥25 N/mm2 / 3700 psi..
− Cube compressive strength fck, cube ≥30 N/mm2 / 4400
psi..
■ Concrete steel reinforcement with:
− characteristic rated value fy ≥435 N/mm2.
− an elasticity module for which Es ≥200000 N/mm2.
− crosswise upper reinforcement, 3.7 cm2/m / 0,075 in²/ft.
each.
− crosswise lower reinforcement, 3.7 cm2/m / 0,075 in²/ft.
each.
− US specification: reinforced with two layers of #5 reinforc-
ing bars 12 in on center and hookes each way.

B743en Floor requirements - Version 2 2-9

 ■ Elastic cushioning of the floor plate on foundation with a min-
imum ballast number of C ≥5000 kN/m3 (loess loam).
■

− No expansion joints are permitted to be within a minimum

area around the machine legs of 750 mm / 30 inches.
− No dummy joints (i.e. the lower reinforcement is active)
are permitted within a minimum area around the machine
legs of 200 mm / 8 inches.
− A structural analyst must be consulted for all other joints
and for distances less than the specified minimum clear-
ances.

Ceiling plate / free span TruLaser X030 + LiftMaster TruLaser X040 + LiftMaster
base plate Effective load 30 kN/m2 / 4.4 psi. Effective load 40 kN/m2 / 5.9 psi.
Minimum thickness 250 mm / Minimum thickness 300 mm /
10 inches (for load capacity 30 kN/ 12 inches (for load capacity 40 kN/
m2 / 4.4 psi.) m2 / 5.9 psi.)
Plates as multiple span girders.
Tab. 2-2

Note
Calculations must be made by a structural analyst if these
requirements are not met or bearing technology is used!

2.3 Weight load

Structural stress analysis The load capacity of the floor surface must be subjected to a
structural stress analysis prior to installation. The weights of the
relevant components and the loads on the support points can be
taken from the following overview.

Foundation load Component Weight Distribution of weight

[kg] / [lb]
Basic machine, pallet with
all support slats and max.
workpiece weight
TruLaser 5030 approx. Weight is distributed over 7
8500 / surfaces.
18750
TruLaser 5040 approx. Weight is distributed over 9
14500 / surfaces.
32000
Laser unit TruDisk 3001 approx. Weight is evenly distributed
850 / 1874 over 4 adjustable legs.
Laser unit TruDisk 5001 approx. Weight is evenly distributed
1200 / 2650 over 4 adjustable legs.

2-10 Weight load - Version 2 B743en

 Foundation load Component Weight Distribution of weight
[kg] / [lb]
Pallet changer incl. two
pallets with all support
slats and (2x) max. work-
piece weight
TruLaser 5030 approx. Weight is evenly distributed
3600 / 7950 over 4 surfaces.
TruLaser 5040 approx. Weight is evenly distributed
6500 / over 4 surfaces.
14350
Pallets
TruLaser 5030 2 x 250 / 2
x 550
TruLaser 5040 2 x 370 / 2
x 820
Support rails (pallet loa-
ded up to 50 %)
TruLaser 5030 2 x 150 / 2
x 330
TruLaser 5040 2 x 200 / 2
x 440
Maximum weight of work-
piece
TruLaser 5030 900 / 1990
TruLaser 5040 1200 / 2650
Transverse conveyor 350 / 770 The edges support the
(option) main load
Compact dust extractor
TruLaser 5030 1500 / 591 The edges support the
main load
TruLaser 5040 850 / 1900
Process cooler for 175 / 386 The edges support the
machine (without cooling main load
water)
Process cooler for laser
(without cooling water)
with TruDisk 3001 320 / 706 The edges support the
main load
with TruDisk 5001 600 / 1325 The edges support the
main load
Isolating transformer 550 / 1220 The edges support the
main load
Tab. 2-3

B743en Weight load - Version 2 2-11

 2.4 Ambient conditions

Ambient temperature Notes

■ One-sided exposure to direct sunlight or unidirectional drafts
should be avoided (e.g. with blinds if the control unit is instal-
led at a window).
■ The ambient temperature should be kept constant while oper-
ating the system. A sufficient circulation of air should be
ensured in the factory hall.

Temperature
Operation between +10 °C /
50 °F and +43 °C /
109 °F
According to NFPA
79, the maximum tem-
perature in the USA
and Canada is 40° C /
104°F.
Storage between +5 °C / 41 °F
and +43 °C / 109 °F
Transport between 0 °C / 32 °F
and +43 °C / 109 °F
Relative air humidity maximum 100 % at
24 °C / 75.2 °F. See
the following dew point
diagram.
Permissible ambient temperature Tab. 2-4

Dew point In order to avoid condensation water, the ambient conditions of

the laser device must be within specific limits.

2-12 Ambient conditions - Version 2 B743en

 U Ambient temperature in °C RL Relative air humidity in %
(°C) (%)
Dew point diagram Fig. 59869

When operating the laser device, the values must be within the
gray area of the dew point diagram.
If the required ambient conditions cannot be maintained, appro-
priate conditions must be created artificially for the laser device
(e.g. cabin, air-conditioning).

Tropical version When the ambient temperature is between +35°C / 95 °F and

+43°C / 109 °F the system is delivered in tropical version.

Cooling the control system The control is cooled in the closed switch cabinet via the cooling
circuit of the machine. This protects the components from dirt
and dust to a large extent.
Damp rooms are not suitable for the operation of the control sys-
tems, mainly because contact corrosion can develop on contac-
tors and relay contacts, resulting in control system errors.

B743en Ambient conditions - Version 2 2-13

 2.5 Cabe racks for laser light cables

If the laser device is not set up directly alongside the machine

and if the optical laser cable (LLK) is longer than 20 m
(78.74 in), the following applies:
■ The laser light cable is guided in cable racks from the instal-
lation site of the laser to the machine. The user must install
the cable racks before the machine is delivered.
■ The cable racks are to be constructed as follows:
− Width of the cable racks 250 mm (10 in).
− Use cable racks open on one side made of slats; thus
the cable will be able to be inserted and fastened in
place easily from the side during installation.
− Design the corner elements and transitions in such a way
that a minimum bending radius of 200 mm (8 in) is
always ensured.
■ The distance between the LLK and the low voltage cables
must be at least 50 mm / 2 in.
■ The LLK is not permitted to be laid together with a high volt-
age cable in the same cable rack.
■ If cable racks are used without slats, then the LLK must be
fastened in place with cable binders.
■ Wall openings must have a minimum diameter for 100 mm /
4 in and be designed with smooth surfaces (e.g. with a core
drill).

Note
The laser light cable will be laid by the TRUMPF service techni-
cian!

2.6 Exhaust air system of the compact

dust extractor

The clean gas exhaust air of the compact dust extractor can be
guided into the open air as needed. The exhaust air system
beginning at the clear gas duct of the compact dust extractor
must be installed by the customer.

Pipeline The pipeline must be installed as follows:

■ Maximum of two 90° pipe elbows (radius = diameter x 1.5).
■ Max. length: 10 m / 33 ft.
■ Transition piece on the compact dust extractor; TRUMPF
mat. no.: 346476.
■ Tube diameter: 280 mm / 11 in.

2-14 Cabe racks for laser light cables - Version 2 B743en

 Note
A ventilation technician or the manufacturer of the compact dust
extractor must be consulted in the event of other configurations.
In all cases, the max. resistance of 10 daPa (= 100 Pa) may not
be exceeded.

2.7 Installation of the cooling unit

Platform installation If process coolers malfunction, water or oil can escape from the
device. If cooling units are placed on a pedestal, the area under-
neath the pedestal is at risk.

Escaping cooling water or oil!

NOTICE
Machines, devices, or installations underneath the pedestal
can be damaged or destroyed.
Ø The platform must be designed in such a way that no
escaping water or oil passes can enter the area below the
platform.

Note
The clearance between the top of the process cooler and the
ceiling of the factory hall must be a minimum of 2 m (6.6 ft), to
guarantee sufficient circulation of the warm process cooler
exhaust air.

B743en Installation of the cooling unit - Version 2 2-15

 3. Gas supply

What does the customer Professional gas installation is a basic prerequisite for smooth
need to do? commissioning and trouble-free operation of the installation. The
following chapter must therefore be passed along to the special-
ist company for industrial gases you have contracted with in a
timely manner in accordance with the planning aid.

Notes
■ Urgent recommendation from TRUMPF: The operator should
consult his gas supplier regarding the gas supply.
■ Installation must be performed by a qualified industrial gas
company. A specialized company certified by the DVGW
(German Technical and Scientific Association for Gas and
Water) or a gas and water fitter is not suitable.
■ The appropriate standards must always be observed.

Short circuit or fire hazard when gas lines and electrical

WARNING cables are laid together.
Ø Do not lay gas lines together with electrical cables in a sin-
gle cable duct.
Ø Keep gas lines separate up to the connection point on the
machine.

3.1 Cutting gases

Purity

Cutting gas Purity

Oxygen (O2) 3.5 99.95% by vol.
Nitrogen (N2) 5.0 99.999 % by vol. 1
Argon (Ar) 4.6 99.996 % by vol.
Compressed air See Section “compressed air supply“
Cutting gas purity Tab. 2-5

1 Oxygen impurities of 100 ppm or more can discolor the cutting edges
during high-pressure cutting if nitrogen of low purity is used. This can
only be avoided by using nitrogen with a purity of 5.0 or by a cutting
gas supply from a gas tank (the nitrogen purity in the gas tank is usu-
ally 5.0).

2-16 Gas supply - Version 2 B743en

 In exceptional cases, nitrogen of purity 4.6 (99.996) or other puri-
ties can be used as long as the following limit values are not
exceeded:
■ O2 ≤ 100 ppm
■ H2O ≤ 5 ppm
■ CnHm ≤ 1 ppm
■ Particles ≤100 (for particles ≤0.3 µm with 2.83 l ≙1 ft3)

Cutting gas consumption

The cutting gas consumption depends on the following:

■ Nozzle diameter
■ Cutting gas pressure
■ Duration of laser cutting

Estimating cutting gas To be able to make an approximate estimation of the expected

consumption cutting gas consumption, the consumption rates for standard and
high-pressure cutting are shown in the following. A differentiated
estimate for certain types of material and sheet thicknesses can
be made with the data collection of the machine.

Standard pressure cutting Standard pressure cutting is cutting with a pressure of ≤6 bar /
≤87 psi on the nozzle. Oxygen and/or nitrogen are used as cut-
ting gases.
For standard pressure cutting with O2 the minimum flow pressure
available at the connection point of the machine is 8 bar / 116
psi (with a gas consumption of 10 m3/h / 6 cfm/h, a nozzle of
∅ 1.7 mm and 6 bar / 87 psi cutting gas pressure).

B743en Cutting gases - Version 2 2-17

 d Nozzle diameter p Pressure
V/t Gas volume as per time
Maximum cutting gas consumption per hour during 100% Fig. 55214
ON-time

High-pressure cutting High-pressure cutting is cutting with nitrogen using pressures >6
bar / 87 psi. Normally, nitrogen is used as cutting gas, in rare
cases also oxygen. High-pressure cutting is an option for
machining stainless steel and aluminum alloys.

■ During high-pressure cutting with N2 the minimum line pres-

sure available at the connection point to the machine is
27 bar / 390 psi (with a gas consumption of 90 Nm3/h / 234
cfm/h, a nozzle with ∅ 2.7 mm and cutting gas pressure of
20 bar / 290 psi).
■ During high-pressure cutting with O2 the minimum flow pres-
sure available at the connection point to the machine is
15 bar / 218.5 psi (with a gas consumption of 20 Nm3/h / 52
cfm/h, a nozzle with ∅ 1.7 mm and a cutting gas pressure of
12 bar / 154 psi).

2-18 Cutting gases - Version 2 B743en

 d Nozzle diameter p Pressure
V/t Gas volume as per time [bar]

Maximum cutting gas consumption per hour during 100% Fig. 55213
ON-time

Supply lines for cutting gas supply

Cutting gas connection point

The customer must provide the cutting gas supply lines up to the
connection point on the machine.
■ The supply lines must be installed up to the connection point
on the installation plan indicated by the symbol on the left.
■ The connection point is approximately 300 mmabove floor
height. The connection is established either from below or
from above through the place marked in the installation plan.
■ Pipes should be used for the entire gas installation from the
gas cylinder or central gas tank to the machine.
■ The vaporizer must be designed to accommodate the maxi-
mum consumption of all connected machines. The line from
the vaporizer to the connection point must be kept as short
as possible for this purpose.
■ The external gas installation should be set up in such a way
that the supply lines to the connection point of the machine
and the connection point itself are unable to ice up.
■ Stopcocks must be built in to all supply lines to the individual
machines. This allows the supply lines to be blocked off dur-
ing maintenance and bled via the purge valves at the con-
nection point of the machine.

Note
The gas temperature may not exceed 50 °C / 122 °F. This is of
particular importance if the required gas pressure is generated
by means of pressure booster systems!

B743en Cutting gases - Version 2 2-19

 Pipes ■ Oil and grease-free lines made of special quality copper pip-
ing ("refrigerator quality", inert-soldered with simple forming
gas) are sufficient for the cutting gases.
■ The tubes must be processed without oil and grease.
■ Swagelok clamping ring screw fittings or constructionally
equivalent clamping ring screw fittings are to be used on
screw fittings. No press-fitting systems may be used.

Notes
■ Teflon tape and sealing sprays are not permitted to be used.
■ Sealing points must be secured with flat gaskets.
■ Stainless steel pipes are not necessary.
■ The pipe ends must be sealed securely to avoid dirt in transit
and storage.

Pipeline section Pipe dimen- Nominal

sions width [mm]
For tank installation: 1" or 28 x 25
1.5
From the vaporizer to the ring circuit
Ring pipeline for supplying one or more
laser systems
From the ring pipeline/main supply strand 3/4" or 22 x 20
to the tapping point 1.0
From the tapping point to the connection 3/4" or 22 x 20
point on the machine (N2); switch to 1.0
clamping ring screw for connection diame-
ter 12
From the tapping point to the connection ½" or 15 x 1 13
point on the machine (O2); switch to
clamping ring screw for connection diame-
ter 8
Cutting gas supply: supply line Tab. 2-6

Note
As a general principle, a stopcock must be mounted before each
branch in a ring pipeline in order to make it possible to shut
down the each ring pipeline segment separately
Observe the information in the section titled "Central laser gas
supply" for the installation and pressure and leak tests.

2-20 Cutting gases - Version 2 B743en

 Requirements on the connection point of
the machine

O2 standard O2 High N2 High

pressure pressure
Min. input pressure [flow 8 / 116 15 / 218 27 / 297
pressure in bar / psi
Max. input pressure (stat.) 21 21 / 305 33 / 480
2[bar/ psi]
Max. cutting gas pressure 6 / 87 12 / 175 25 / 365
[bar / psi]
Volume rate of flow3 [m3/h / 10 / 5.9 45 / 24.3 98 / 58
cfm]
Nozzle diameter [mm] 1.7 2.7 2.7
Tab. 2-7

Cutting gas supply with cylinders or

bundles

Note
Cylinders or bundles are not suitable for high-pressure cutting
with N2.

Cylinders or bundles ■ The supply of cutting gas with pressure reducers for cylin-
ders or bundles require increased handling, however, due to
the high level of consumption. One bundle consists of twelve
cylinders = approx. 120 Nm3 / 13 200 gal gas.
■ The gas flow is interrupted when changing the cylinder or
bundle.

Cylinder banks or cylinder ■ Switchover devices are required for uninterrupted operation
bundle banks with bottle or cylinder banks.
■ The switchover is performed manually or automatically.4
■ Cylinder banks or cylinder bundles are frequently installed at
some distance from the laser machine. For this reason, the
use of a tapping point pressure reducer close to the laser
system is recommended.

2 The machine is equipped with blow-off valves that respond at high

input pressure, making a whistling sound in the process.
3 The volume rate of flow depends on the maximum cutting gas pres-
sure selected and the nozzle diameter specified.
4 We recommend using a signaling unit for automatic switchover, since
otherwise both sides of the cylinder or bundle bank could be drained
without being noticed.

B743en Cutting gases - Version 2 2-21

 Pressure control O2 Standard pres- N2 High pressure
specifications sure
Admission pressure 0-200 / 0-2900 0-200 / 0-2900
in bar / psi
Max. permissible 25 / 360 40 / 580
back pressure in
bar / psi
Min. flow rate in 30 / 18 90 / 54
Nm3/h / cfm
Other requirements Suitable for oxygen Oil and grease-free
Oil and grease-free
Cutting gas supply: pressure control specifications Tab. 2-8

Note
The pressure must be monitored by installing the specified pres-
sure regulators on the supply unit. The pressure regulators must
be secured against the maximum input pressure (intrinsically
safe).

Cutting gas supply with gas tank

■ A tank system is appropriate for safe gas supply at a gas

consumption of at least about 200-400 Nm3/week /
7000-14,000 ft³.
■ The optimum tank size depends on the tapping quantity and
on the local conditions.
■ The customer should consult the gas supplier.

The following are requirements for high-pressure cutting with

nitrogen:
■ Do not use a tapping point pressure regulator between the
gas tank and the machine behind the pressure regulating
station.
■ Between the gas tank and the machine, a stop valve must
be installed at the end of the pipeline, i.e. at the machine
entrance.

O2 Stand- O2 high N2 High

ard pres- pressure pressure
sure
Required pressure [bar / 18 / 261 36 / 522 36 / 522
psi]
Minimum required tapping 14 / 203 16 / 232 29 / 421
pressure [bar / psi]
Cutting gas supply: Tank system Tab. 2-9

2-22 Cutting gases - Version 2 B743en

 Pressure control O2 Stand- O2 high N2 High
specifications ard pres- pressure pressure
sure
First pressure stage
(tank)
Safety pressure regula- Optional Optional Recommen-
tion system5 ded
Second pressure stage
(tapping point)
Tapping point pressure Recommen- Recommen- Not recom-
regulator ded ded mended
Back pressure [bar / psi] 0 -16 / 4-25 / -
0-232 58-363
Other requirements Suitable for Suitable for Oil and
oxygen; free oxygen; free grease-free
of oil and of oil and
grease grease
Cutting gas supply: pressure control specifications Tab. 2-10

3.2 Nitrogen for cutting unit ventilation

Purity Nitrogen (N2) 5.0, i.e. 99.999% by vol.

Input pressure An input pressure of at least 11 bar must be
ensured for cutting unit ventilation with nitrogen,
regardless of the cutting gas.
Nitrogen consump- The cutting unit ventilation has the following
tion nitrogen consumption: max. 0.9 Nm³/h / 0.6 cfm
Nitrogen for cutting unit ventilation Tab. 2-11

In exceptional cases, nitrogen of purity 4.6 (99.996) or other puri-

ties can be used as long as the following limit values are not
exceeded:
■ O2 ≤ 100 ppm
■ H2O ≤ 5 ppm
■ CnHm ≤ 1 ppm
■ ≤100 particles (for particles ≤0.3 µm (with 2.83 l ≙ 1 ft2)

Note
It is recommended not to switch off the nitrogen supply off after
switching off the machine, so that nitrogen still flows through the
cutting unit when the machine is switched off (consumption of
approx. 1 Nl/min). This creates constant excess pressure in the

5 The safety pressure regulation system is installed close to the tank. It

ensures uniform pressure in the circuit. The built-in pressure relief
valve ensures that gases are blown away into the open air in the
event of malfunctions. In this way, risks are avoided in the area of the
laser system due to a concentration of oxygen (O2) or depletion of
oxygen (N2).

B743en Nitrogen for cutting unit ventilation - Version 2 2-23

 cutting unit, which prevents particles of dirt from entering the cut-
ting unit from the ambient air.

2-24 Nitrogen for cutting unit ventilation - Version 2 B743en

 4. Electrical supply

What does the customer Professional electrical installation is a basic prerequisite for
need to do? smooth commissioning and trouble-free operation of the installa-
tion. The following chapter must therefore be passed along to
the specialist company for electrical installation you have
contracted with in a timely manner in accordance with the plan-
ning aid.

4.1 Electrical connection

The machine was designed for the following nominal voltages:

Nominal voltage Frequency

400 V ±10 % 50 Hz ±1 %
460 V +10%/ -5% 60 Hz ±1 %
Nominal voltage and Frequency Tab. 2-12

An isolating transformer must be installed if the existing nominal

voltage deviates from the nominal voltage specified above (400
V or 460 V).6

The electrical supply is connected to the control cabinet on the

machine at the connection point marked on the installation plan
by the symbol shown on the left. The other system components
(cooling/suction-unit) are supplied via this connection. For the
version with three separate power supplies for the basic
machine, laser device and process cooler, these are indicated in
the installation plan. The symbol on the left indicates the connec-
tion points in the installation plan.

In the following cases, a sub-distributor for the laser and the

laser process cooler must be made:
■ The laser device is equipped with more than one outlet.
Machine is set up in a special installation, not standard
installation.
The following table applies for the connection of the basic
machine and for the connection of the laser device process
cooler.

6 The tolerance of the circuit 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.

B743en Electrical supply - Version 2 2-25

 Electrical supply Version according to DIN EN
60204-1/4.3.1
Connecting line, cable Four-pole copper cable (L1, L2, L3,
PE): Single-wire or multi-wire with
conductor end sleeves, make the
connection finger-safe, clockwise
phase rotation
Connecting line, cross-section Version according to VDE 0100
Part 430
Connecting line, ground wire According to VDE 0100 part 540
(IEC 60364-5-54)
Electrical connection Tab. 2-13

The following table applies for the connection of the laser device.

Electrical supply Version according to DIN EN

60204-1
TN network according to 60364-1
cos φ (DPF) with rated output 0.98
λ with rated output 0.91
Electrical connection of TruDisk Tab. 2-14

NEC conditions Note

The NEC applies only to Canada and the USA.

■ A four-pole connection is required: L1, L2, L3 and PE.

■ THHN copper or equivalent is recommended (2000 V maxi-
mum output) designed for a maximum temperature 90°C/
194°F.
■ No aluminum cables may be used to connect the machine.
■ The conductor cross-section must correspond to NEC 670-4
(a), with a permissible amperage of at least 125% of the full
operating current specified on the nameplate.
■ To ensure voltage stability and rating, the line dimension
should be larger than specified in the NEC table 310-16.

4.2 Power supply

Line structures With IT and TT line structures as well as asymmetrical lines (one
phase grounded- "corner grounded"), the machine must be con-
nected via an isolating transformer by the customer.

2-26 Power supply - Version 2 B743en

 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 system, the
short-circuit and overload responses of the UPS system are
to be taken into account besides the continuous power and
the electrical connected loads .
■ As a rule: overload capacity of the UPS ≥200 % for 0.5 s.

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 residual current circuit breaker has to be used
depends upon the local electricity company.
■ On the line side, only residual current circuit breakers of type
B (sensitive to all types of fault current, EN 50178/5.2.11.2;
VDE 0160) are approved.

A residual current circuit breaker provides protection from fault

currents due to directly or indirectly touching live parts.

Residual current circuit If a residual current circuit breaker is used to provide protection
breaker for direct contact from direct contact, an unregulated isolating transformer must
be used (EN 50178 section 5.2.11.1, VDE 0160). This is
because the fault current resulting from the design is >30 mA.

Residual current circuit If a residual current circuit breaker is to be used to provide pro-
breaker for indirect contact tection 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 fault currents
than the typical value specified. The main electricity supply and
the machine must then be separated by an unregulated isolat-
ing transformer.

NEC conditions 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.

B743en Power supply - Version 2 2-27

 NEC conditions

Note
The NEC applies only to Canada and the USA.

Grounding
■ The machine and power distributor system must be equipped
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.

Grounded power supply system with star connection

■ Power supply lines in ungrounded power supply systems with
delta connection are not fail-safe by nature. Delta power sup-
ply systems tend to generate transient overvoltage to ground.
Delta power supply systems can also result in excess voltage
being applied to the connected devices. The control system
or machine can no longer be operated reliably if a potential
to ground occurs in the system. For this reason a grounded
transformer must be installed in the star connection in delta
power supply systems (see NEC article 450-5).

Isolating transformer

The following information must be observed if the machine is

equipped with an isolating transformer:
■ The cable from the isolating transformer to the control cabi-
net of the machine must be provided by and laid by the cus-
tomer.
■ The customer must determine the location of the isolating
transformer. The isolating transformer is not indicated on the
installation plan.
■ The dimensions of the isolating transformer are as follows:
− Length: 1050 mm / 41 in
− Width: 750 mm / 30 in
− Height: 1400 mm / 55 in
■ The isolating transformer must be installed in such a way
that access via the door on the front side (door with name-
plate) remains free. The required safety distance according to
IEC is 800 mm, according to NEC 1070 mm / 42 in. 100
mm / 4 in safety distance must be maintained both behind
and next to the transformer.

2-28 Power supply - Version 2 B743en

 1 Isolating transformer 2 Safety distance
Space requirements for the isolating transformer Fig. 22107

The documentation "Series Transformer MD 90000" of the manu-

facturer Roller and Fischer applies to the isolating transformer.
The documentation (mat. no. see spare parts list) is available in
German, English, and French.
The series transformer MD 90000 is not allowed to be used in
the USA.

Isolating transformers of If the system is not equipped with the isolating transformer listed
other manufacturers above (e.g. in the USA), the following applies:
■ The kVA power of the transformer must be at least 10%
higher than specified on the machine nameplate.
■ Short-circuit voltage of 2% to 3%.
■ Taps are required on the primary side of the transformer to
equalize voltages that are constantly above or below the
nominal supply voltage.
■ The taps should be +10 V, +20 V, -10 V and -20 V of the
nominal supply voltage.

B743en Power supply - Version 2 2-29

 4.3 Connected loads, fuse protection and
frequency

TruDisk 3001 TruDisk 5001

Total connected load including 40 55
laser unit and process cooler and
possible options [kVA]
Maximum fuse protection of the 80 (IEC); 80 100 (IEC); 100
entire system (NEC) (NEC)

at 400 V and 460 V [A] 7

Connected load of machine [kVA] 22 22
Fuse protection of the machine 63 (IEC); 60 63 (IEC); 60
7
(NEC) (NEC)
at 400 V and 460 V [A]
Laser connected load [kVA] 21 35
Fuse protection of the laser 50 (IEC); 50 63 (IEC); 60
7
(NEC) (NEC)
at 400 V and 460 V [A]
Connected load for process cooler 10 18
[kVA]
Fuse protection of the process 25 (IEC); 25 35 (IEC); 35
cooler (NEC) (NEC)

at 400 V and 460 V [A] 7

Maximum acceptable interruption of See EN 60204, See EN 60204,

the nominal voltage [ms] part 1, sec. part 1, sec.
4.3.2, Alternat- 4.3.2, Alternat-
ing current sup- ing current sup-
ply ply
Connected loads Tab. 2-15

7 Circuit breaker with tripping characteristic gL/gG in the IEC range, RK1
or Class J in the NEC range.

2-30 Connected loads, fuse protection and frequency - B743en

Version 2
 4.4 Electrical power input

P Power input of machine and P Laser power as % of maximum

[kW]laser [%] power
Electrical power input including suction unit and process Fig. 56642
cooler at ambient temperature 25 °C.

4.5 Network connection

For production control projects connected to a CELL SERVER,

the power supply must be provided by the customer next to the
PC cabinet.
■ Power supply (except in the USA and Canada): 230 V with
grounded outlet socket. The machine is provided with a
grounded coupling.
■ 115 V power supply in the USA and Canada with standard
USA socket.

Network tolerance In relation to the nominal voltage and the frequency the same
tolerance as in the section "Electrical power supply" applies for
both power supplies.

4.6 Teleservice

Note
Teleservice is possible via internet or via analog modem.

B743en Electrical power input - Version 2 2-31

 The following interfaces are available in the machine switch cab-
inet:
■ Interface for analog modem: RJ12, 6-pin or plug-in clamping
screw Combicon(USA: RJ11 plug).
■ Network connection interface: RJ45 plug.

Teleservice connection via telephone modem

The connection point for the telephone modem is indicated on
the installation plan by the symbol shown on the left.

The customer must arrange for the following work to be done:

■ Installation of a telephone jack by the customer's telephone
company.
■ Direct outward dialing via digit code must be possible for the
modem.
■ It must be possible to access the modem with a direct dialing
number. Otherwise, a separate exchange line is required.

Net work requirements for For Teleservice via internet the following configuration is required
Teleservice via internet in the user's LAN:
UDP Port 500 and UDP Port 4500, enabled for internet access
via the LAN.

Note
Access to the user's LAN from the internet is not required: com-
munication takes place via the two enabled UDP ports.

4.7 Enhanced shop floor programming

The TruTops programming system is available at the machine

with enhanced shop floor programming. The machine is connec-
ted to a computer on which TruTops is installed. The installation
DVD is supplied with the machine.

Customer tasks:
■ Provide a separate computer to be used exclusively for
enhanced shop floor programming. See http://www.trumpf-
machines.com/services/software for computer or server hard-
ware and software requirements.
■ Install TruTops on the computer from the installation DVD
provided.

Note
A separate computer is not necessary if the server operating
system can be installed on an existing terminal server or if a

2-32 Enhanced shop floor programming - Version 2 B743en

 powerful enough computer with virtual machine installed is avail-
able.
The machine can be connected to the TruTops server if TruTops
is already installed as a client/server system. Refer to the "Tru-
Tops Installation Manual" for detailed information on the client/
server installation.

B743en Enhanced shop floor programming - Version 2 2-33

 5. Compressed air supply

What does the customer For professional use with respect to the subject of compressed
need to do? air supply, please consult a suitable specialist company and pass
along the following subchapter to the appropriate officials there.

Compressed air supply The connection point for compressed air is shown on the instal-
lation plan. The following should be paid attention to during
installation:
■ The compressed air connection may be flexible or may con-
sist of a fixed pipeline to the machine.
■ The compressed air supply must be equipped with a hand-
operated 3/2 directional valve with air exhaust on the
machine immediately in front of the machine input.

Connected loads for The requirements for all compressed air connections established
compressed air at the system are identical.

Required network pressure [bar / min. 6 / 878

psi]
Average consumption [Nm3/h / approx. 31 / 18 = 516 l/min
cfm]
(required volume rate of flow
according to ISO 1217 or DIN
1945):
Excess consumption during approx. 20 / 12 = 333 l/min
compressed-air cutting (option)
[Nm3/h / cfm]
Excess consumption with auto- See installation conditions of the
mation automation components
Tab. 2-16

Supply lines for compressed Min. nominal diameter of the ½" (DN13)
air supply supply line
Ring pipeline length [m / ft] max. 50 / 164 (due to formation of
water condensation)
Ring pipeline diameter at least 1" (26 mm)
Length of the connection line max. 5 / 16.4
from the ring circuit to the con-
nection point on the machine
[m / ft]
Tab. 2-17

The compressed air must have the following properties at its tap-
ping point:

8 The max. possible network pressure (e.g. on existing compressed air

networks) is 12 bar / 174 psi. A minimum network pressure of 7.5
bar / 109 psi is required if a nozzle of Ø 2.7 mm is used for com-
pressed-air cutting.

2-34 Compressed air supply - Version 2 B743en

 The compressed air must have the purity class 744 as per ISO
°8573-1 at the connection point of the machine:

Property Requirement Quality class Measure (rec-

ISO°8573-1 ommendation)
Edition 2001
Dust-free maximum parti- 7 Air filter on the
cle size: 40 μm compressor
Maximum parti-
cle density:
10 mg/m3
Condensate-free cooled to +3°C / 4 Cold dryer
37°F (pressure
dew point)
Oil-free Maximum oil 4 Oil-free com-
content: 5 mg/ pressing screw-
m3 type compressor
Requirements Tab. 2-18

B743en Compressed air supply - Version 2 2-35

 6. Operating materials

What does the customer The following operating materials must be provided by the oper-
needs to do? ator in due time before the machine is delivered.

6.1 Gases

Gas types, their purity and connections, hoses, etc. are specified
in section 2, "Gas supply."

6.2 Cooling water.

Cooling water is required to cool the laser unit and the optical
components on the machine. Cooling is performed via two cool-
ing circuits: a copper and an aluminum cooling circuit.

Cooling water requirements The machine is equipped with three separate cooling circuits:
■ Internal process cooler in the TruDisk laser with copper cool-
ing circuit.
■ External laser process cooler.
■ External machine process cooler with copper cooling circuit.

Note
The required amount of cooling water (approx. four times the
amount of cooling water) is to be provided by the customer when
commissioning the system.

Int. laser cooling Ext. machine cool- Ext. laser cooling

circuit ing circuit circuit
Cooling water Demineralized or Demineralized or Demineralized or
deionized water deionized water deionized water
Total amount of cooling water in l / gal-
lons
TruDisk 3001 60 / 15.9 / 21.1 64 / 16.9 125 / 33
TruDisk 5001 80 / 21.1 64 / 16.9 300 / 79.3
Conductivity for newly replaced water Max. 10 Max. 10 Max. 10
[μS/cm]
Conductivity for newly replaced water max. 20 max. 20 max. 20
after 10 minutes of circulation [μS/cm]
Conductivity limit of the cooling water Max. 200 Max. 200 Max. 200
during operation [μS/cm]
Max. permissible carbonate content [mg/ Less than 100 Less than 100 Less than 100
l]
Color Colorless Colorless Colorless

2-36 Operating materials - Version 2 B743en

 Int. laser cooling Ext. machine cool- Ext. laser cooling
circuit ing circuit circuit
Cloudiness none none none
Odor odorless odorless odorless
Conditions and requirements Tab. 2-19

Notes
■ The specified chemical/physical properties must be complied
with without exception. Consult your supplier with regards to
this matter.
■ Do not use distilled water since the quality of distilled water
can fluctuate considerably.

Storage Demineralized water may only be stored for a short period of

time in order to avoid impairment of the water quality.
The water must be moved in clean plastic containers (without
deposits, no odors).

Handling ■ Avoid any unnecessary contact with the water (e.g. with your
hands). Contact with foreign matter, except that specified by
TRUMPF, has a negative affect on the water quality.
■ Additional equipment for filling water such as pumps, hoses
or stop cocks should be used exclusively for operation with
the system water.
■ The demineralized water must undergo a simple inspection
regarding color, cloudiness and odor before filling.

Color/cloudiness Any type of cloudiness (e.g. from suspended matter, threads,

flakes, particles) indicates that the water is impure. In such
cases, the system must not be filled with this water.

Odor Odor is an indication of a biological contamination of the water.

In such cases, the system must not be filled with this water!

Installing cooling unit in an If the cooling unit is installed in an area with a risk of frost, then
area with a risk of frost the "high purity ethylene glycol" antifreeze agent must be added
to the cooling water. The antifreeze agent is to be provided by
the customer at machine start-up.
The mixing ratio is dependent on the temperature at the installa-
tion site.

Temperature to -15°C / to -24°C /

2°F 11.2°F
Percent of weight in % 30 40
Volume percentage in % 27 35
Mixing ratio Tab. 2-20

B743en Cooling water. - Version 2 2-37

 7. Transportation of the machine

Machine conveyance to In some countries the customer can have TRUMPF transport the
customer´s site by TRUMPF 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
below, including the auxiliary tools and means of transportation.

What does the customer Note

needs to do?
The TruDisk-Laser may not be exposed to temperatures below 5
°C at any time during transport and/or during any storage peri-
ods!

All components are to be examined upon receipt for any damage

caused during transit. Any visible damage caused during transit
must be recorded on the consignment note and countersigned by
the truck driver. Hidden damage caused during transport must be
reported to the insurance company and to TRUMPF within six
days at the latest.
The arrangements and transport of the system from the truck to
its final installation site need to be prepared and carried out by
the customer. The transport route to the machine's installation
site must be clarified in due time prior to the machine's delivery.
In particular, gates, header heights, cable rack heights, ground
conditions for armored rollers etc. must be checked. The installa-
tion site must be free of obstructions.
The transport route must take the dimensions of the machine
into account according to the installation plan.

Component Length Width (mm) Height

(mm) (mm)
Machine body
TruLaser 5030 5800 / 229 3200 / 126 2300 / 91
TruLaser 5040 7000 / 275.6 3700 / 145.7 2300 / 91
Laser device
TruDisk 3001 1600 / 65 950 / 40 1550 / 60
TruDisk 5001 2000 / 78.8 1200 / 47.3 1550 / 60
Pallet changer
TruLaser 5030 3500 / 137.8 2800 / 110.3 1000 / 39.4
TruLaser 5040 4400 / 173.3 3350 / 131.9 1000 / 39.4
Laser process cooler
TruDisk 3001 1750 / 68.9 800 / 31.5 2000 / 78.8
TruDisk 5001 1880 / 74 874 / 34.4 2055 / 80.9

2-38 Transportation of the machine - Version 2 B743en

 Component Length Width (mm) Height
(mm) (mm)
Process cooler for machine 750 / 29.6 750 / 29.6 1150 / 45.3
Compact dust extractor
TruLaser 5030 3150 / 124 1050 / 41.4 2550 / 100.4
TruLaser 5040 1350 / 53.2 1280 / 50.4 2000 / 78.8
Isolating transformer 1050 / 41.4 750 / 29.6 1400 / 55.1
Dimensions of system components incl. transport devices Tab. 2-21

Weight The basic machine, which is the heaviest component to move,

weighs 8500 kg / 18740 lbs.

Auxiliary and transport The customer must provide:

equipment ■ Crane truck for machine, pallet changer, and accessory sys-
tems. A hydraulic crane truck with at least 80 t hoisting
power is recommended; if the local conditions require a
larger lever arm, a crane truck with greater hoisting power
must be used instead.
■ Fork lift truck (carrying capacity 2.5 t)
■ Gantry crane: carrying capacity 9 t on TruLaser 5030.
■ Armored rollers (1 steerable and 2 fixed)
■ At least 2 hydraulic hoisting jacks of at least 5 t lifting
capacity (min. adjustable height: ≤30 mm)
■ Hoisting iron (1 m) and extension.

Note
Without a gantry crane, subsequent removal of the eyelets for
securing the load on the truck is a difficult and tedious process.

Transport regulations Detailed information on the conditions for transporting the system
can be found in the TruLaser 5030 (L41) Transport Regulations
– Drawing No. 93735-8-10. A copy of the transport regulations
can be found in a clear plastic envelope on the machine upon
delivery.

7.1 Measures to be taken by the

customer

Please observe ■ All transport work must be carried out in accordance with the
transport regulations.
■ The machine may not be lowered onto the ground without
supports since otherwise the bottom of various components
will be damaged. The distance from the machine bearing
plates to the floor must be ≥100 mm / 4 in. This distance to

B743en Measures to be taken by the customer - Version 2 2-39

 the floor must also be maintained during the transportation of
the machine to its installation site.
■ The floor requirements at the installation site must comply
with the installation requirements. Cut outs, bore holes, etc.
in the factory floor must be prepared by the customer in
accordance with the foundation plan prior to the installation
of the machine.

Unloading the machine from ■ Unload the machine from the truck with a crane truck of suit-
the truck able lifting power.
■ If there is no gantry crane available at the installation site,
remove the eyelets for securing the load on the truck next to
the machine legs, provided the machine is connected to the
crane shackles.
■ The control cabinets, cooling units, suction system and RF-
generator can be transported directly from the truck to the
installation site of the machine with a fork lift truck.

Transporting the machine Note

from the field to the
Without a gantry crane, subsequent removal of the eyelets for
installation site
securing the load on the truck is a difficult and tedious process.

■ Transporting the machine from the yard into the factory hall
on armored rollers.
■ Either a gantry crane of sufficient carrying capacity or arm-
ored rollers can be used to continue transportation to the
installation site.

Installing the machine at the ■ Hydraulic hoisting jacks are required to set down and align
installation site the machine at the installation site if armored rollers are
used.
■ Place the machine + pallet changer on armored rollers next
to the actual installation site.
TRUMPF Customer Service must be informed without fail at
an early date if space considerations prohibit this. In this
case the machine can be placed on the supplied installation
elements at the final installation site following consultation.
■ As long as the installation is not hindered, the control cabi-
net, cooling unit and compact dust extractor can be set down
at the final installation site.

7.2 TRUMPF service work

Leveling the machine The machine is leveled by TRUMPF service technicians.

Putting the system into The machine is put into service by TRUMPF service technicians.
service This includes the installation of the components according to the

2-40 TRUMPF service work - Version 2 B743en

 installation plan, the connection of the system to the supplies as
well as instructing personnel and the functional inspection of the
machine.

B743en TRUMPF service work - Version 2 2-41

2-42 TRUMPF service work - Version 2 B743en
 Chapter 3

Description

1 The most important assemblies 3-3

1.1 Closed machine frame 3-4
1.2 Motion unit 3-5
1.3 TruDisk Laser 3-6
1.4 Fiber optic laser cable 3-7
1.5 Cutting unit 3-8
1.6 Multi-chamber suction system 3-9
1.7 Compact dust extractor 3-10
1.8 Longitudinal conveyor belt 3-10
1.9 Partitioned slag container 3-10
1.10 Automatic pallet changer 3-11
1.11 Spraying equipment 3-11
1.12 Cleaning brush 3-12
1.13 Laser pointer diode 3-12
1.14 Electrical rolling roof 3-12

2 Control system 3-13

2.1 Integrated E-shop 3-14

B743en 2011-10-07 Description 3-1

 2.2 Teleservice 3-15
2.3 Shop floor programming 3-15

3 The most important functions 3-17

3.1 One-cutting-head strategy 3-17
3.2 FocusLine 3-17
3.3 FastLine 3-17
3.4 FlyLine 3-18
3.5 PierceLine 3-19
3.6 Laser power control 3-20
3.7 NitroLine 3-20
3.8 ControlLine 3-20
3.9 ContourLine 3-21
3.10 Compressed-air cutting 3-21
3.11 Auto-shutdown 3-21

4 Safety 3-22
4.1 CE marking 3-22
4.2 Closed safety cabin with rolling roof 3-23

5 The most important options 3-24

5.1 Nozzle changer 3-24
5.2 Clamps 3-25
5.3 TruTops Laser complete package 3-26
5.4 TruTops Message 3-27
5.5 Camera for process monitoring 3-28

6 Automation 3-29
6.1 Example 3-30

7 Technical data 3-31

3-2 Description 2011-10-07 B743en

 1. The most important assemblies

1 TruDisk laser 4 Pallet changer 6 Control panel

2 Motion unit 5 Safety cabin with door 7 Cutting unit
3 Electrical rolling roof
Most important assemblies of the machine Fig. 58002

B743en 2011-10-07 The most important assemblies 3-3

 1.1 Closed machine frame

Closed machine frame Fig. 57928

Stable basis for all The closed machine frame is a self-stiffening steel/welding con-
components struction. It limits the processing area of the machine.

Advantage ■ High stability: the fixed arrangement of the left and right lat-
eral carriers increases the stability of the machine.
■ Easy transport: The machine can be transported "in one
piece," and therefore more easily.
■ Quick installation: The machine is installed "in one piece".
This results in shorter installation times and makes the instal-
lation uncomplicated overall.

3-4 Closed machine frame 2011-10-07 B743en

 1.2 Motion unit

Motion unit Fig. 57929

Motion unit for high- The motion unit is based on a highly stable, FEM-calculated
precision machining cross member, which has a lightweight welded steel design.
Design features and manufacturing methods enabling extremely
lightweight construction were deliberately selected with this pur-
pose in mind.
The machine operates in accordance with the principle of flying
optics. The workpiece stays in place and the abrasive cutting
head moves.
Rack and pinion systems execute the travel motion.

Advantage ■ High dynamics with simultaneously high accuracy, because

only precisely defined masses are moved.
■ The sheet and the machined parts are not moved.

B743en 2011-10-07 Motion unit 3-5

 1.3 TruDisk Laser

Generating the laser beam

1 Deflection mirror 5 Pump laser beam

2 Parabolic mirror 6 Rear mirror
3 Output coupling mirror 7 Crystal disk, laser active
4 Decoupled laser beam medium
8 Cavity
A glimpse inside the cavity of a disk laser Fig. 49053

The laser active medium is a thin crystal disk made from

Yb:YAG (Ytterbium-endowed yttrium aluminum garnet). The disk
laser is pumped with the help of diode lasers. The laser beam is
generated in the crystal disk and leaves the cavity through a
hole at the center of the parabolic mirror.

Solid-state laser The TruDisk can be used in pulsing mode as well as in CW

mode thanks to its diode pumped simulation.

Advantages of the solid state laser:

■ Very good beam shape due to a small opening angle with a
small beam waist.
■ High levels of efficiency.

Advantage ■ High beam quality.

■ No laser gas required.
■ Beam guidance through an optical laser cable.
■ Low power consumption.
■ Network-compatible: The laser is equipped with an additional
beam outlet and can supply several systems at the same
time.

3-6 TruDisk Laser 2011-10-07 B743en

 Additional documents ■ "Solid-state laser" technical information.

1.4 Fiber optic laser cable

Transmitting the laser beam

1 Cable conduit with steel shell 3 Protective covering

2 Safety circuit 4 Optical fiber
Fiber optic laser cable Fig. 50158

The frequency of the laser light of the disk laser enables the
coupling of the laser beam in one optical laser cable.
The optical fiber comprises silica fiber with two layers, the fiber
core and the coat. The laser light spreads in the fiber core. Its
diameter amounts to 100 µm. The coat encloses the fiber core
and keeps the laser light inside it. A plastic layer encloses the
silica fiber and protects it from damage.

Advantage ■ No contamination of the beam guidance.

■ Uncomplicated layout of the mirror systems.
■ Few mechanical parts.
■ Low costs.
■ The maximum length of 40 m enables very flexible installa-
tion of the laser unit.

B743en 2011-10-07 Fiber optic laser cable 3-7

 1.5 Cutting unit

1 Optical laser cable 6 Lens for focusing the beam

2 Cover slide 7 Lens for offsetting the focal
3 Blowing nozzle position
4 Lens for offsetting the focal 8 Sensor system status LEDs
diameter 9 Nozzle
5 Drive status LEDs
Complete cutting unit Fig. 59871

Bundling the laser beam in The cutting unit is arranged at the end of the optical laser cable.
the focus
A cover slide prevents the penetration of impurities in the cutting
unit and thus contamination of the lenses.
The focusing lens in the cutting unit concentrates the laser
beams on the focal point where the energy density of the radia-
tion is at its highest.

3-8 Cutting unit 2011-10-07 B743en

 The three lenses in the cutting unit have the following functions:
■ Automatic offsetting of the focal position from +10 to -30 mm.
For optimum cutting results, the focus must be set to a
defined point relative to the workpiece surface.
■ Automatic offsetting of the focal diameter.

Deflection of the cutting A deflection mechanism ensures that movement is stopped as

head in case of a collision quickly as possible and the cutting unit is not destroyed in the
event of a collision. The lower part of the cutting unit is only
swung out and can be moved back into its original position by
hand. During smaller collisions, the cutting head automatically
moves back into position. Processing can then be resumed with-
out any further setting work being required.
The laser beam and the cutting gas for machining are directed
onto the workpiece through the cutting nozzle, which is addition-
ally cooled with purified compressed air.

Advantage ■ The complete material and material thickness spectrum can

be cut with a cutting head.
■ The cover slide in the cutting head directs the beam guid-
ance in the direction of the beam emission point, so that dirt
cannot enter the beam guidance through the cutting head.
■ Due to this, the relevant cutting gas can be put under pres-
sure in the cutting head in order to support the cutting proc-
ess optimally.
■ No cleaning of the lens required.
■ In case of a collision, the cutting unit is not destroyed by the
deflection mechanism.

1.6 Multi-chamber suction system

Multi-chamber suction A suction system consisting of several suction chambers is

system present within the working range of the laser cutting machine.
Each suction chamber is opened and closed using a pneumati-
cally-operated flap and is connected to the central suction chan-
nel.
During the cutting operation, only the flap of the suction chamber
below the cutting head is opened.

Advantage ■ The suction power is concentrated on only one chamber at a

time, which ensures optimum suction of the fumes and air-
borne particles.
■ The suction system ensures that the particle concentrations
fall well within the load values permitted at the work station.

B743en 2011-10-07 Multi-chamber suction system 3-9

 1.7 Compact dust extractor

Cleaning exhaust air The compact dust extractor with surface filter extracts the
exhaust gas dust produced during laser cutting.
A continuous purging cycle ensures optimum utilization of the fil-
ters' capacity.

Advantage The exhaust air is cleaned or dusted using the compact dust
extractor.

1.8 Longitudinal conveyor belt

Transporting scrap and The wide longitudinal conveyor belt (hinge conveyor) below the
small parts away working area takes up falling small parts and slag during pro-
cessing and transports them into a container at the end of the
belt.

Advantage Automatic removal transport of the falling slag and small parts.

1.9 Partitioned slag container

At the end of the longitudinal conveyor belt, there is a tripartite

slag container that collects the accumulating slag, small and
waste parts.
The container is pulled out from under the machine body for
emptying.
Due to the tripartite division, the slag container does not have to
be pulled out completely but can be pulled out piece by piece
and emptied.

Advantage ■ Space-saving pull out of the partitioned slag container.

■ Easy emptying of the partitioned slag container due to lower
weight of individual segments.

3-10 Compact dust extractor 2011-10-07 B743en

 1.10 Automatic pallet changer

Automatic pallet changer Fig. 58007

Loading and unloading in The pallet changer is designed to handle two pallets. The pallets
productive time are responsible for transport of the workpieces between the load-
ing and unloading position (in the changer) on the one hand and
the machining position (in the machine) on the other hand. At
the same time, the pallet in the machine is used as a work table
for the workpieces (sheets).

Advantage ■ Pallets can be loaded and unloaded while machining. As a

result, the machine downtimes are reduced to a minimum.
■ The pallet changer can be used as an interface to further
automation components, e.g. to the loading equipment, to the
LiftMaster, etc.

1.11 Spraying equipment

Avoiding slag adherence For mild steel with a dry surface, a large amount of upward
material ejection occurs when piercing on full laser power. The
result is a slag ring around the piercing hole. The spraying
equipment is used to prevent slag adherence around the piercing
crater.
The program-controlled spraying equipment sprays a thin spray
film accurately onto the sheet in the area of the piercing hole.
Slag adherence is reduced considerably due to this spray film

B743en 2011-10-07 Automatic pallet changer 3-11

 and a large part of the slag is immediately blown away by the
blow air.

Advantage ■ Low spray material consumption.

■ After purification generally not required.
■ Low filter contamination.
■ Protects the environment.

1.12 Cleaning brush

Sheet cleaning The sheet cleaning brush removes contaminants located on the
upper side of the sheet when the pallet is inserted into the
machine. A brush is moved downward by pneumatic cylinder for
this purpose before the pallet moves into the machine.

Advantage Enhanced process reliability: No impurities are to be found on

the sheet during processing.

1.13 Laser pointer diode

Exact positioning A laser diode is mounted immediately next to the cutting head
determination with laser which generates a red point of light (Ø approx. 3 mm). Using
light this readily visible point of light makes it possible to establish the
start point for the next laser cut exactly, even on sheets that
have already been machined. The position is saved by pressing
a button and passed along to the control system as a new start
position.

Advantage ■ Optimum utilization of the sheet.

■ Exact positioning of the cutting head, even manually.

1.14 Electrical rolling roof

The electrical roof encloses the working area of machine from

top. In this way beam cannot escape upwards from the machine
during machining with the solid-state laser.

Laser system Class 1 The closed safety cabin with the radiation safe viewing window,
together with the electrical rolling roof, means that the machine
is classified as Laser system Class 1 during normal operation.

Advantage ■ Easy and comfortable access to the work area when the roof
is open.

3-12 Cleaning brush 2011-10-07 B743en

 2. Control system

Fig. 58006

Open and simple control The TRUMPF CNC controller is based on the high-speed Sie-
system mens SINUMERIK 840D sl control system:
■ Easy-to-use operator prompting on the operating environment
developed by TRUMPF.
■ High-quality TFT (Thin Film Transistor) color display or con-
trol panel with touchscreen (TruLaser 3030 (L20), Tru-
Laser 3040 (L32)).

Advantage ■ All functions required in daily operation can be started by

pressing fewer buttons.
■ The operation of the machine is readily learned.
■ This allows operating personnel to take over production with-
out a prolonged training period or knowledge of the whole
functional scope of the 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 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 be subject to a correspond-
ing obligation.

B743en 2011-10-07 Control system 3-13

 2.1 Integrated E-shop

Fig. 53110

Convenient online ordering At the E-Shop, not only is it possible to find replacement parts in
of replacement parts exploded views and order them; shopping carts can also be
compiled and saved and orders archived.
Register easily and quickly at www.mytrumpf.com.

Advantage Quick and convenient ordering of replacement parts. Determining

the material number, querying the price, placing the order - all of
these tasks are made quicker and easier.

Additional document "E-Shop" technical telegram.

3-14 Integrated E-shop 2011-10-07 B743en

 2.2 Teleservice

Connecting online to An internet or modem connection is established between the

customer service machine and a technician of Technical Customer Service at
TRUMPF via Teleservice.

■ Remote control.
− Allows access to the applications and the operating sys-
tem of the operator's computer.
− Used to support the machine operator in the event of
operation and input errors.
■ Remote diagnostics
− Errors in nearly all control components can be detected.
This includes the NC, PLC, the user interface and the
operating system for example.
■ Remote administration
− Allows errors to be eliminated, sub-modules of the NC,
PLC and user interface to be updated, configurations to
be modified and updated and network configurations to
be modified.
■ Data transfer
− Enables the exchange of operating system system files
and numerous other files and streams for example.
■ Dialog mode
− If there is no voice connection by telephone, communica-
tion can take place via the dialog mode of the Teleser-
vice software.

Advantage ■ Higher machine availability.

■ Significantly quicker fault elimination.
■ Less on-site service required.
■ Safer and quicker information exchange.
■ Ideal preparation of on-site service work.
■ Examples of assistance via Teleservice:
− Correction of handling errors of the operator.
− Detection of programming and parameter errors.
− Localization of a defective assembly.
− Modification of machine applications.
− Software configuration and updates.

2.3 Shop floor programming

Simple shop floor In 5 steps from the geometry to the program. The simple shop
programming floor programming integrated in the control enables rapid pro-
gram creation directly from available geometry data. The latter

B743en 2011-10-07 Teleservice 3-15

 can, for example, be loaded from the USB stick. Offline program-
ming away from the machine is thus no longer necessary. The
automatic nesting assistant provides optimum and material-effi-
cient sheet layout.

Enhanced shop floor Workpieces can be programmed in a minimum of time with the
programming enhanced shop floor programming. Machining strategy and sheet
layout are generated automatically. The full-fledged programming
system runs on a customer computer and is mirrored on the
control. This means that the integrated product data manage-
ment (PDM), the rectangle nester and DXF and MI interfaces are
also available on the machine.

Fast post-production The post-production module makes it possible to produce addi-

tional individual parts from an existing program. And that without
any additional programming effort.

Advantage ■ Fast post-production can be programmed directly on site -

especially important during the night shift when there are no
programmers available.
■ Simple shop floor programming.
■ Program adaptations can be made rapidly and directly on the
shopfloor in a few steps.
■ The software care contract available for TruTops Laser also
enables you to update the shop floor programming. This
ensures that the two systems are always compatible with
each other.
■ By connecting the office programming system TruTops Laser,
the data can also be managed together. The programmer
can also be informed via the PDM and versioning as to what
has been changed on the shop floor.
■ Access management means employees can be blocked or
allowed as desired.

Characteristic feature The shop floor programming is installed on a separate computer

which is connected to the machine. The program is started up
via the machine control.

3-16 Shop floor programming 2011-10-07 B743en

 3. The most important functions

3.1 One-cutting-head strategy

Cutting everything with one With the lens cutting head of the above-mentioned machine, it is
cutting head possible to machine all materials and material thicknesses with-
out having to carry out a cutting head replacement.

Advantage ■ Reduction of downtime because cutting head replacement is

no longer needed.
■ No impurities of any sort are introduced into the beam guid-
ance system during a cutting head replacement.

Characteristic feature A cutting head with a focal length of 130 mm can also be used
for high-speed cutting.

3.2 FocusLine

Adjusting the focal position FocusLine is used to automatically adjust the focal position. The
automatically focal position is adapted by a motor which changes the arrange-
ment of the lenses in the cutting unit.
This changes the angle of divergence of the laser beam so that
the focus can be repositioned systematically upwards or down-
wards.

Advantage ■ The focus is automatically adjusted to the relevant material

thickness and type.
■ The focal position does not have to be set manually anymore
within the automatic setting range which is possible with
FocusLine.
■ The focal position specified in the technology table is set
automatically resulting in operating errors being excluded as
far as possible.
■ The focal position can be varied automatically while execut-
ing a program, making it possible to optimize the process.
■ The focal position is kept virtually constant over the entire
working range, regardless of the beam length.

3.3 FastLine

FastLine The transition from piercing to cutting the contour is carried out
more quickly and with higher quality with FastLine. This is ach-
ieved by changing decisive process parameters that cooperate to

B743en 2011-10-07 The most important functions 3-17

 significantly improve the process regarding speed and quality
especially with thin sheets.
The pure piercing time is slightly longer. Parameters that it would
take time to modify remain unchanged. Thus the waiting times
when converting the gas pressure, when changing the setting
dimension, and during the lateral air blast can be eliminated.

Advantage ■ It saves time: Much faster transition from piercing to cutting.

■ It increases productivity: Dependent on the type of material
and material thickness and the quantity of contours which are
to be processed, productivity increases of up to 100 % in the
thin sheet range are possible.
■ It increases parts quality: Because of the reduced laser
power when piercing with a ramp, there is less upward mate-
rial ejection and thus less spatter on the upper side of the
material.
■ FastLine is most useful in machining workpieces in the thin
sheet range that have many contours, i.e. many piercings:
− Mild steel up to s = 4 mm.
− Stainless steel up to s = 4 mm.
− Aluminum up to s = 3 mm.

Additional documents "FastLine" technical telegram.

3.4 FlyLine

FlyLine FlyLine is machining strategy that can be used especially effec-

tively when machining hole grids.

The most important machining features of FlyLine are:

■ Laser beam is switched on and off on-the-fly with a high
degree of position accuracy. Axes are not stopped when
laser is switched on and off.
■ Fragmentation of individual right-angle contours located along
a single line. This makes it possible to avoid corner machin-
ing. The speed is reduced only in the few instances where
the direction is changed.

Advantage Saving time: Using FlyLine allows you to achieve a drastic

reduction in the machining times. The more contours there are in
a part, the greater the time saved by FlyLine.

Additional document Technical telegram “FlyLine", "Laser cutting news", etc.

3-18 FlyLine 2011-10-07 B743en

 3.5 PierceLine

Fig. 34633

Monitoring and regulating PierceLine is in the position of not only monitoring every piercing
the process process, but also controlling it – and this is independent of mate-
rial type and thickness. The regulation ensures that middle power
is maintained as high as possible during piercing. This means
that, particularly in the case of gentle piercing, the average
power is always kept just under the threshold beyond which
uncontrolled material burn-off would occur.

Advantage ■ Clearly reduced piercing times.

■ Almost continually improved quality during piercing.
■ Less material ejection and, therefore, the nozzle and cutting
head range are spared.
■ Smaller piercing holes and, therefore, the option to process
more narrow contours lying against one another.
■ Less heat input into the material.
■ Increased process reliability due to less material ejection and
residual piercing on the sheet surface. This considerably
reduces the possibility of faults, particularly for automated
systems.
■ Piercing-end-recognition across the entire material and mate-
rial thickness spectrum.
■ The piercing spot does not need to be sprayed for mild steel
s ≤12 mm – the refinishing operation associated with this is
also not required.
■ The blow out after the piercing process can be partially
reduced or completely omitted.
■ The modified air nozzle used with PierceLine ensures consid-
erably decreased material clinging.
■ Reduced wear of the support slats due to punctual ending of
the piercing process.

Additional document "PierceLine" technical telegram.

B743en 2011-10-07 PierceLine 3-19

 3.6 Laser power control

For optimum cutting edges NitroLine means: fusion cutting with nitrogen and a cutting gas
pressure of no more than 20 bar, which quickly drives out the
melt downwards.

Advantage ■ Oxide-free cutting edges.

■ Prevention of burr formation.

Characteristic features Mainly recommended for machining stainless steel and aluminum
alloys.

3.7 NitroLine

For optimum cutting edges NitroLine means: fusion cutting with nitrogen and a cutting gas
pressure of no more than 20 bar, which quickly drives out the
melt downwards.

Advantage ■ Oxide-free cutting edges.

■ Prevention of burr formation.

Characteristic features Mainly recommended for machining stainless steel and aluminum
alloys.

3.8 ControlLine

ControlLine controls the ControlLine coordinates and controls various machine functions
processes centrally:
■ Capacitive distance control system for constant nozzle -
sheet distance.
■ Measure the workpiece position automatically and correct the
coordinate system if required.
■ PierceLine
■ PlasmaLine

Advantage ■ No scratching of the sheet caused by shifting the sheet man-

ually.
■ Unproblematic machining of uneven sheets by means of the
capacitive height regulation.
■ Central control function.

3-20 Laser power control 2011-10-07 B743en

 3.9 ContourLine

Cutting small holes The ContourLine function makes it possible to cut holes whose
diameter is less than the material thickness. The most important
feature of this method is its pulsed cutting with a gating fre-
quency of 10 Hz.

Advantage Cutting small holes with diameter < material thickness (up to 0.4
x material thickness).

3.10 Compressed-air cutting

Cutting with compressed air Compressed-air cutting uses filtered compressed air as the cut-
ting gas. The machine must be equipped with additional compo-
nents for this.
The exact specifications are provided in the installation condi-
tions of the machine.

Advantage Economical cutting gas.

Characteristic features ■ The cutting edge is rougher than during oxygen or nitrogen
high-pressure machining.
■ The cutting edge of stainless steel oxidizes.

3.11 Auto-shutdown

Saving energy and going A switch element is used to activate or deactivate automatic
easy on the machine shutdown. If automatic shutdown is active, the machine's ON/
OFF button flashes with increased frequency.
The machine is automatically shut down if a program end or "job
end" is present for longer than five minutes or if there is no axis
motion for ten minutes.

Advantage In addition to energy savings, the auto-shutdown also reduces

wear-and-tear on the machine.

Characteristic feature Automatic shutdown is only of value in combination with machine

automation for manless operation.

B743en 2011-10-07 ContourLine 3-21

 4. Safety

4.1 CE marking

Fig. 47694en

Legal specifications are TRUMPF confirms the fulfillment of all requirements in accord-
observed ance with the following directives of the European Community
with the CE marking (CE = French Communauté Européenne)
and the corresponding EC Declaration of Conformity:
■ EC machinery directive.
■ EC directive on electromagnetic compatibility.
■ EC low voltage directive.
■ EC pressure equipment directive (depending on the machine
type).

Advantage ■ Machines with CE markings are reliable in their operation.

■ No additional measures are required by the customer.

3-22 Safety 2011-10-07 B743en

 4.2 Closed safety cabin with rolling roof

The safety cabin is equipped with an electrical rolling roof and is

thus completely closed. In this way it fully meets the require-
ments for certification for systems with a solid-state laser.

1 Rolling roof, half closed 2 Viewing window 3 Safety cabin

Machine with half-closed rolling roof Fig. 58005

B743en 2011-10-07 Closed safety cabin with rolling roof 3-23

 5. The most important options

5.1 Nozzle changer

Fig. 54802

Changing nozzles The nozzle changer is programmed to change nozzles automati-

automatically cally when necessary:
■ When changing materials.
■ When changing to other material thicknesses.
■ When the nozzle is worn.

Advantage ■ Minimum machine downtimes.

A programmed nozzle change is carried out immediately after
the program end.
■ No machine waiting times.
The machine does not need to "wait" till an operator changes
the nozzle.
■ Increased process reliability.
The change process is program-controlled and thus carried
out without the operator's intervention. In addition to this,
replacement of worn nozzles is also program-controlled and
thus always on time.
■ Flexibility in manless multi-shift operation.
Manless operation is possible even for a wide range of large
parts and materials.
■ Ideal supplement to the one-cutting-head strategy.

Additional document "Nozzle changer" technical telegram.

3-24 The most important options 2011-10-07 B743en

 5.2 Clamps

Fig. 60660

Holding the sheet securely The workpiece can be fastened to the workpiece support (pallet)
during machining with the two clamps which are installed firmly
on the pallet frame.

A few conditions under which a clamping device is to be used

are specified in the following:
■ Very thin sheets of lightweight stainless steel can slip during
high-pressure cutting.
■ With small blanks, e.g. strips, since they can fall between the
support slats.
■ When machining semifinished products, e.g. angle pieces, in
order to clamp the workpiece in a defined position for
machining.
■ With prepunched sheets and slightly curved sheets, since
they do not rest cleanly on the carrier slats and can therefore
slip during machining.

Advantage ■ Secure fastening of very thin and lightweight stainless steel

sheets, small blanks during machining.
■ Clamping fixture for machining semifinished products.

Characteristic feature Risk of collision: Do not use in conjunction with auxiliary pallets
or nozzle changer.

B743en 2011-10-07 Clamps 3-25

 5.3 TruTops Laser complete package

Fig. 51912

Programming laser flatbed TruTops Laser is the CAD/CAM system for 2-D laser machining.
machines
The machine and production system form a precisely coordinated
unit.

Advantage ■ Database (machine data, material data, laser technology

data) with the concentrated technological knowledge of
TRUMPF.
■ Automatic creation of machining and NC-programs.
■ Central storage and management of data compatible with all
products using PDM (product data management).
■ Efficient operation due to:
− Practice-oriented programming sequence.
− Menu bar.
− Icon-based tool bars.
− Function browser with important functions.
− Shortcuts for standard operations (e.g. saving).

3-26 TruTops Laser complete package 2011-10-07 B743en

 ■ Contains all conventional tools for drawing parts.
− Tools for drawing notches, bevels and roundings and
rows and circles of holes are adapted specifically to the
sheet metal processing.
− Supports the standard formats DXF, DWG (optional),
IGES (optional) and MI.
■ Flexible sheet layout and optimum utilization of the sheet by
nesting processors.
■ Production plan.
■ Waste optimization by means of the "Common cuts" function.

Additional document "TruTops Laser" product information.

5.4 TruTops Message

Fig. 53107

Receiving messages from Fewer operators or unmanned shifts are particularly typical for
the machine night and weekend shifts. Malfunctions and downtimes arising
from them are mostly noticed (too) late. Check patrols are
required to avoid long downtimes.

TruTops Message is:

■ A TRUMPF-developed multiclient server system. The user
can connect one or more TRUMPF machines to this software
system.
■ A communication system between the control system (MMC),
one or more TRUMPF machines and a central PC of the
user.

B743en 2011-10-07 TruTops Message 3-27

 The heart of the software is the database in which all information
and data are saved.

Advantage ■ Automatic worldwide notification of a responsible person via

FAX, SMS and E-mail about job data, error messages and
operating statuses (e.g. standstill) of the connected
machine(s).
− Downtimes are reduced considerably.
■ Malfunctions are detected quickly and can be eliminated by
the operator.

Characteristic features ■ A GSM modem belongs to the scope of delivery. It can be

used to send messages to any mobile phone as text mes-
sages via the mobile network.
■ The collected messages can be output in an XML file. This
allows them to be further processed very easily for further
evaluation (PDA/MDA).

Additional document "TruTops message" technical telegram.

5.5 Camera for process monitoring

The camera, which is firmly installed in the machine room, dis-

plays images of the working area and enables the monitoring of
the cutting process.
The camera has an interface and a holder for an external moni-
tor.

Advantage ■ Optimum control of the cutting process.

3-28 Camera for process monitoring 2011-10-07 B743en

 6. Automation

Step-by-step automation A multistage automation concept has been developed for auto-
mation of loading and unloading cycles.
This concept makes it possible to meet the requirements of the
customer specifically. The degree of automation of the machine
is adapted to the requirements of the customer.

The automation concept for the TruLaser machines has four

stages:
■ Stage 1: automatic loading using LoadMaster.
■ Stage 2: automatic loading and unloading using LiftMaster.
With or without connection to storage.
■ Stage 3: automatic loading and unloading as well as sorted
storage of the finished parts using LiftMaster Sort and Sort-
Master. With or without connection to storage.
■ Stage 4: automatic loading and unloading as well as sorted
storage of the finished parts using LiftMaster Store. With
direct connection to storage.

The following loading and unloading cycles can be automated:

■ Storage/supply of raw sheets.
■ Loading of raw sheets.
■ Removal of machined sheets.
■ Storage of machined sheets in a storage system.
■ Sorted removal and depositing of small ready parts up to 6
mm sheet thickness.
■ Removal and separated storage of maxi-parts and waste
grid.

Additional document Technical information "TruLaser Series 3000 / 5000" automation

concept.

B743en 2011-10-07 Automation 3-29

 6.1 Example

Fig. 57162

3-30 Example 2011-10-07 B743en

 7. Technical data

TruLaser 5030 TruLaser 5040

(L41) (L47)
Laser TruDisk 3001 TruDisk 3001
TruDisk 5001 TruDisk 5001
Working areas Working area X/ 3000 x 1500 4000 x 2000
Y axis mm mm
Working area Z 115 mm
axis
Accuracy Central position- ±0.03 mm/m
ing variation in
the sheet
Positioning ±0.1 mm/m
accuracy Pa in
the sheet
Smallest pro- 2.3 mm
grammable
increment
Control system TRUMPF CNC SINUMERIK 840D sl
based on
Main memory 1 GB
PC
Hard disk 2 x 40 GB
Color screen, 17"
TFT
Monitor screen 1024 x 768"
resolution
USB connection Yes
Ambient temper- Permissible +10 to 35 °C
ature ambient temper-
ature
Dimensions and Length 9300 mm 12000 mm
weights
Width 4600 mm 5300
Height 2200 mm
Approx. weight 12,700 kg 19,700 kg
Entire system Electrical con- With TruDisk 3001 40 kVA / 80 A
nection /
With TruDisk 5001 55 kVA / 100 A
Fuse protection
with process
cooler
at 400 V / 50
Hz or
at 460 V/60 Hz)

B743en 2011-10-07 Technical data 3-31

 TruLaser 5030 TruLaser 5040
(L41) (L47)
Electrical power 7,8 kW, 19 - 29 kW (with TruDisk
consumption 3001)
incl. process
7,8 kW, 28 - 48 kW (with TruDisk
cooler in
5001)
standby mode
and at 100 %
laser power (at
400 V / 50 Hz
or at 460 V / 60
Hz)
Sheet thickness Mild steel O2 20 mm (with TruDisk 3001)
maximum
25 mm (with TruDisk 5001)
Stainless steel 15 mm (with TruDisk 3001 / 5001)
N2
Aluminum N2 15 mm (with TruDisk 3001)
20 mm (with TruDisk 5001)
Copper 6 mm (with TruDisk 3001)
10 mm (with TruDisk 5001)
Brass 6 mm (with TruDisk 3001)
Tab. 3-1

3-32 Technical data 2011-10-07 B743en

 Chapter 4

Operating
Auxiliary systems at the user interface 4-4

1 Description of the operating elements 4-5

1.1 User interface 4-10
User interface layout 4-10
1.2 USB connection 4-13
1.3 Keyboard 4-13

2 Switch on the machine 4-14

2.1 Unlock EMERGENCY STOP 4-14
2.2 Switch on the machine 4-14

3 Switch the machine off 4-16

3.1 Switch the machine off 4-16

4 User interface: Basic settings 4-17

4.1 Calibrate the touchscreen 4-17
4.2 Set language, measuring system, date and 4-18
time

B743en 2011-10-07 Operating 4-1

 4.3 Switching off the user interface (MMC) 4-18

5 Production 4-19
5.1 Prepare program 4-19
5.2 Executing a program automatically 4-20
5.3 Displaying program 4-21
5.4 Pause program 4-21
5.5 Aborting a program 4-22
5.6 Performing post-production 4-22

6 Flexible entry into the program 4-23

6.1 Restarting the program after an interruption 4-24
Entry at the point of interruption 4-24
Entry at a piercing 4-26
Entering at a specific part 4-27

7 Modifying technology parameters man- 4-29

ually
7.1 Modifying loading modes 4-29
7.2 Lasertechnologie anpassen 4-29
7.3 Modifying microjoints 4-30
7.4 Modifying sheet technology 4-31
7.5 Modifying the sheet measurement 4-31

8 Manual functions 4-32

8.1 Using manual functions 4-34

9 Working with the production plan 4-35

9.1 Manually creating a production plan 4-36
9.2 Deleting a job 4-36
9.3 Modifying the sequence of the jobs 4-37
9.4 Starting the production plan 4-37
9.5 Resume production plan after an interruption 4-37
9.6 Displaying production overview 4-38
9.7 Displaying the machine or component status 4-38
during re-entry

10 Setup 4-39
10.1 Moving the axes manually 4-39
10.2 Releasing brakes for the Z axis drive 4-39
10.3 MDA 4-40

4-2 Operating 2011-10-07 B743en

 Creating programs block-by-block 4-40

11 Programming 4-41
11.1 Process Part 4-41
Add a part to the partlist 4-41
Process part 4-41
11.2 Create Program 4-43
Create a program 4-43
11.3 Management Part Files 4-44
Manage files 4-44
Delete files or clear folder 4-44

12 Program management 4-45

12.1 Displaying program 4-45
12.2 Edit program 4-45
12.3 Modifying technology parameters in the Edi- 4-46
tor
12.4 Finding and replacing in the NC program 4-47
12.5 Renumbering the program 4-48
12.6 Delete program 4-49
12.7 Exporting program 4-49
12.8 Editing a program 4-49
12.9 Copying a program 4-50

13 Help in the case of problems 4-51

13.1 Switch off the machine if malfunctions occur 4-51
13.2 Activating remote diagnostics 4-51

B743en 2011-10-07 Operating 4-3

 Auxiliary systems at the user interface
If anything remains unclear with regard to operation, tools, pro-
gramming or other topics concerning the machine, then the Main
Help function can be called up via the question mark on the user
interface.
A Key Word and Index Search function are provided to ensure
that the correct topic can be found quickly. Contents that are
often required can be designated with a bookmark.

4-4 Operating 2011-10-07 B743en

 1. Description of the operating elements

Operating elements outside Operat- Designation Description

of the control panel ing ele-
ment
MAIN SWITCH Switches the machine's power sup-
ply on or off.

Tab. 4-1

Operating elements on the

start post

Fig. 61264

Operat- Designation Description

ing ele-
ment
EMERGENCY STOP Pressing the EMERGENCY STOP
impact button results in the follow-
ing:
■ All travel motions of the
machine and of the pallet
changer are aborted.
LIGHT BARRIER Button flashes when the light bar-
INTERRUPTED rier has been interrupted in the
area of the pallet changer.

START Prerequisites
■ No errors pending.
■ The light barrier has been
acknowledged.
The loading operation is started.

B743en 2011-10-07 Description of the operating elements 4-5

 Operat- Designation Description
ing ele-
ment
ACKNOWLEDGE Pressing the foot-operated switch
LIGHT BARRIER on the start pedestal activates the
light barrier in the area of the pallet
changer.
ACKNOWLEDGE Pressing the button acknowledges
PALLET CHANGE pallet loading and a pallet change
is performed automatically when
next activated in the program.
Operating elements on the start post Tab. 4-2

Control panel with

touchscreen

1 User interface with touchscreen 2 Operating elements of the

machine
Fig. 55385

4-6 Description of the operating elements 2011-10-07 B743en

 Control elements of the Operat- Designation Description
machine ing ele-
ment
MACHINE ON/OFF Switching the machine on or off.

With MACHINE ON:

■ The power supply for the drives
is activated.
■ Test cycles are performed in
order to monitor the supply devi-
ces (compressed air, axes, oil
supply etc.).
■ The machine is ready for opera-
tion when the button lights up.

MACHINE OFF is triggered by:

■ EMERGENCY STOP impact
button.
■ Errors which trigger an EMER-
GENCY STOP.
LASER ON/OFF Pressing the key starts the auto-
matic power-up or shutdown cycle
of the laser.
Button flashes slowly: the laser
control system is switched on; the
laser is off or is starting up until
communication is established.
Button flashes quickly: the laser
control system is switched on.
Communication with the laser is
available. The laser is starting up.
Button flashes briefly: laser control
system is switched on. Communi-
cation with the laser is available.
Laser is in standby mode.
Button lit up: laser and laser con-
trol system are switched on. If the
button is pressed again for longer
than 3 seconds, the automatic
shutdown cycle begins.
Button is not lit up: laser control
system is switched off.
APPROACH HOME Referencing axes and establishing
POSITION the machine's home position:
■

Pushbutton lights up when the

home position has been reached.
Pushbutton flashes if the home
position has not been reached.

B743en 2011-10-07 Description of the operating elements 4-7

 Control elements of the Operat- Designation Description
machine ing ele-
ment
FEEDRATE POTENTI- The potentiometer can be used to
OMETER regulate the positioning speed of
the X- and Y-axes between 4%
and 120%..
The travel regulation in the main
activity Production is 4-100 m/min.
The travel regulation in the main
activity Setup is 4-15 m/min with
simultaneous axis motion.
JOG BUTTON Prerequisites
■ No EMERGENCY STOP is
active.
■ No FEED HOLD is active.
■ The Setup activity is selected.

ACKNOWLEDGE THE The indicator lamp flashes if the

LIGHT BARRIER light barrier is interrupted.

FEED HOLD Stop all movements on the

machine and on the pallet changer.
■ The button lights up with FEED
HOLD.
■ The reference points are
retained.
■ The laser beam and cutting gas
are switched off.
■ No machine motion is possible
as long as FEED HOLD is
active.
■ Pressing START cancels the
FEED HOLD.
RESET RESET interrupts control mode and
resets the control system to the
default condition.
All active error messages are
deleted. An active program is abor-
ted and closed. The reference
points are retained.
The home position can be lost by a
RESET.
PLAY / START Prerequisites
■ No errors pending.
■ The light barrier has been
acknowledged.
Acknowledge FEED HOLD.
START PROGRAM Execute NC program.

4-8 Description of the operating elements 2011-10-07 B743en

 Control elements of the Operat- Designation Description
machine ing ele-
ment
EMERGENCY STOP Pressing the EMERGENCY STOP
impact button results in the follow-
ing:
■ All travel motions of the
machine and of the pallet
changer are aborted.
■ Cutting gas supply is interrup-
ted.
■ The beam trap is closed and the
laser beam is switched off.
■ The power supply for the entire
system (except the 24 V voltage
of the control) is interrupted.
■ The reference points of the axes
are retained.
■ The system must be put back
into its home position.
■ An active machining program is
aborted and needs to be restar-
ted, if required.
DOOR SWITCH BUT- Unlock protective door.
TON
The safety door is locked via the
DOOR SWITCH button or the
START button. If the safety door is
closed properly, the LED in the
button lights up blue. In this state,
the door can be opened only after
pressing the button.
BEAM BLOCK KEY The safety circuit of the laser is
SWITCH interrupted by turning the key
switch.
The laser beam cannot be ignited if
the beam block is active and the
key has been removed.

OPEN/CLOSE BEAM In the main activity Production:

TRAP ■ The button is illuminated: The
light path is enabled.
■ The button is not illuminated:
The light path is disabled.
BEAM ON/OFF In the main activity Production:
■ The button is illuminated: The
beam has been activated.
■ The button is not illuminated:
the beam has been switched off.
Tab. 4-3

B743en 2011-10-07 Description of the operating elements 4-9

 1.1 User interface

User interface layout

1 Login status 4 Status bar 6 Sub-operations

2 TRUMPF logo 5 Message line 7 Context buttons
3 Main activity
Touchscreen Fig. 58615

Status bar Symbol in status bar Description of the symbol

Home position missing.

Home position has been established.

Light barrier has been interrupted.

Depending on the program status, actions can

be triggered or procedures blocked.
■ Program is running.
■ Program has stopped: the program has been
stopped with NC stop axes, M00, M01 or
single block mode.
Laser beam is off, beam trap (TruFlow) or
absorber (TruDisk) is closed.

Laser beam is off, beam trap (TruFlow) or

absorber (TruDisk) is open.

Laser beam is ignited, beam trap (TruFlow) or

absorber (TruDisk) is closed.

4-10 User interface 2011-10-07 B743en

 Status bar Symbol in status bar Description of the symbol
Laser beam is ignited, beam trap (TruFlow) or
absorber (TruDisk) is open.

Laser beam is off, beam lock is active.

Touchscreen is not active.

Alarm messages have been received (the num-

ber of messages is displayed next to the sym-
bol).
Warning messages have been received (the
number of messages is displayed next to the
symbol).
Maintenance symbol (maintenance work is
pending).

Tab. 4-4

Message line The message line is divided into four areas and is used to dis-
play information (gray), warnings (yellow) and error messages
(red):
■ The time at which the message appeared.
■ The corresponding message number.
■ A brief description of the message that appeared.
■ Source of the error: element of the control system or of the
machine that caused the message.

Note
Details concerning information text, notes and error messages
are listed under Diagnostics.

Login status Three pieces of information are displayed to the right, next to the
status bar and message line:
■ Logged-on user.
■ Current date.
■ Current time.

The following functions are displayed on pressing on the informa-

tion displayed in the login status:
■ Information about the user.
− Language.
− Unit of measurement.
■ Information about the system.
− Date and time.
− Region.

B743en 2011-10-07 User interface 4-11

 TRUMPF logo User Log Off: press on the TRUMPF logo.
To exit user interface (MMC): press the TRUMPF logo, press
System, press Exit HMI.

Main activities Main activities Functions in the main activity

Main activity: production plan
■ Process several jobs arranged in sequence.

Main activity Production:

Prerequisite: Home position has been estab-

lished.
■ Loading programs.
■ Preparing programs.
■ Producing programs.
■ Modifying technology parameters.
■ Executing a production plan.
■ Managing inventories for the production plan.
■ Viewing manual functions and partially actua-
ting them.
Main activity Set-up:
■ Moving axes manually (active only with con-
trol system: Stop).
■ Using manual functions.
■ MDA
Main activity Programming:
■ Program management.
■ Editing existing programs.
■ Working with the production plan.
Main activity Technology:
■ Modifying technology parameters.
■ Viewing information on the cutting head.

Main activity Maintenance & start-up.

Main activity Diagnostics:

■ Display warnings, alarms and information
messages.
■ Sort messages.
■ Display software versions.
■ Displaying digital inputs and outputs.
The Diagnostics button flashes when a new
warning or alarm is received.

4-12 User interface 2011-10-07 B743en

 Main activities Main activities Functions in the main activity
Main activity Help:
■ Search.
■ Index.
■ Bookmark.
Tab. 4-5

List selection On pressing ,a list opens up from which parameters can be

selected: the manual functions, for example.

Sub-operations Each main activity can consist of several sub-operations (tabs).

1.2 USB connection

If there is no direct connection between production system and

machine, data transfer can take place via the USB interface. The
USB connection is on the left hand side of the control panel.

1.3 Keyboard

The keyboard is divided into typewriter keys and special keys.

Key Function
<F1> Calling up documentation.
<F11> or <F12> Equivalent to Focus
<Shift + F11> or Equivalent to Magnifying glass
<CNTRL+F11>
<CNTRL+F5> Equivalent to Page up
<CNTRL+F6> Equivalent to Page down
<Shift + F12> Corresponds to Toggle.
<CNTRL+F3> Corresponds to locking the touchscreen
<CNTRL+F2> Equivalent to Change of application
<Backspace> Pressing the <Backspace> key moves the cursor of
an input field to the left by one character, deleting
each character as it goes.
<Num> The <Num> key activates the number pad on the con-
trol panel.
Special keys Tab. 4-6

B743en 2011-10-07 USB connection 4-13

 2. Switch on the machine

2.1 Unlock EMERGENCY STOP

The EMERGENCY STOP impact button is located on the control

panel.

Ø To release the EMERGENCY STOP impact button: press the

impact button and turn it to the left.

2.2 Switch on the machine

Condition
■ EMERGENCY STOP is released.

Note
If the machine has been switched off at the main switch and will
then be immediately switched back on, the following must be
observed: the main switch may not be turned back to position A
until the light above the main switch has gone off. Otherwise, the
user interface is not completely shut down and a black screen is
displayed.

1. Switch on the gas supply.

2. Turn the air supply on.
3. Turn the MAIN SWITCH on the switch cabinet to I.
The control system of the machine starts. This can take
some time. The start page of the user interface appears.
4. Press LASER ON/OFF .
LIGHT BARRIER INTERRUPTED lights up on the operating
panel and on the start pedestal of the pallet changer.
5. Press the ACKNOWLEDGE THE LIGHT BARRIER FOOT
SWITCH at the start pedestal.
Press ACKNOWLEDGE LIGHT BARRIER on the operating
panel.
The FEED HOLD button lights up. START flashes .
6. To acknowledge Feed hold: press START .
The MACHINE ON/OFF button flashes.
7. Press MACHINE ON/OFF .
8. Press APPROACH HOME POSITION .

4-14 Switch on the machine 2011-10-07 B743en

 The axes move to home position, whereby first the Z axis and
then the X and Y axes move into home position.
Pallet changer moves to home position.
When the home position has been reached, the APPROACH
HOME POSITION button will light up.

B743en 2011-10-07 Switch on the machine 4-15

 3. Switch the machine off

3.1 Switch the machine off

Conditions
■ No program is being executed.
■ The machine is in JOG mode.

1. Press LASER ON/OFF until a message appears that the

laser control system is switched off.
The automatic shutdown cycle is started.
2. Wait until the message appears that the laser control system
is switched off.
3. Press MACHINE ON/OFF .
4. Turn the MAIN SWITCH to 0.
5. Switch off the air supply and lock it.
6. Switch off the gas supply.

4-16 Switch the machine off 2011-10-07 B743en

 4. User interface: Basic settings

4.1 Calibrate the touchscreen

The touchscreen (a monitor with sensor fields) must be calibra-

ted in order to ensure that the user interface buttons react in an
optimal fashion when touched.
It may be that operators of different height will need to readjust
the touchscreen.

1. Press on the date on the user interface.

The "Settings" mask is displayed.
2. Press Calibrate touchscreen.
The following mask is displayed:

Calibrate touchscreen: one of the destinations Fig. 38281

Note
Do not press on the middle of the screen!
3. Press the destinations that are displayed, one after another,
while in a normal operating position.
4. To confirm the setting: press the button with the green check
mark.

B743en 2011-10-07 User interface: Basic settings 4-17

 4.2 Set language, measuring system,
date and time

Adopt changes 1. Press the date on the user interface next to the TRUMPF
logo.
"Settings" is opened.
2. Modify entries and press OK.
The modifications are accepted.
Permanently save 3. Press the TRUMPF logo.
modifications
The "Log Off" mask is displayed.
4. Press Yes.
The "TRUMPF Operating System - PNC-P[XPe]" (TOS) mask
is displayed.
5. Press MMC, MMC with servers.
The changes are permanently saved. The user interface is
displayed.

4.3 Switching off the user interface

(MMC)

1. On the user interface, press the TRUMPF logo.

2. Press System.
3. Press Exit HMI.
The user interface is shut down.

4-18 User interface: Basic settings 2011-10-07 B743en

 5. Production

5.1 Prepare program

All of the NC programs required at the machine must first be

imported into the control system. The NC programs can be
imported from a master file of the machine, from any random
network drive or from a local PC.

Load program 1. Press Production, "Prepare program".

2. Open the "storage location" with .
3. Select Internal management.
All programs that have been split up are listed in the pro-
gram list.
4. Open the "storage location" with .
5. Select Drives.
6. Switch to the directory from which the program is to be loa-
ded.
7. Press Import....
8. Activate one or several programs.
9. To import all programs: press Select all.
10. Select Import .
11. Open the "storage location" with and select Internal
management.
The selected program has been applied in the internal man-
agement system of the control.
Modifying parameters 12. Mark a program for which the parameters are to be modified.
13. Press Technology correction....
14. Modify parameters if necessary .
15. Press Finish.
Check program 16. Mark a program that is to be checked.
17. Press "Check program".

B743en 2011-10-07 Production 4-19

 5.2 Executing a program automatically

Conditions
■ The machine is ready for operation.
■ Laser is ready for operation.
■ The home position of the machine has been established.
■ The NC program is stored in the internal management sys-
tem in split form.
■ The Cancelled program status is displayed.

Viewing programs 1. Press Production, Select program....

"Select program" is opened.
2. Open the "storage location" with .
All programs that are stored in this folder are displayed in the
list.
3. Switch to the directory from which the program is to be loa-
ded.
Reading in program via USB 4. Connect the USB memory stick.
interface 5. Open the "storage location" with and select Drives.
6. Select under "Path".
7. Select the drive (H:\ or G:\) for the USB memory stick

Filtering the program Note

The list of programs can be limited by the use of filters.
8. To filter in accordance with designation, enter search string
under "Filter", e.g. the first letter or digit of the file name.
All programs that have the entered search string in their
name are displayed.
9. To undo the search, press next to the input field.
Load program 10. Select a program from the list.
The selected program is highlighted in yellow.
11. Press Next.
If the installed cutting head or nozzle doe not correspond to
the selected program, the Select program: Load cutting head
mask is displayed.
The required cutting head and nozzle data are listed in the
"TO LOAD" column.
12. To replace the cutting head: press Head change position.
13. Replace the cutting head.
14. To replace the nozzle: press Nozzle change position.
15. Replace the nozzle on the cutting head.
16. Press Apply.
Modified components are accepted by the control system.

4-20 Production 2011-10-07 B743en

 The program is loaded. A graphical NC simulation is started, the
sheet graphics will be displayed in the preview. Information about
the currently loaded program is displayed on the right side of the
screen.

5.3 Displaying program

Condition
■ A program is active.

1. Press Production, "Current program".

The top line contains program information such as program
name, material, etc.
2. Open the "View" with .
3. Select NC simulation+NC blocks.
The sheet diagram is displayed in the preview. The right side
of the user interface shows the program name and the previ-
ous, the currently active and the next NC block.
or
Select NC simulation+process data.
The sheet diagram is displayed in the preview. The axis
positions and the feed are displayed on the right-hand side
of the user interface.
or
Select NC program + NC blocks call-up sequence.
The right side of the user interface shows the program name
and the previous, the currently active and the next NC block.

5.4 Pause program

The machine can be stopped during processing, e.g. to check

the parts.

Condition
■ A program is being executed.

1. Press FEED HOLD .

FEED HOLD lights up.
The machine is now at a standstill.
The "Paused" program status is displayed.

B743en 2011-10-07 Production 4-21

 2. Open safety door and check the cutting result.
FEED HOLD blinks.
3. When the check is finished, close the safety door.
START flashes.
4. To acknowledge FEED HOLD : pressSTART .
The machine resumes operation.

5.5 Aborting a program

Condition
■ A program is being executed.

1. Press FEED HOLD .

FEED HOLD lights up.
The machine is now at a standstill.
2. Press RESET .
The current program is interrupted. To resume the program (see
"Flexible entry into the program", pg. 4-23).

5.6 Performing post-production

Immediately after the execution of a program it is found that

additional parts are needed from the program that has just been
executed. Reasons for this may include additional needs or dam-
aged parts.

1. Press Post-production.
A dialog box for post-production opens.
2. Enter sheet format and zero point offset (ZPO).
3. Press Next.
4. Select the desired parts.
5. Enter the desired number of pieces.
6. Press Next.
7. If other parts are to be post-produced, press Previous, other-
wise press Finish.
8. Execute a program.

4-22 Production 2011-10-07 B743en

 6. Flexible entry into the program

The user interface displays the entire sheet in an overview with

the already complete machining. A second area shows a sheet
section previously defined by the operator.

1 Sheet 2 Zoomed-in section

Overview: flexible entry Fig. 57321

If the program is interrupted (interruption place = white cross),

machining can be resumed via the type of entry using different
strategies.

Possible types of entry:

■ (see "Entry at the point of interruption", pg. 4-24).
■ (see "Entry at a piercing", pg. 4-26).
■ (see "Entering at a specific part", pg. 4-27).

B743en 2011-10-07 Flexible entry into the program 4-23

 6.1 Restarting the program after an
interruption

Entry at the point of interruption

Conditions
■ The main activity Production is active.
■ A program is selected or canceled.
■ The home position has been approached.

Define abortion point 1. Press Production, Flexible entry....

The "Flexible entry: Select abortion point" mask is displayed.
2. Press "Current abortion point" ("Saved abortion point": ).
Sheet and blank are shown.
The abortion point is marked with a white cross.
More information on the abortion point, such as "Active NC
block" or "Current machining type" are displayed.
3. To zoom in on a section:
− In the "Sheet" graphic, select the desired area with the
mouse or your finger.
− To zoom in, press the MAGNIFYING GLASS + button.
− To zoom out, press the MAGNIFYING GLASS - button.
4. Press Continue.
The "Flexible entry: Select type of entry" mask is displayed.
Determine type of entry 5. Select "At the interruption point"

Type of entry Note

At the interruption The box is grayed out if the interruption point is
point unknown or the program was not yet started.
Selection of type of entry Tab. 4-7

6. Press Continue.
The "Flexible entry: Distance to interruption point" mask is
displayed.
For laser machining, "Details" shows the path length, the
path length already processed, and the path length before
and after the interruption point.
7. Select "At block begin" (default setting)
The complete travel command of the NC block for this
machining is performed anew.
or
To move the point of entry in front of the interruption point
for laser machining: Select "Corrected position" and enter a
value.

4-24 Restarting the program after an interruption 2011-10-07 B743en

 1 Entry at block begin (yellow 2 Interruption point (white
target) cross)
Flexible entry at block begin Fig. 57322

All performed actions are displayed in the graphic.

8. Press Continue.
The "Flexible entry: Select option" mask is displayed.
Select option, start flexible 9. Activate "Accelerated block search run"
entry
In the background the program is worked through without
positioning motions of the machine and without tools up to
the reentry point. The option "Accelerated block search run"
shortens this process.

Tip
If an error message appears when the option "Accelerated
block search run" is set, which may happen in programs of
third-party programming systems, the option must be dese-
lected.
10. Press Finish.
"Current program" is displayed. The sheet graphic can be
used to follow how the reentry point is searched for. The
symbol for the flexible entry is shown in the status bar.
The START button blinks.
11. Press START.
The flexible entry starts within a few seconds.

B743en 2011-10-07 Restarting the program after an interruption 4-25

 Entry at a piercing

Conditions
■ The Production main activity is active.
■ A program is selected or aborted.
■ Die Grundstellung ist angefahren.

Define cancellation point 1. Press Production, Flexible entry....

The "Flexible entry: Select abortion point" mask is displayed.
2. Press "Current abortion point" ("Saved abortion point": ).
Sheet and blank are shown.
The abortion point is marked with a white cross.
More information on the abortion point, such as "Active NC
block" or "Current machnining type" are displayed.
3. To zoom in on a section:
− In the "Sheet" graphic, select the desired area with the
mouse or your finger.
− To zoom in, press the MAGNIFYING GLASS + button.
− To zoom out, press the MAGNIFYING GLASS - button.
4. Press Continue.
The "Flexible entry: Select type of entry" mask is displayed.
Determine type of entry 5. Select "At a certain piercing"

Type of entry Note

At a certain piercing Piercing:
■ Reentry takes place in the NC block at the
NC cycle "TC_LASER_ON".
Selection of type of entry Tab. 4-8

6. Press Continue.
The "Flexible entry: Piercing" is displayed.
7. Enter piercing directly under "Selected".
or
Select piercing via Previous, Next.
or
Select piercing by right-clicking the graphic.
8. Press Continue.
The "Flexible entry: Select option"mask is displayed.
Select option, start flexible 9. Activate "Accelerated block search run"
entry
In the background the program is worked through without
positioning motions of the machine up to the reentry point.
The option "Accelerated block search run" shortens this proc-
ess.

4-26 Restarting the program after an interruption 2011-10-07 B743en

 Tip
If an error message appears when the option "Accelerated
block search run" is set, which may happen in programs of
third-party programming systems, the option must be dese-
lected.
10. Press Finish.
"Current program" is displayed. The sheet graphic can be
used to follow how the reentry point is searched for. The
symbol for flexible entry appears in the status bar.
The START button blinks.
11. Press START.
The flexible entry starts within a few seconds.

Entering at a specific part

Conditions
■ The Production main activity is active.
■ A program is selected or aborted.
■ Die Grundstellung ist angefahren.

Define cancellation point 1. Press Production, Flexible entry....

The "Flexible entry: Select abortion point" mask is displayed.
2. Press "Current abortion point" ("Saved abortion point": ).
Sheet and blank are shown.
The abortion point is marked with a white cross.
More information on the abortion point, such as "Active NC
block" or "Current machnining type" are displayed.
3. To zoom in on a section:
− In the "Sheet" graphic, select the desired area with the
mouse or your finger.
− To zoom in, press the MAGNIFYING GLASS + button.
− To zoom out, press the MAGNIFYING GLASS - button.
4. Press Continue.
The "Flexible entry: Select type of entry" mask is displayed.
Determine type of entry 5. Select"At a certain part".
6. Press Continue.
The "Flexible entry: Part" mask is displayed.
7. Enter part directly under "Selected".
or
Select part via Previous, Next.

B743en 2011-10-07 Restarting the program after an interruption 4-27

 or
Select part by right-clicking the graphic.
8. Press Continue.
The "Flexible entry: Select option"mask is displayed.
Select option, start flexible 9. Activate "Accelerated block search run"
entry
In the background the program is worked through without
positioning motions of the machine up to the reentry point.
The option "Accelerated block search run" shortens this proc-
ess.

Tip
If an error message appears when the option "Accelerated
block search run" is set, which may happen in programs of
third-party programming systems, the option must be dese-
lected.
10. Press Finish.
"Current program" is displayed. The sheet graphic can be
used to follow how the reentry point is searched for. The
symbol for flexible entry appears in the status bar.
The START button blinks.
11. Press START.
The flexible entry starts within a few seconds.

4-28 Restarting the program after an interruption 2011-10-07 B743en

 7. Modifying technology parameters
manually

The technology parameters can be modified, even if a program

has already been started. Modifications are saved at once and
become effective the next time the parameter is activated in the
program.

The following can be modified:

■ Loading: parameters for different loading options.
■ Laser technology: Parameters for machining the part with the
laser.
■ Microjoint: parameters for execution of microjoints.
■ Sheet technology: parameters for specification of the sheet or
of the workpiece.
■ Sheet position measuring: parameters for measuring the
sheet position.

7.1 Modifying loading modes

The loading tables can be used to define parameters for the

loading procedure for the machine.

Conditions
■ A program is active.
■ FEED HOLD is active.

1. Press Production, Current program/Prepare program, Tech-

nology correction....
2. Activate "Loading".
3. Press Next .
"Technology correction: Loading" opens.
4. Modify parameters for the loading mode.
5. Press Close.
6. Press START .

7.2 Lasertechnologie anpassen

Laser technology tables are applicable to more than one pro-

gram, and are stored in the control system. All parameters
required to machine the part with the laser are stored in these
tables.

B743en 2011-10-07 Modifying technology parameters manually 4-29

 Conditions
■ A program is active.
■ FEED HOLD is active.

Modifying parameters 1. Press Production, Current program/Prepare program, Tech-

nology correction....
2. Activate "Laser technology".
3. Press Next .
The "Technology correction: Select technology" mask is
opened.
4. Select the desired technology with Previous technology or
Next technology.
5. Press Next .
The "Technology correction: Edit laser machining" mask
appears.
6. To select the desired table: Press Previous technology or
Next technology.

Note
The system applies the modified parameters when a field is
exited. Modifications do not need to be confirmed.
7. Press Save and selection or Save and close.
8. Press START .
The current program is displayed.

7.3 Modifying microjoints

The microjoint tables can be used to modify the parameters for

the execution of microjoints.

Conditions
■ A program is active.
■ FEED HOLD is active.

1. Press Production, Current program/Prepare program, Tech-

nology correction.
2. Activate "Microjoint".
3. Press Next .
"Technology correction: Microjoint" opens.
4. Modify the parameters for the execution of microjoints.
5. Press Close.
6. Press START .

4-30 Modifying technology parameters manually 2011-10-07 B743en

 7.4 Modifying sheet technology

The sheet technology tables can be used to modify the parame-

ters for the execution of the sheet/the workpiece.

Condition
■ FEED HOLD is active.

1. Press Production, Current program/Prepare program, Tech-

nology correction.
2. Activate "Sheet technology".
3. Press Next .
"Technology correction: Sheet technology" opens.
4. Modify the parameters for the execution of the sheet/the
workpiece.
5. Press Close.
6. Press START .

7.5 Modifying the sheet measurement

The tables can be used to modify the parameters for the execu-
tion of sheet position measurement.

Condition
■ FEED HOLD is active.

1. Press Production, Current program/Prepare program, Tech-

nology correction.
2. Activate "Sheet position measuring".
3. Press Next .
"Technology correction: Sheet position measuring" opens.
4. Modify the parameters for the execution of sheet position
measurement.
5. Press Close.
6. Press START .

B743en 2011-10-07 Modifying technology parameters manually 4-31

 8. Manual functions

The "Manual functions" switch machine functions. Only a limited

number of functions is available when the machining is in the
main activity Production. In the main Setup operation, all func-
tions can be modified.

The user interface displays the switch state of the manual func-
tions:
■ Activate a switch state, e.g. General.
■ Two switch states, e.g. Automatic shutdown on or off.
■ Multiple switch states (max. 6): the state can be set in
stages.

Main activity Manual function Note

Production General Work area illumina- Switch the work area illumination on and
tion off.
STOP single contour After processing an individual contour, stop
processing.
STOP after part After processing a part, stop processing.
Piercings up to the Entering the number of piercings until noz-
brushes zle brushing is performed.
Tapeshot Start dialog-driven utility program to center
the lens nozzle.
Reducing feed Limit positioning speed, e.g. in the night
shift.
Conveyor forward Let the longitudinal and transverse con-
veyor belts (optional) run forward.
Conveyor reverse Let the longitudinal and transverse con-
veyor belts (optional) run in reverse.
Auto-shutdown When auto-shutdown is activated, the
machine and laser machine switches into standby mode 10
min (default setting) after the last axes
motion. Running NC programs continue to
be processed until program end.
Pallet change Acknowledg-ment Acknowledge pallet change.
Sheet cleaning Move sheet cleaning brush to the upper,
brush middle, or lower position.
Service Analyser Is used exclusively during commissioning
and thus always has to be switched to "off".
The contact element analyzer may only be
used by service technicians!
Gas pressure Displaying the current cutting gas pressure.
Set-up General Release brake Z Opening and closing the brake of the Z
drive (cutting head).
Work area illumina- Switch the work area illumination on and
tion off.
Conveyor forward Let the longitudinal and transverse con-
veyor belts (optional) run forward.
Conveyor reverse Let the longitudinal and transverse con-
veyor belts (optional) run in reverse.

4-32 Manual functions 2011-10-07 B743en

Main activity Manual function Note
Suction system ON/ Switching the compact dust extractor on
OFF and off.
Electric roof open/ Opening and closing the electric roof
close
Pallet change Exchange pallets Replace the pallet in the changer with the
pallet in the machine.
Pall. A+B to changer Move both pallets into the changer.
A pallet to machine Move pallet A (upper pallet) into the
changer.
B pallet to machine Move pallet B (lower pallet) into the
changer.
Acknowledg-ment Move the pallet changer into the position
where the pallet can move directly from the
machine into the changer the next time the
pallet is changed.
Sheet cleaning Move sheet cleaning brush to the upper,
brush middle, or lower position.
PaCh. man. Index inside Open indexing in the machine.
Release brake PaCh Release brake of the pallet changer.
Lifting device Move the lifting frame of the pallet changer
up or down.
Pallet to machine Move a pallet currently at insertion height
into the machine.
Pallet in changer Move a pallet currently in the machine into
the changer. This is possible only when
there is no pallet at insertion height in the
changer.
Laser machining Cutting gas Select the cutting gas type.
Gas pressure Display of the current cutting gas pressure.
ControlLine Switching the distance control system on or
off. The distance control system is switched
on by default. The distance control system
must be switched off if, for example, an
already cut contour is traveled a second
time and the danger exists while doing so
that the cutting head will be able to collide
with the sheet through an opening.
Test marking A program is executed in "Laser test mode"
with parameters for marking from the laser
technology table; e.g. to check whether all
parts processed by the program fit on the
sheet. The LASER TEST key will be illumi-
nated after this button has been pressed.
Real time test mode A program with permanently preset parame-
ters is tested (laser power 1 %; cutting gas
pressure 2 bar). This test mode is used for
tracking the amounts of time elapsed. Func-
tions such as spraying, blow out, etc., are
not run in the test mode, the times are
however taken into account.
Tapeshot Start the "TAPESHOT" utility program.
Cutting unit Only for the Service Department!
Service Freeing the head After a collision, enable the axes so that
you can move the cutting head forward in
jog mode.

B743en 2011-10-07 Manual functions 4-33

 Main activity Manual function Note
Lubrication cycle The next time the program is started, a
lubrication cycle will be executed.
Axis diagnose Only for the Service Department!
All vacuum flaps Only for the Service Department!
Siemens license Only for the Service Department!
dial. box
Chain position Only for the Service Department!
Jog mode roof Only for the Service Department!
Monitoring flow con- Only for the Service Department!
troller
Empty mode dust The worm for conveying away the dust runs
extractor for maximum 5 min after, depending on
how long the button is pressed.
Nozzle changer Nozzle changer Nozzle changer is retracted or extended.
(option) position
Tooling position Nozzle changer is retracted or extended. In
addition, the C1 axis of the nozzle changer
is rotated into position 0.
Separating cut Type Select type of separating cut.
Save point Save a point of the separating cut contour.
Number of points Save number of taught points.
X axis Select axis to move the X axis in jog mode.
Y axis Select axis to move the Y axis in jog mode.
Z axis Select axis to move the Z axis in jog mode.
Overview of all manual functions Tab. 4-9

8.1 Using manual functions

1. To only view the state of the function: press Production,

"Manual functions".
or
To activate the function: press Setup, "Manual functions".
2. Open the manual function with .
3. Select the desired group e.g. Machine.
Possible functions are displayed.
4. Press the functions one after the other, for which the status
is to be changed.

4-34 Manual functions 2011-10-07 B743en

 9. Working with the production plan

The production plan is comprised of several jobs aligned in a

sequence. One job contains an NC program with any number of
repetitions.
The production plan can be used in the following configurations:

■ Machine without automation.

■ Machine + loading unit.
■ Machine + LiftMaster Compact without storage system.
■ Machine + LiftMaster Sort with a loading and unloading plat-
form.
■ Machine + ext. (customer-side) loading and unloading unit.

Job status Symbol Status Description

Available Job is released and can be started.

Running Job is currently being produced.

Last run-through The last sheet of a job has been star-

ted.

Ready Job is completely produced.

Blocked This job is not to be produced.

Error An error has occurred during execu-

tion. This job will not be produced.

Tab. 4-10

Status of the production The respective status symbol for the production plan status is
plan displayed after the production plan is called up. The following
states are possible in the production plan:

Symbol Status Description

Stationary Production plan is ready and can be
started.

Running Production plan is running.

Tab. 4-11

B743en 2011-10-07 Working with the production plan 4-35

 9.1 Manually creating a production plan

The production plan can be directly created on the machine user

interface. For this purpose, new jobs must be created and the
execution sequence must be defined. A job always consists of
an NC program. The execution of this job can be repeated man-
ually any number of times by means of the required quantity.
The created jobs are combined to a production package.

Creating a new job 1. Press Production plan.

2. Press Create.
3. Select storage location (internal management or drives).
Searching for an NC 4. To filter according to an NC program: Enter the program
program name as a search string in the field "Designation filter". The
first letter of the alphabet entered will already act as a filter.
or
Press to delete the filter.
5. Mark the desired program.
6. Press OK.
7. Enter the "Actual quantity" and the "Required quantity".
Enabling and disabling jobs. 8. Select a job.
To disable the job: press Disable.
or
To enable the job: press Enable.
Change quantity 9. Select the desired job and adjust the actual and required
quantity.
10. Apply the modification by clicking into another field.

9.2 Deleting a job

1. Press Delete.
The delete dialog box opens.
2. Select the desired jobs (the jobs should not be active).
3. Select the jobs to be deleted.
4. Press Delete orders or Programs and jobs.
The desired orders/programs and jobs are deleted.

4-36 Working with the production plan 2011-10-07 B743en

 9.3 Modifying the sequence of the jobs

1. To modify the sequence of the jobs: select Production, Pro-

duction plan.
2. Select the desired job.
3. Move the job to the desired position with or .

9.4 Starting the production plan

Condition
■ The desired job must be enabled.

1. Press Production plan.

2. Press Prepare.
It is checked, whether the components to be used during the
execution of the production plan (cutting head, laser, noz-
zles...) are available. If this is not the case, the respective
program is aborted during the execution of the production
plan at the point where the required component is not found.
3. Press Start.

9.5 Resume production plan after an

interruption

If the production plan stops for some reason during execution,

proceed as follows:
■ Error due to an incorrect inventory: rectify error on the con-
trol system. The production plan is automatically continued
afterwards.
■ Error which can only be rectified by manual operator inter-
vention, e.g. the LiftMaster interrupts loading operation due to
having recognized a double sheet:

1. Press Continue. All devices or only the defective device are

displayed in a mask, i.e. the LiftMaster in this example.
2. Rectify problem by separating the sheets for instance.
3. Press Repeat.
4. Press Cancel; e.g. remove the damaged sheet and dispose
of it.
5. Finish loading operation manually.

B743en 2011-10-07 Working with the production plan 4-37

 6. Press Exit. This confirms that the loading operation is com-
plete.
The production plan is automatically continued.

9.6 Displaying production overview

Ø Press Production, "Production overview".

In addition to the time details for the running program and pro-
duction plan, the time is displayed with the anticipated end of the
production plan in large numbers.

Tip
If the production plan has been completely processed, the time
is highlighted in blue. The operator can thus recognize whether
the production plan has been ended and the machine is station-
ary even from a large distance.

9.7 Displaying the machine or component

status during re-entry

The following statuses are possible:

Symbol Status Description

Stationary The machine or the component is sta-
tionary or is not active.

Stopped An error has occurred at the machine

or the component. If an error has
occurred, for instance, at an automa-
tion component, the following proce-
dure can be used: activate the line of
the component concerned and re-exe-
cute the aborted action.
Running The machine or the component is
active.

Tab. 4-12

Ø Press Re-entry.
The respective status symbol for the machine or components
status is displayed.

4-38 Working with the production plan 2011-10-07 B743en

 10. Setup

10.1 Moving the axes manually

The machine has three axes. The X, Y, Z axes of the machine

can be moved manually with the JOG BUTTONS on the control
panel.

Conditions
■ No FEED HOLD is active.
■ The home position of the machine is established.
■ No NC program is running.
■ FEEDRATE POTENTIOMETER is set to >0%.

Axis name Direction of movement

X axis Horizontal motion axis of the motion unit.
Y axis Horizontal motion axis of the cutting head.
Z axis Vertical motion axis of the cutting head.
Tab. 4-13

1. Press Setup, "Axes motion".

2. Select the desired axis.
The current axis position is displayed under "Actual value >".
3. To move the axes manually: select "Continuous" and press
the + or - JOG BUTTONS on the control panel.
or
Select "Incremental" and enter the increment for the axis
motion.
The modified axis position is displayed under "Actual value >".

10.2 Releasing brakes for the Z axis drive

To move the Z axis manually after a collision, the brakes need

to be released (bled).

Condition
■ EMERGENCY STOP is pending.

1. Press Setup, "Manual functions".

2. Press to open the manual functions.
3. Select General.

B743en 2011-10-07 Setup 4-39

 Note
The cutting optics can move downwards slowly if the brake
has been released!
4. Press Release brake Z.
The axis can be moved manually.

10.3 MDA

Under MDA (Manual Data Automatic), you can create and exe-
cute NC programs block by block. To do so, the keyboard can
be used to enter the desired movements individually in the form
of single NC blocks.

Creating programs block-by-block

1. Press Setup, "MDA".

2. Enter the desired NC text.
3. Either
Ø To copy the text: select the text and press Copy.
Ø Place the cursor at the new position and press Paste.
or
Ø To cut the text: select the text and press Cut.
Ø Click on the new position with the mouse pointer (cursor).
Ø Press Paste.
A yellow strip on the left border highlights the modified text
segment in the NC text.
4. Press Undo to undo the last action that was carried out.
5. To execute the created NC text as a whole (in successive
mode): press Start.
6. To execute the created NC text block-by-block: press "Single
block".
7. Press Start to execute each NC block individually.
8. Delete the created NC text with Delete all.

4-40 MDA 2011-10-07 B743en

 11. Programming

Note
The Process Part and the Create Sheet functions are wizard-
guided.

The programming functionality provides the following possibilities:

■ Process Part: Load a part (*.GEO,*.DXF, *.GMT) and create
a single program out of it with all laser technology data
added.
■ Create Program: Nest parts on a sheet and create a com-
plete program out of it.
■ Management Part Files: Organize part files.

11.1 Process Part

Add a part to the partlist

1. Press Programming .
2. Select "Process Part".
3. If the desired part is stored on a usb stick, insert the stick
now.
4. Press Change... next to the displayed folder path.
− Select the desired storage medium.
− Select the desired folder.
− Press Apply.
All parts ready to be processed in the desired folder are dis-
played in the part list.

Process part

Choose a part 1. Press Programming .

2. Select "Process Part".
3. Highlight the desired part in the list.
or
If the desired part is not displayed, choose the correct folder
4. Press Start.

B743en 2011-10-07 Programming 4-41

 Confirm contour Note
If the desired part is a dxf file the correct contour needs to
be confirmed.
5. Press Show Alternatives to switch between the contours
found.
or
Press Confirm suggestion to confirm the part contour.
Rotate part 6. Keep checkbox "Do not rotate" activated.
− Press rotate left or rotate right to rotate the part
manually by 90°.
or
Activate checkbox "Allow rotation" to allow automatic rotation
if needed.
or
Activate checkbox "Rotate only in rolling direction" to allow
rotation in rolling direction if needed.
7. Press Next to continue.

Select technology table Note

The tech table list can be narrowed down by sorting it by
Material, Thickness, Gas or Variant.
8. Highlight the correct tech table out of the list.
9. Press Next to continue.
Choose microjoint options 10. Specify the desired microjoint strategy by activating the cor-
responding radio button.
11. Press Process part to continue.
The laser processings are displayed with red lines for lead-
ins, green lines for contours and blue lines for positionings.
Move Lead In Position 12. Press Show Alternative to move the lead in position to the
desired position.
13. Press Next to continue.
Save part 14. Open the virtual keyboard by pressing next to the
"Enter part name" field.
The virtual keyboard is displayed.
15. Enter the part name.
16. Press Finish to save the part to the default directory (F:\pro-
grammingTool).
The part is saved as a *.GMT file.

4-42 Process Part 2011-10-07 B743en

 11.2 Create Program

Create a program

Note
The program creation process can always be aborted by press-
ing Cancel.
To undo a step in the process, press Back.

Start creating 1. Press Programming .

2. Select "Create Program".
3. Enter the desired sheet measurements and the direction of
rolling of the sheet.
4. Press Start.

Select Part To Nest Notes

■ Only parts in the F:\programmingTool folder are dis-
played.
■ The first part selected defines material, thickness, assist
gas and technology table of the program. Only parts with
equivalent specifications can be added to the program.
5. Highlight the desired part in the list.
6. Specify the desired quantity in the "Quantity to nest" field.
7. Press Next.
The nesting process starts.

View Nest Results Note

In the "View Nest Result" screen, the nest result and the list
of nested parts are displayed. The "List of nested parts"
shows the individual quantity nested on the sheet and shows
also if it was not possible to nest all parts on the sheet.
8. Press Next to continue with creating the program.
or
Press Add another part to add another part to the nest.
− See Select Part to Nest.
or
Press Delete last part to delete the part added last.
Choose options 9. Activate or deactivate checkbox "Evaporate (whole contour)".
10. Press Next to continue.
Save New program 11. Open the virtual keyboard by pressing next to the
"Enter new program name" field.
The virtual keyboard is displayed.
12. Enter the program name.

B743en 2011-10-07 Create Program 4-43

 13. Press Finish to save the program to F:dh\topsmanu.dir.
The program is saved as a *.LST file.

11.3 Management Part Files

In the "Manage Part Files" tab files (*.DXF, *.GEO, *.GMT) can
be deleted and copied from a source to a target directory.

Note
GMT files cannot be copied onto the machine.

Manage files

1. Press Programming .
2. Select "Manage Part Files".
3. Select the desired source and target directory.
4. Press Copy File to copy a file from the source to the target
directory.

Delete files or clear folder

Note
Deleting single files or clearing complete folders is only possible
on the "Target" side.

1. Select the desired Target directory.

2. Highlight the desired file.
3. Press Clear Folder to delete all files in the folder.
or
Press Delete file to delete the highlighted file.

4-44 Management Part Files 2011-10-07 B743en

 12. Program management

The following functions can be executed in the "Programs" main

operation:
■ Loading programs in the internal management system.
■ Editing.
■ Deleting.
■ Exporting.

12.1 Displaying program

The NC program of a program (main program and subroutine)

can be displayed in the NC editor.

Condition
■ The NC program was split up and is located on the
machine's control system.

1. Press Programming, "Programs".

2. Open the "storage location" with .
All programs that are stored in this folder are displayed in the
list.
3. To filter in accordance with designation, enter search string
under "Filter", e.g. the first letter or digit of the file name.
All programs that have the entered search string in their
name are displayed.
4. Press Edit.
If subroutines exist, they are listed on the left side. The NC
program of the selected program is displayed on the right
side.

12.2 Edit program

Existing programs can be edited in the NC editor.

Condition
■ The program status is .

1. Press Programming, "Programs".

B743en 2011-10-07 Program management 4-45

 2. Open the "storage location" with .
All programs that are stored in the internal management sys-
tem are displayed in the list.
3. To filter in accordance with name, enter search string under
"Filter" e.g. the first letter or digit of the file name.
All programs that have the entered search string in their
name are displayed.
4. Mark the desired program.
5. Press Edit.
The "Edit program" screen is opened.

Tip
You can find an overview of all NC functions in the current
programming manual for your machine.

6. Highlight the text to be edited.

7. Either
Ø To copy the selected text: press Copy.
Ø Place the cursor at the new position and press Paste.
or
Ø To cut out the selected text: press Cut.
Ø Click on the new position with your mouse pointer (cur-
sor).
Ø Press Paste.
A yellow strip on the left border highlights the modified text
segment in the NC program.
8. Press Undo to undo the last operation that was carried out.
9. Press Repeat to restore the operation that was undone.
10. Either
Ø To save the changes: press Save.
The changes are saved in the NC program.
or
Ø To quit the editor: press Save and close.

12.3 Modifying technology parameters in

the Editor

When executing an NC program on the machine, a screen with

technology parameters of which the data is accessed by the con-
trol system, can be selected using a defined table call instruc-
tion. These parameters can also be modified in the NC program
itself.

4-46 Program management 2011-10-07 B743en

 Parameters can be called up for the following text segments:
■ To subroutines. These are highlighted in yellow and under-
lined in the display.
■ To NC cycles, e.g. TC_SHEET_TECH (Sheet technology).
This are underlined in the display.

Conditions
■ The "Edit program" screen is opened.
■ NC program is displayed in the editor.

1. Click on the desired subroutine pr NC cycle.

2. Press Go to.
A screen with table parameters is opened.
3. Modify the desired parameters.
4. Press Finish.
The editor is displayed.
5. Either
Ø To quit the program: press Save and close.
or
Ø To modify more tables: repeat steps 1 to 4 until all the
desired parameters have been changed.
Ø Press Save and close.
The changes are applied for the selected program.

12.4 Finding and replacing in the NC

program

The search function can be used to search for a sentence or a

function in the NC program to replace it if required.

Condition
■ The "Edit program" screen is displayed.

1. Open the selection field with .

2. Select Find + Replace.
3. Enter the search string under "Search for".
4. To jump to the next search word: press Find next.
The cursor jumps to the position of the next search string.
5. If the search string is to be replaced: enter the new string
under "Replace with".

B743en 2011-10-07 Program management 4-47

 6. Either
Ø Press Replace.
The search string is replaced.
or
Ø Press Replace all.
All search strings found in the NC program are replaced.
A yellow strip on the left border highlights the modified text
segment in the NC program.
7. Either
Ø To save the changes: press Save.
The changes are saved in the NC program.
or
Ø To quit the editor: press Save and close.

12.5 Renumbering the program

There are block numbers at the beginning of each program

block. The block number is used to number individual program
blocks and is necessary for the normal program sequence. It is
useful to use ascending block numbers after making subsequent
changes.

Condition
■ The "Edit program" screen is displayed.

1. Open the selection field with .

2. Select Numbering.
3. To restart numbering after modifying the NC program: enter
the number with which renumbering is to be started under
"Start number".
4. Enter the increment that is to be inserted between the follow-
ing program blocks under "Increment".
5. Press Number.
The NC program is renumbered.
6. Either
Ø To save the changes: press Save.
The changes are saved in the NC program.
or
Ø To quit the editor: press Save and close.

4-48 Program management 2011-10-07 B743en

 12.6 Delete program

1. Press Programming, "Programs".

2. Select the desired program.
The selected program is highlighted in yellow.
3. Press Delete.

12.7 Exporting program

A program is stored in the internal management of the control

system and is to be exported as master file.

Condition
■ An NC program is stored in the internal management system.

1. Select the program to be exported.

The selected program is highlighted in yellow.
2. Press Export....
The master file is saved in the topsmanu.dir directory as *.lst
file type.

12.8 Editing a program

In the editor, a new program can be created manually or an

existing one can be copied or renamed. A new program is
always empty and needs to be filled with NC program first.

Condition
■ Drives is selected as storage location.

Creating a new program 1. To create a new program: select the "path" under which the
program is to be saved.
2. Press New.
The program is created at the end of the list. By default, the
name is NEW with a consecutive number.
Rename program 3. To rename the new program: select the program.
4. Press Rename.
5. Enter the new name and press OK.
Editing a program 6. To fill the new program with content: select the program and
press Edit.

B743en 2011-10-07 Program management 4-49

 7. Enter the desired NC program.
8. Press Save and close.

12.9 Copying a program

1. To copy an existing program: select the program.

2. Press Copy.
The copied program is given the original name plus the addi-
tion: Copy.
3. To rename the copied program: select the program.
4. Press Rename.
5. Enter the new name and press OK.

4-50 Program management 2011-10-07 B743en

 13. Help in the case of problems

13.1 Switch off the machine if

malfunctions occur

Ø Press the EMERGENCY STOP impact button on the operat-

ing panel.
or
Ø Turn the MAIN SWITCH to 0.

13.2 Activating remote diagnostics

Remote diagnostics establishes an online connection between

the machine and a service technician at TRUMPF.
The service technician can access the operating environment to
localize problems and occasionally to eliminate them directly.
The remote diagnostics must be activated on site in the "Trumpf
Operating System" (TOS).
An analog telephone modem in the machine's switch cabinet is
included in the scope of delivery.

Conditions
■ A telephone socket for an analog modem must be installed
on the machine's switch cabinet.
■ A digital connection must be converted to an analog connec-
tion by a converter.
■ It must be possible to access the telephone modem with a
direct dialing number. Otherwise, a separate exchange line is
required.

Displaying TOS 1. Either

Ø When booting the control system and the user interface,
wait until the "TRUMPF Operating System - PNC-P
[XPe]" screen is displayed.
or
Ø If the control system and the user interface have already
booted, select "TRUMPF Operating System - PNC-P
[XPe]" with the key combination <Alt> + <Tab>.
2. Press remote diagnostics.
Remote diagnostics is active if under "Remote diagnostics sta-
tus", the status of Program not in RAM changes to Wait for call.

B743en 2011-10-07 Help in the case of problems 4-51

4-52 Help in the case of problems 2011-10-07 B743en
 Chapter 5

Setting work

1 Safety information 5-3

2 Luminous displays on the cutting unit 5-4

2.1 Luminous displays on the upper cutting unit 5-4
2.2 Luminous displays on the lower cutting unit 5-5

3 Center the beam to the nozzle 5-6

3.1 Procedure with adhesive strips 5-6

4 Determining the focal position 5-9

4.1 Procedure 5-9
4.2 CP_FOCUS_COMB focus search program 5-9

5 Setting work on the pallet conveyor 5-10

5.1 Replace cam assembly 5-10
5.2 Replacing pallet conveyor chain 5-11
Procedure 5-12
Case differentiation 5-12

B743en 2011-10-07 Setting work 5-1

 Procedure in case 1 5-13
Procedure in case 2 5-14

6 Further utility programs and files 5-15

6.1 CP_TRIM_OFF parting cut program 5-15
6.2 CP_CUTTING_TOOLS - utility program for 5-15
the optimization of the parameters
6.3 Files on cutting wear parts of the workpiece 5-15
support

5-2 Setting work 2011-10-07 B743en

 1. Safety information

The following information is for your safety during setting work

on the TruLaser 5030, especially if the work is carried out with
the laser beam ignited.

Setting work Max. laser output To be carried out by

Power measurement 100 % Service personnel
Focus setting Setting work performed in Normal Novice
operation (laser system class 1)
Centering the beam to the nozzle Setting work performed in Normal Novice
operation (laser system class 1)
Setting work Tab. 5-1

Invisible, high-energy laser radiation

DANGER
Serious burns of the skin and injury to the eyes may occur.
Ø Setting work that requires 100% laser power may be carried
out only by specially trained service personnel.
Ø Protective gloves and laser safety glasses must always be
worn during setting work if the laser is switched on.
Ø The customer may have to take additional precautions to
secure the danger zone (e.g. using partition walls of sheet
steel).

Danger class ■ The danger class of the laser system in service mode is
class 4.
■ The setting work which the operator is allowed to carry out is
conducted in normal mode of the machine. The danger class
of the laser system in normal mode corresponds with
class 1.

Note
Please make sure that all setting and maintenance work on the
optical components may only be performed in a clean environ-
ment and with clean hands.

B743en 2011-10-07 Safety information 5-3

 2. Luminous displays on the cutting unit

2.1 Luminous displays on the upper

cutting unit

Luminous displays on the upper cutting unit display the status of

the drives in the cutting unit.

L1 Focal diameter adjustment drive L2 Focal position adjustment drive

Luminous display on the upper cutting unit Fig. 59870

Sequence ■ After switching the machine or the drives on, the cutting unit
is supplied with voltage and the drives in the cutting unit
move to the reference height.
■ The four LEDs on the housing show the status of both
drives.

Green LED is lit up. Drive L1 or L2 is ready.

Yellow LED is lit up. No error has occurred.
Green and yellow LEDs are lit up. The cutting unit is available.
Yellow LED flashes. There is an error.
Tab. 5-2

Note
Inform Trumpf customer service when an error occurs.

5-4 Luminous displays on the cutting unit 2011-10-07 B743en

 2.2 Luminous displays on the lower
cutting unit

Luminous displays for the sensor system electronics on the Fig. 59895
lower cutting unit

After switching the machine on and after starting the control, the
four LEDs display the status of the sensor system electronics.

Green, orange and yellow LEDs The sensor system electronics is

are lit up. ready
Green LED is lit up Power supply available
Orange LED is lit up Receiving CAN telegram
Red LED is lit up Bootloader active
Yellow LED is lit up Main program is active
Red LED is lit up and yellow LED Main program update
flashes
Yellow LED is lit up and red LED Bootloader update
flashes
Yellow and red LED flash Bootloader and main program
defective. If this is the case, con-
tact TRUMPF customer service.
Tab. 5-3

B743en 2011-10-07 Luminous displays on the lower cutting unit 5-5

 3. Center the beam to the nozzle

After the insulator has been replaced, and if necessary after the
protective glass in the cutting unit has been cleaned or replaced,
the lens should be set in such a way that the laser beam goes
through the center of the nozzle hole.

3.1 Procedure with adhesive strips

Condition
■ The characteristic curve recording for the distance control
system has been carried out.

Means, Tools, Materials

■ Thermal board.
■ Measuring magnifier (10 to 20 times magnification) and adhe-
sive strips (Tesa Film clear).
■ Edding 400 felt-tip pen.
■ Allen key size 3.
■ 10 mm open-end or box-end wrench.

The beam is centered to the nozzle with the assistance of the

menu-driven CP_TAPESHOT utility program.

1 Adjusting screw 1 3 Lock nut

2 Adjusting screw 2
Cutting unit Fig. 58808

5-6 Center the beam to the nozzle 2011-10-07 B743en

 1 Nozzle orifice 4 Beam adjustment direction
2 Nozzle with marking from below No. Adjusting screw 1 (see Fig.
3 Adhesive strip 1 58808, Pos. 1)
No. Adjusting screw 2 (see Fig.
2 58808, Pos. 3)
Adjustment directions Fig. 58809

1. Call up the CP_TAPESHOT program (the program can be

started via the “PRODUCE - General - Tapeshot“ activity
field as well).
2. Mark the position of the nozzle.
3. Stick adhesive strips without tension over the nozzle orifice.
Do not touch the adhesive strips in the scorching areas to
prevent impurities or traces of grease.
4. Put the thermal board on the sheet support.
5. Close the safety doors.
6. Release a laser pulse by pressing the Pulse softkey.
7. Open the safety door.
8. You can check whether the beam has ignited or not by the
discoloration of the thermal board.

Note
A nozzle with larger diameter must be used if no hole can be
seen or only a hole at the very edge of the nozzle orifice can
be seen, despite the laser beam being ignited.
9. Screw out the nozzle.
10. If the hole in the adhesive strip is not centered relative to the
nozzle orifice, the mark made on the nozzle must be used to
determine the direction in which it must be adjusted (see Fig.
58809).
11. The adjusting screws can be used to adjust the lens, and
hence the beam, diagonally in relation to the nozzle hole.
Note: one turn of the adjusting screw ≙ shifting the lens by
0.25 mm.

B743en 2011-10-07 Center the beam to the nozzle 5-7

 12. Undo the lock nut of each adjusting screw.
13. Turn the adjusting screw with the Allen key to the desired
position.

Note
The lock nut must be tightened again after each adjustment!
14. Tighten the lock nut again; fix the adjusting screw in position
with the Allen key.
15. Stick a new adhesive strip on the nozzle orifice and screw
the nozzle back in again each time after making adjustments.
16. Close the safety doors.
17. Trigger another laser pulse by pressing the Pulsing softkey.
18. Open the safety door.
19. Check the centricity of the hole with a magnifier.
20. Repeat this procedure until the hole is centered to the nozzle
orifice.

5-8 Center the beam to the nozzle 2011-10-07 B743en

 4. Determining the focal position

4.1 Procedure

This setting work performed with the machine in Normal opera-

tion.
All openings of the beam delivery are closed. Safety devices are
not bypassed.

Note
Danger class of the laser system in Normal operation: class 1.

To achieve good cut quality when processing workpieces, it is

necessary to set the laser beam focus at a precisely defined
position.

4.2 CP_FOCUS_COMB focus search

program

The dialog-driven focus search program CP_FOCUS_COMB is

stored in the control system and serves for detection of the
actual focal position.

Integrated help The information necessary for operation has been integrated into
the program and can be retrieved using the Information softkey.

B743en 2011-10-07 Determining the focal position 5-9

 5. Setting work on the pallet conveyor

Application Note
The setting work can be omitted on the pallet conveyor with the
TruLaser 3030 Lean Edition.

■ When replacing the cam assembly.

■ When replacing the chain.

5.1 Replace cam assembly

Procedure see Fig. 25042+59884

1. Release the brake (refer to chapter "Operation").

2. Move the chain by hand about 1 m in exit direction.

1 Lock nut 3 Threaded rod 5 Driven chain wheel

2 Chain tension control display 4 Chain X Setting dimension for the chain
tension
Adjusting device chain tension Fig. 59884
3. Undo or unscrew the lock nut (Fig. 59884, Pos.1).
4. Turn the threaded rod (Fig. 59884, Pos. 3) back until the
spring is relieved of tension.

Note
If the chain has to be removed completely, you must first
mark the position of the cam on the driven chain wheel with
a felt-tip pen.

5-10 Setting work on the pallet conveyor 2011-10-07 B743en

 1 Chain wheel 2 Chain joints
Rear deflection point of the chain Fig. 25042
5. Take the chain off the chain wheel (Fig. 25042, pos. 1).
6. Unfasten the closing links of the chain.
7. Insert a new cam assembly and install the closing links.
8. Replace the guide rails at the pallet.

Note
If the chain was completely removed, make sure when laying
the chain that it is placed in such a way that the cam sits
again on the marked position on the driven chain wheel.
9. Place the chain back onto the chain wheel.
10. Retighten the threaded rod (Fig. 59884, Pos. 3) until the set-
ting dimension of X=84 ±2 mm is achieved.
11. Secure using the lock nut (Fig. 59884, Pos. 1).
12. Push the chain in infeed direction into the home position by
hand.

5.2 Replacing pallet conveyor chain

Application ■ If the chain breaks or a worn chain is to be replaced.

■ Arrangement of the pallet changer - automation components
are lost by chain elongation.

B743en 2011-10-07 Replacing pallet conveyor chain 5-11

 Procedure

See Figs. 9304, 25042, 59884.

1. Release the brake (refer to chapter "Operation").

2. Undo or unscrew the lock nut (Fig. 59884, Pos.1).
3. Turn the threaded rod (Fig. 59884, Pos. 3) back until the
spring is relieved of tension.

Note
Before the chain is removed, you must mark the position of
the cam on the driven chain wheel with a felt-tip pen.
4. Take the chain off the chain wheel (Fig. 25042, pos. 1).

Case differentiation

To ensure the correct arrangement of the chain and drive of the

pallet infeed, the chain must be placed in an exactly defined
position on the driven chain wheel.

When the chain is laid, there are two possible initial situations
that must be distinguished for the following procedure:
■ Case 1: The driven chain wheel was not displaced and is
located in the same position as when the chain was
removed.
■ Case 2: The driven chain wheel was moved for some reason
and is not located in the same position as when the chain
was removed.
Please note: In this case, the chain exchange can only be
prepared by the customer. TRUMPF customer service must
be contacted for the subsequent commissioning.

Note
When installing the chain, make sure the cam on the chain is at
the lower chain strand. The cam on the chain can be "aligned"
into the guide rails on the pallet only from below.

5-12 Replacing pallet conveyor chain 2011-10-07 B743en

 Procedure in case 1

1 Chain wheel 2 Chain joints

Rear deflection point of the chain Fig. 25042

1. Lay the new chain on the chain wheel; make sure that both
chain joints are located on the back chain wheel and that the
chain is positioned in such a way that the cam sits on the
marked position on the driven chain wheel.

1 Lock nut 3 Threaded rod 5 Driven chain wheel

2 Chain tension control display 4 Chain X Setting dimension for the chain
tension
Adjusting device chain tension Fig. 59884
2. Retighten the threaded rod (Fig. 59884, Pos. 3) until the set-
ting dimension of X=84 ±2 mm is achieved and then secure
with the lock nut (Fig. 59884, Pos. 1).
3. Push the chain in infeed direction to the home position by
hand, in doing so "align" the pallet.
4. Replace damaged guide rails on the pallet if necessary.

B743en 2011-10-07 Replacing pallet conveyor chain 5-13

 Procedure in case 2

1. Select the "SETUP - Switch elements - Manual pallet

change" operation.
2. Press the "Pallet in changer" switch element.
3. Lay the new chain in such a way that the cam bolt (next to
the chain lock) and the indexing pin are horizontal or on the
vertex of the chain.
4. Lay the indexing pin on the front wheel.

1 Lock nut 3 Threaded rod 5 Driven chain wheel

2 Chain tension control display 4 Chain X Setting dimension for the chain
tension
Adjusting device chain tension Fig. 59884
5. Retighten the threaded rod (Fig. 59884, Pos. 32) until the
setting dimension of X=84 ±2 mm is achieved and then
secure with the lock nut (Fig. 59884, Pos. 1).
6. Push the chain in infeed direction to the home position by
hand, in doing so "align" the pallet.
Further commissioning work must be performed by a member of
the TRUMPF customer service office staff.

5-14 Replacing pallet conveyor chain 2011-10-07 B743en

 6. Further utility programs and files

For support in day-to-day operations, a series of dialog-driven

utility programs and files are supplied with the machine. The
most important utility programs (apart from those already descri-
bed in this chapter) and files are listed and described in the fol-
lowing section.

6.1 CP_TRIM_OFF parting cut program

Application After processing a sheet completely or partially, the scrap skele-

ton should be separated in order to reduce the required storage
space.
The sheet can be separated in the X or Y direction using the
separating cut program.

6.2 CP_CUTTING_TOOLS - utility

program for the optimization of the
parameters

Application The laser machining parameters are to be checked and opti-

mized, depending on the desired quality of cut.

Integrated help The information necessary for operation has been integrated into
the program and can be retrieved using the Information softkey.

6.3 Files on cutting wear parts of the

workpiece support

The machine comes with programs that the customer can use to
cut the wearing parts for the workpiece support (pallet).

B743en 2011-10-07 Further utility programs and files 5-15

5-16 Files on cutting wear parts of the workpiece support 2011-10-07 B743en
 Chapter 6

Maintenance

1 General guidelines 6-4

2 Maintenance Overview 6-6

3 Lubrication 6-9
3.1 Overview 6-9
3.2 Maintenance Instructions 6-10
Central lubrication 6-10
Guide rails on the pallet 6-13
Longitudinal conveyor belt brush lubrica- 6-13
tion
Chain and cam assembly of the pallet 6-14
transport and pallet index

4 Hydraulic unit 6-15

4.1 Maintenance Instructions 6-15
Hydraulic unit 6-15
Hydraulic hoses 6-16

B743en 2011-10-07 Maintenance 6-1

 5 Mechanics 6-18
5.1 Overview 6-18
5.2 Maintenance Instructions 6-18
Z axis bellows 6-18
Slats, copper installation and slat support, 6-19
area under the pallet changer
X and Z energy chain 6-19
Bulkheads, grid sheets and flaps 6-19
Storage bin for slag and dust, scrap car- 6-20
riage
Pallet conveyor cam assembly 6-20
Disposable container of the compact dust 6-21
extractor
Compact dust extractor purging valves 6-22
CO2 fire extinguishing system in the com- 6-22
pact dust extractor (option)
Tube bend and suction tube of the suction 6-22
system
Longitudinal conveyor belt 6-23
Track rollers of pallets, brass brushes and 6-23
guide rails for the pallet
Calibration plate and nozzle-cleaning 6-23
brushes

6 Pneumatics 6-25
6.1 Overview 6-25
6.2 Maintenance Instructions 6-26
Input controller operating pressure 6-26
40 μm filter for compressed air supply 6-26
Filter B compressed air supply 6-26
Filter A compressed air supply 6-27
Activated carbon filter compressed air 6-27
supply
Cutting gas filter for oxygen and nitrogen 6-28
Filter elements in the compact dust 6-28
extractor
Differential pressure indicator at the com- 6-29
pact dust extractor
Filter-lubricator unit on compact dust 6-30
extractor
Filter (only with the compressed-air cutting 6-31
option)

6-2 Maintenance 2011-10-07 B743en

 Microfilter (only with the compressed-air 6-31
cutting option)
Activated carbon filter 1 (only for the com- 6-32
pressed-air cutting option)
Activated carbon filter 2 (only for the com- 6-32
pressed-air cutting option)
Spraying equipment 6-34

7 Machine cooling circuit 6-36

7.1 Maintenance Instructions 6-36
Process cooler 6-36

8 External cooling circuit laser 6-42

8.1 Maintenance Instructions 6-42
External laser process cooler 6-42

9 Electrics 6-44
9.1 Maintenance Instructions 6-44
Switch cabinet 6-44
Safety light barrier 6-49

10 Optic 6-50
10.1 Overview 6-50
10.2 Maintenance Instructions 6-50
Cartridge in the cutting unit 6-50

B743en 2011-10-07 Maintenance 6-3

 1. General guidelines

Correct maintenance is essential for maintaining the quality of

the machine. This avoids operational malfunctions and their con-
sequences.

Risk of fatal injury during maintenance work with the

DANGER machine switched on!
Ø Unless expressly stated otherwise, switch off the MAIN
SWITCH, lock the MAIN SWITCH and pull out the key.
Ø Strictly observe the safety regulations.

Before putting the machine The machine must be lubricated carefully in accordance with the
into service lubrication chart before being put into service. The entire lubrica-
tion of the machine has to be checked if the machine has not
been used for a long time (e.g. overseas transport). If required,
the gummy oil must be completely removed from all lubrication
points and supply lines.

Notes on cleaning ■ The entire system should be cleaned at regular intervals.

■ Brush off large particles of dirt or remove them using an
industrial vacuum cleaner.

Notes on lubrication Refer to the lubrication chart and maintenance instructions for
the lubrication of the machine. The following points should also
be observed:
■ Keep the filling nozzle and drain caps clean and do not leave
them open for longer than necessary.
■ Drain the waste oil only at operating temperature.
■ Use only lint-free cleaning cloths and low-viscosity spindle oil
("scavenge oil") to clean oil chambers and lubricating points.
Do not use cleaning wool, kerosene or benzole.
■ 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.
■ Dispose of waste oil appropriately.

Qualifications of All maintenance work may only be performed by persons who

maintenance personnel have been trained for the maintenance work described and who
have acquired the relevant knowledge.
Certain types of maintenance work (e.g. in the area of the RF
Generators) require, in addition to the above-mentioned qualifica-
tions, complete professional training or advanced training in elec-
trotechnology. Furthermore these specialists require authorization
to perform electrical work on this system (electrician for defined
tasks in accordance with BGV A 3 (VBG4)).
Furthermore, the regulations of the relevant country are also
applicable.

6-4 General guidelines 2011-10-07 B743en

 Maintenance number Maintenance work with an interval <2000 h is indicated on the
machine by stickers on the corresponding maintenance points.
Within this chapter, these maintenance numbers are indicated in
square brackets, e.g. [21] after the designation of the mainte-
nance work in the margin.

B743en 2011-10-07 General guidelines 6-5

 2. Maintenance Overview

Interval/ Maintenance point Maintenance work Page

operating
hours
8 Disposable container of the compact dust Checking the disposable container [02] 6-21
extractor
40 Slats, copper installation and slat support, Clean or replace slats, copper installation 6-19
area under the pallet changer and slat support, area under the pallet
changer [25]
40 Bulkheads, grid sheets and flaps Bulkheads, grid sheets and flaps [24] 6-19
40 Storage bin for slag and dust, scrap car- Checking the storage bins and scrap car- 6-20
riage riages [26]
40 Differential pressure indicator at the com- Checking the differential pressure indica- 6-29
pact dust extractor tor [23]
500 Guide rails on the pallet Lubricating the guide rail [41] 6-13
500 Longitudinal conveyor belt brush lubrica- Checking the filling level [46] 6-13
tion
500 Compact dust extractor purging valves Checking purging valves [44] 6-22
500 Longitudinal conveyor belt Checking the longitudinal conveyor belt 6-23
(belt tension) [43]
500 Calibration plate and nozzle-cleaning Cleaning [42] 6-23
brushes
500 Filter (only with the compressed-air cut- Replace the filter element 6-31
ting option)
500 Activated carbon filter 1 (only for the com- Checking the filter element [47] 6-32
pressed-air cutting option)
500 Activated carbon filter 2 (only for the com- Checking the filter element [48] 6-32
pressed-air cutting option)
500 Process cooler Checking the filling level 6-36
500 Safety light barrier Cleaning the safety light barrier [51] 6-49
1000 Tube bend and suction tube of the suc- Dismantling and cleaning the tube bend 6-22
tion system and suction tube [45]
1000 Switch cabinet Cleaning the fan [64] 6-44
2000 Chain and cam assembly of the pallet Checking the chain of the pallet transport 6-14
transport and pallet index and pallet index (locking piece lateral on
the frame)
2000 Hydraulic unit Checking pressure gauge 6-15
2000 Hydraulic hoses Checking the hydraulic hoses 6-16
2000 Z axis bellows Checking and cleaning the Z axis bellows 6-18
2000 X and Z energy chain Checking the X and Z energy chain 6-19
2000 Track rollers of pallets, brass brushes and Checking the track rollers and brass 6-23
guide rails for the pallet brushes, cleaning the guide rails
2000 40 μm filter for compressed air supply Replacing the filter cartridge 6-26
2000 Filter B compressed air supply Replacing the filter cartridge 6-26
2000 Filter A compressed air supply Replacing the filter cartridge 6-27
2000 Activated carbon filter compressed air Replacing the filter cartridge 6-27
supply
2000 Filter elements in the compact dust Checking the filter elements 6-28
extractor

6-6 Maintenance Overview 2011-10-07 B743en

Interval/ Maintenance point Maintenance work Page
operating
hours
2000 Filter-lubricator unit on compact dust Checking the pressure reducer and com- 6-30
extractor pressed air supply
2000 Filter-lubricator unit on compact dust Checking and cleaning the filter cartridge 6-30
extractor
2000 Microfilter (only with the compressed-air Replace the filter element 6-31
cutting option)
5000 Longitudinal conveyor belt brush lubrica- Checking brushes [46] 6-14
tion
5000 Pallet conveyor cam assembly Replacing the cam assembly of the pallet 6-20
transport
5000 Cutting gas filter for oxygen and nitrogen Replacing the filter elements 6-28
10000 Hydraulic unit Changing oil 6-15
Annually Process cooler Replacing cooling water 6-38
Annually External laser process cooler Replace cooling water 6-42
Every 2 years CO2 fire extinguishing system in the com- To maintain the CO2 fire extinguishing 6-22
pact dust extractor (option) system
Every 3 years Switch cabinet Replacing the battery pack of the UPS 6-45
Every 3 years Switch cabinet Replacing the buffer battery for the real 6-46
time clock
As needed Activated carbon filter 1 (only for the com- Replacing the filter element [47] 6-32
pressed-air cutting option)
As needed Activated carbon filter 2 (only for the com- Replacing the filter element [48] 6-33
pressed-air cutting option)
As needed Spraying equipment Refilling the spraying agent [92] 6-34
As needed Cartridge in the cutting unit Check the cartridge, clean if necessary 6-50
[01]
When indica- Central lubrication Checking and refilling the lubricant level 6-10
ted by the [82]
control sys-
tem
When indica- Hydraulic unit Refilling with oil [85] 6-15
ted by the
control sys-
tem
When indica- Input controller operating pressure Checking the operating pressure 6-26
ted by the
control sys-
tem
When indica- Process cooler Replacing the filter mat 6-36
ted by the
control sys-
tem

For single shift operation the following relations hold:

8 operating hours daily

40 operating hours weekly
500 operating hours every 3 months

B743en 2011-10-07 Maintenance Overview 6-7

 1000 operating hours every 6 months
2000 operating hours annually
5000 operating hours every 2½ years
10000 operating hours every 5 years
Annually regardless of the number of operat-
ing hours
Every 2 years regardless of the number of operat-
ing hours
Every 3 years regardless of the number of operat-
ing hours

6-8 Maintenance Overview 2011-10-07 B743en

 3. Lubrication

3.1 Overview

1 Longitudinal conveyor belt brush 3 Pallet conveyor chain 5 Hydraulic unit

lubrication 4 Guide rails on the pallet
2 Lubricant container for central
lubrication
Fig. 58585

Specifications of lubri- Check filling level

cation intervals in
Refill if required
operating hours
Read the maintenance Check the oil level
instructions
Lubrication with oil can Replace the contents
or spray can of the container

Tab. 6-1

B743en 2011-10-07 Lubrication 6-9

 Lubrication Quantity [l] Recommended lubricants Identification Viscosity, TRUMPF
point consistency order no.
Lubricant 0.12 - 0.36 KLÜBER Microlube GB 00 GP00 G-10 NLGI Nr. 00 1 l: 111780
container for (consult the manufacturer for
central lubri- details on miscibility with other
cation lubricants).
Guide rails on
the pallet
Pallet con-
veyor chain
Longitudinal 0.20 ASEOL TOPSLIDE A Max. ISO VG 5 l: 136414
conveyor belt 32
ESSO Febis K-32
brush lubrica-
tion
Hydraulic unit 20 ARAL Vitam DE 32 ISO VG 32
ARAL Vitam GF 32
BP Energol HLP-HM 32
CASTROL Hyspin AVS 32
ELF POLYTELIS 32 1 l: 125503
ELF ELFOLNA HMD 32 18 kg:
037805
ESSO TERESSO 32
ESSO NUTO H 32
FUCHS RENOLIN MR 10 VG
32
MOBIL DTE 24
SHELL Tellus Oil C 32
SHELL Tellus OL DO 32
Lubricants Tab. 6-2

Note
The lubricant table contains a list of approved lubricants. We rec-
ommend using the listed lubricants or verifiable equivalents from
other mineral oil companies.

3.2 Maintenance Instructions

Central lubrication

(see "Overview", pg. 6-9)

100685: Maintenance interval: When indicated by the control system

Checking and refilling the
lubricant level [82]
The central lubrication supplies the following components with a
lubricant:

6-10 Lubrication 2011-10-07 B743en

 ■ X and Y drive pinions
■ Ballscrew bearings of the X and Y axes
■ Bearings of the X and Y rails

1 Single-piston pump and lubri- 6 40 μm filter for compressed air 11 3/2 directional valve
cant container for central lubri- supply 12 Filter9
cation system 7 Filter B compressed air supply
13 Microfilter9
2 Electrical lubricator for chain on 8 Filter A compressed air supply
the longitudinal conveyor belt 14 Activated carbon filter 19
9 Activated carbon filter com-
3 Spraying equipment pressed air supply 15 Activated carbon filter 29
4 Cutting unit ventilation pressure 10 Gas filter for oxygen and nitro-
reducer gen
5 Operating pressure reducer
Instrument panel Fig. 58584

One-shift operation 100 cm3

Two-shift operation 200 cm3
Three-shift operation 300 cm3
Yearly refilling requirements (250 days) Tab. 6-3

9 For compressed-air cutting only

B743en 2011-10-07 Lubrication 6-11

Checking the lubricant level Note
The grease and air apportionment is determined at the fac-
tory.
The lubrication cycle is activated every eight hours by the
control system.
The next time a program is started, a lubrication cycle will be
run automatically.
The "Check lubricant level" message appears on the screen
every three months.
The lubricant container must not be emptied; otherwise the
entire system must be bled.
Since the lubricant loses its optimal lubrication qualities after
three years, it is recommended to store only small quantities.
The refill quantity should always be enough to make it nec-
essary to refill once a year. The following values are used to
calculate the amount of top-up oil:
1. Check the lubricant level.
2. Acknowledge the fill level check on the control system.

Refilling the lubricant Note

The manufacturer should be consulted on its miscibility with
other low-viscosity grease types.
3. Take off the cover.
4. Pour the lubricant slowly to avoid bubbles.
5. Put the lid back on.

6-12 Lubrication 2011-10-07 B743en

 Guide rails on the pallet

(see "Overview", pg. 6-9)

105319: Maintenance interval: 500 operating hours

Lubricating the guide rail
[41]

1 Guide rail 2 Pallet frame

Guide rail for longitudinal installation Fig. 55766

Ø Lubricate the guide rails with the lubricating grease and

check it for fixed seat.

Longitudinal conveyor belt brush

lubrication

(see "Overview", pg. 6-9)

105330: Maintenance interval: 500 operating hours

Checking the filling level
[46]
Side board chains are lubricated using brush lubrication.

B743en 2011-10-07 Lubrication 6-13

 Note
After filling, the oil container empties completely in about 2 –
10 hours. The oil container, however, may only be refilled
after 500 hours.
Ø Check the filling level.

Sticker on the oil container with filling volume information Fig. 48372

105416: Maintenance interval: 5000 operating hours

Checking brushes [46]

Ø Check the brushes for wear and replace if necessary.

Chain and cam assembly of the pallet

transport and pallet index

(see "Overview", pg. 6-9)

105321: Maintenance interval: 2000 operating hours

Checking the chain of the
pallet transport and pallet
index (locking piece lateral 1. Clean and lubricate the chain using a brush.
on the frame) 2. Inspect visually for damage and check the parts are securely
fixed in place.
3. Check the chain tension (see chapter “Setting work“).

6-14 Lubrication 2011-10-07 B743en

 4. Hydraulic unit

4.1 Maintenance Instructions

Hydraulic unit

105322: Maintenance interval: When indicated by the control system

Refilling with oil [85]

The hydraulic unit has an automatic level check. A message is

issued if the oil level drops below a certain level.

Note
The lifting frame of the pallet changer must be in the bottom
position so that the oil level can be checked.
1. Check the oil level (3/4 to full).
2. If necessary, refill with hydraulic oil.

105324: Maintenance interval: 2000 operating hours

Checking pressure gauge
1. Check that the pressure on the pressure gauge during actua-
tion (starting up and shutting down the pallet changer) is in
the green range (100 - 130 bar).
2. If necessary, search for the cause of error (e.g. defective
hydraulic pump, etc.).

100779: Maintenance interval: 10000 operating hours

Changing oil
Note
Only use the same type of oil as before for topping up.

1. Switch off and lock the MAIN SWITCH. Remove the key.
2. Remove the hydraulic unit from the base plate and raise it.
3. Open the oil drain plug.
4. Drain waste oil.
5. Place new gasket on the oil drainage plug and close it.
6. Remove the cover of the cleaning opening.
7. Remove the waste oil residue with a lint-free cloth.
8. Check the gasket and replace if necessary.
9. Close the cover.
10. Replace the oil filter.

B743en 2011-10-07 Hydraulic unit 6-15

 Hydraulic hoses

105325: Maintenance interval: 2000 operating hours

Checking the hydraulic
hoses
Note
The hydraulics hose lines should be checked by an expert to
assure safe operating standards. This check should also be car-
ried out before the first machine start-up.
A specialist is someone who has completed an appropriate train-
ing course (e.g. TRUMPF training course "Certificate of qualifica-
tion - Pressure vessel regulations").
In addition to these instructions, the safety regulations for
hydraulic hoses (order no. ZH 1/74) and the relevant national
safety regulations should be observed and adhered to.

Issued by:
Hauptverband der gewerblichen Berufsgenossenschaften e.V.
(Central Federation of the German Statutory Accident Institutions
in Industry and Trade)
Postfach 2052
D-53757 St. Augustin
Sales:
Carl Heymanns Verlag KG
Luxemburger Str. 449
D-50939 Köln

1. Switch off the machine in the correct way, switch off the
MAIN SWITCH, lock it, and remove the key.
2. Remove the cover plate.
3. Check the hydraulic hoses for defects.
Possible defects:
− Damage in the outer layer extending to the inner lining
(chafe marks, cuts, cracks).
− Brittleness of the outer layer (crack formation of the hose
material).
− Deformations that do not correspond to the natural form
of the hose in a depressurized or a pressurized state or
when bent (separation of layers, bubble formation, crush
or bent areas).
− Leaks
− Installation requirements not observed.
− The hose dislodging itself from the fittings.
− Damage or distortion of the fittings, thereby diminishing
function and stability of the fittings or impairing the con-
nection between hose and fittings.

6-16 Hydraulic unit 2011-10-07 B743en

 − Corrosion of the fittings; this results in impairing the func-
tion and stability of the fittings.
− Expired storage time or period of use (according to ZH
1/74).
4. Install the cover plate again.

B743en 2011-10-07 Hydraulic unit 6-17

 5. Mechanics

5.1 Overview

1 Z axis bellows 5 Spark arrester (dust chamber) 8 Scrap carriage (2x)

2 X and Z energy chain compact dust extractor 9 Longitudinal conveyor belt
3 Purging valves for compact dust 6 Pallet track rollers and brass 10 Bulkheads in suction chambers,
extractor brushes grid sheets and flaps
4 Disposable container for com- 7 Slats, copper installation and
pact dust extractor slat support, area under the pal-
let changer
Fig. 58616

5.2 Maintenance Instructions

Z axis bellows

(see "Overview", pg. 6-18)

100848: Maintenance interval: 2000 operating hours

Checking and cleaning the Z
axis bellows
1. Check the bellows for damage such as cracks or holes.
Check also that they are securely fixed in place.
2. Clean the bellows.

6-18 Mechanics 2011-10-07 B743en

 Slats, copper installation and slat support,
area under the pallet changer

(see "Overview", pg. 6-18)

105329: Maintenance interval: 40 operating hours

Clean or replace slats,
copper installation and slat
support, area under the Ø Visual inspection, clean and replace if required.
pallet changer [25]

X and Z energy chain

(see "Overview", pg. 6-18)

100785: Maintenance interval: 2000 operating hours

Checking the X and Z
energy chain
Ø Check the joints, cables and hoses for damage and wear.

Bulkheads, grid sheets and flaps

(see "Overview", pg. 6-18)

100851: Maintenance interval: 40 operating hours

Bulkheads, grid sheets and
flaps [24]

1 Bulkhead 3 Vacuum flap

2 Grid guard plate 4 Longitudinal conveyor belt
Fig. 55382

B743en 2011-10-07 Mechanics 6-19

 1. Move the pallets into the pallet changer.
2. Remove slag remnants from the side walls.
3. Clean the grid guard plates.
4. Check the flaps in the suction channel

Note
The flaps can get stuck in the case of deposit build-up on
the front side. Then the flaps cannot be opened anymore,
even if the cutting head is above the respective suction
chamber.
5. Move the motion unit back in jog mode.

Storage bin for slag and dust, scrap

carriage

(see "Overview", pg. 6-18)

105326: Maintenance interval: 40 operating hours

Checking the storage bins
and scrap carriages [26]
1. Pull the storage bins (2x) under the conveyor belt deflection
shafts out from the front in Y direction.
2. Empty the storage bins or vacuum with an industrial vacuum
cleaner.
3. Push the storage bin under the machine up to the back stop;
they must not protrude.
4. Empty the storage bin for the transverse conveyor (optional)
or vacuum it with an industrial vacuum cleaner.

Pallet conveyor cam assembly

105327: Maintenance interval: 5000 operating hours

Replacing the cam assembly
of the pallet transport
Note
Wear appears on the cam assembly after approx. 5000 operating
hours.

Ø Replace the cam assembly in case of wear (see chapter

“Setting work”).

6-20 Mechanics 2011-10-07 B743en

 Disposable container of the compact dust
extractor

(see "Overview", pg. 6-18)

105288: Maintenance interval: 8 operating hours

Checking the disposable
container [02]
Notes
■ This involves extremely fine metal dust particles which must
not be brought into contact with burning objects due to the
risk of explosion.
Always wear a close-fitting dust mask (e.g. fine dust mask of
filter class 3) as personal protective gear when working on
the compact dust extractor.
■ The following safety precautions must be observed after
changing the material from aluminum/aluminum alloys to
galvanized sheets, mild steel or stainless steel, or vice versa:
Wait for the lag time of the suction system after the process-
ing program ends.
The disposable containers in the compact dust extractor
should be changed. It is recommended to use separate con-
tainers for each of these material groups and to label them
accordingly.
■ Disposal as hazardous waste is not necessary. However, it is
vital to find out the relevant national, regional, and local reg-
ulations and follow them closely.
If the machine is used as intended, the filtered dust can be
supplied for metal recycling.

According to German national regulations, the containers must

be marked as follows according to the dust they contain:

Metal dust Identification

Dust from steel machining ■ LAGA key 35101 (ferrous dust
without harmful impurities).
■ EAK code 120102 (ferrous parti-
cles);
EAK group: waste from mechan-
ical shaping (incl. welding, cut-
ting)
Dust from aluminum machining ■ LAGA key 35304 (aluminum
scraps)
■ EAK code 120103 (chips and
waste containing non-iron metal)
EAK group: waste from mechan-
ical shaping (incl. welding, cut-
ting)
Tab. 6-4

B743en 2011-10-07 Mechanics 6-21

 1. Checking the disposable container.
2. If there is a smoldering fire: replace the container.
3. Check differential pressure indicator on the front of the unit.
4. Check the filling level of the disposable containers for coarse
dust and fine dust. If they are 2/3 full, close them tightly with
a lid and dispose of them completely.
5. Install a new container.
The containers must rest against the funnel.

Compact dust extractor purging valves

(see "Overview", pg. 6-18)

100855: Maintenance interval: 500 operating hours

Checking purging valves
[44]
Ø Check the purging valve acoustically and clean if necessary.

CO2 fire extinguishing system in the

compact dust extractor (option)

105417: Maintenance interval: Every 2 years

To maintain the CO2 fire
extinguishing system
Note
Refer to the documentation from the manufacturer.
Ø Carry out the maintenance work as specified by the manu-
facturer.

Tube bend and suction tube of the suction

system

100973: Maintenance interval: 1000 operating hours

Dismantling and cleaning
the tube bend and suction
tube [45] Ø For information on procedure, refer to the documentation
from the manufacturer.

6-22 Mechanics 2011-10-07 B743en

 Longitudinal conveyor belt

(see "Overview", pg. 6-18)

105328: Maintenance interval: 500 operating hours

Checking the longitudinal
conveyor belt (belt tension)
[43] Ø Please refer to the procedure for maintenance work in the
documentation supplied by the manufacturer.

Track rollers of pallets, brass brushes and

guide rails for the pallet

(see "Overview", pg. 6-18)

100798: Maintenance interval: 2000 operating hours

Checking the track rollers
and brass brushes, cleaning
the guide rails 1. Check the track rollers and brass brushes for damage and
replace them if necessary.
2. Clean the pallet guideways with a broom.

Calibration plate and nozzle-cleaning

brushes

100858: Maintenance interval: 500 operating hours

Cleaning [42]

Ø Clean the calibration plate and nozzle-cleaning brushes on

the two pallets. Check the nozzle-cleaning brushes and
replace them if necessary.

B743en 2011-10-07 Mechanics 6-23

 1 Nozzle-cleaning brush 3 Pallet frame
2 Calibration plate
Position on pallet changer, longitudinal view Fig. 55768

6-24 Mechanics 2011-10-07 B743en

 6. Pneumatics

6.1 Overview

1 Single-piston pump and lubri- 6 40 μm filter for compressed air 11 3/2 directional valve
cant container for central lubri- supply 12 Filter10
cation system 7 Filter B compressed air supply
13 Microfilter10
2 Electrical lubricator for chain on 8 Filter A compressed air supply
the longitudinal conveyor belt 14 Activated carbon filter 110
9 Activated carbon filter com-
3 Spraying equipment pressed air supply 15 Activated carbon filter 210
4 Cutting unit ventilation pressure 10 Gas filter for oxygen and nitro-
reducer gen
5 Operating pressure reducer
Instrument panel Fig. 58584

10 For compressed-air cutting only

B743en 2011-10-07 Pneumatics 6-25

 6.2 Maintenance Instructions

Input controller operating pressure

(see "Overview", pg. 6-25)

100801: Maintenance interval: When indicated by the control system

Checking the operating
pressure
1. Check whether the setting is on 5 +0.5 bar.
2. Check the condensate status.

40 μm filter for compressed air supply

(see "Overview", pg. 6-25)

103801: Maintenance interval: 2000 operating hours

Replacing the filter cartridge
1. Switch off the machine in the correct way, switch off the
MAIN SWITCH, lock it, and remove the key.
2. Push the release downwards.
3. Rotate the filter bowl to the right and pull it off downwards
(bayonet lock).
4. Replace the filter element.
5. To re-install the filter bowl, perform the above steps in
reverse order.
6. Unlock the MAIN SWITCH and switch it on.
7. Switch on the machine.

Filter B compressed air supply

(see "Overview", pg. 6-25)

103802: Maintenance interval: 2000 operating hours

Replacing the filter cartridge

1. Switch off the machine in the correct way, switch off the
MAIN SWITCH, lock it, and remove the key.
2. Push the release downwards.
3. Rotate the filter bowl to the right and pull it off downwards
(bayonet lock).
4. Replace the filter element.

6-26 Pneumatics 2011-10-07 B743en

 5. To re-install the filter bowl, perform the above steps in
reverse order.
6. Unlock the MAIN SWITCH and switch it on.
7. Switch on the machine.

Filter A compressed air supply

(see "Overview", pg. 6-25)

103803: Maintenance interval: 2000 operating hours

Replacing the filter cartridge

1. Switch off the machine in the correct way, switch off the
MAIN SWITCH, lock it, and remove the key.
2. Push the release downwards.
3. Rotate the filter bowl to the right and pull it off downwards
(bayonet lock).
4. Replace the filter element.
5. To re-install the filter bowl, perform the above steps in
reverse order.
6. Unlock the MAIN SWITCH and switch it on.
7. Switch on the machine.

Activated carbon filter compressed air

supply

(see "Overview", pg. 6-25)

103804: Maintenance interval: 2000 operating hours

Replacing the filter cartridge

1. Switch off the machine in the correct way, switch off the
MAIN SWITCH, lock it, and remove the key.
2. Push the release downwards.
3. Rotate the filter bowl to the right and pull it off downwards
(bayonet lock).
4. Replace the filter element.
5. To re-install the filter bowl, perform the above steps in
reverse order.
6. Unlock the MAIN SWITCH and switch it on.
7. Switch on the machine.

B743en 2011-10-07 Pneumatics 6-27

 Cutting gas filter for oxygen and nitrogen

(see "Overview", pg. 6-25)

100866: Maintenance interval: 5000 operating hours

Replacing the filter elements

Note
The filter elements must be replaced once after the first 1000
operating hours. After this, another subsequent replacement is
not required.

1. Shut down the machine properly. Switch off the MAIN

SWITCH, lock it and pull out the key.
2. Cut off the pressure at the stop valve.
3. Let off pressure via the purge valve.
4. Undo the screw joint on the hose.
5. Screw out the filter housing.
6. Replace the filter element.

Filter elements in the compact dust

extractor

100809: Maintenance interval: 2000 operating hours

Checking the filter elements

Notes
■ Observe the procedures and the safety information in the
operator's manual provided by the manufacturer when
replacing the filter elements.
■ Filter elements must be replaced if:
The suction capacity falls
The filter resistance increases
The filter elements exhibit caking
Ø Check the filter elements for damage:
− Wear, holes or cracks?
− Replace in case of heavy contamination.

6-28 Pneumatics 2011-10-07 B743en

 Differential pressure indicator at the
compact dust extractor

100971: Maintenance interval: 40 operating hours

Checking the differential
pressure indicator [23]
Ø Check the nominal value on the pressure gauge. The value
must read between 8 and 16 mbar (green range). If the
value reads above 16 mbar (red range), proceed as descri-
bed in the documentation from the manufacturer.

B743en 2011-10-07 Pneumatics 6-29

 Filter-lubricator unit on compact dust
extractor

100813: Maintenance interval: 2000 operating hours

Checking the pressure
reducer and compressed air
supply

1 Pressure setting knob 4 Filter bowl

2 Pressure gauge 5 Condensation water cap screw
3 Release
Fig. 49062

Ø Check whether the setting is on 5+0.5 bar.

100926: Maintenance interval: 2000 operating hours

Checking and cleaning the
filter cartridge
1. Shut down the machine properly. Switch off the MAIN
SWITCH, lock it and pull out the key.
2. Push the release downwards.
3. Rotate the filter bowl to the right and pull it off downwards
(bayonet lock).

6-30 Pneumatics 2011-10-07 B743en

 4. Check the filter element for contamination and clean it if nec-
essary.
5. Replace the filter cartridge if it is very dirty.
6. To re-install the filter bowl, perform the above steps in
reverse order.
7. Unlock the MAIN SWITCH and switch it on.
8. Switch on the machine.

Filter (only with the compressed-air cutting

option)

(see "Overview", pg. 6-25)

103805: Maintenance interval: 500 operating hours

Replace the filter element
1. Shut down the machine properly. Switch off the MAIN
SWITCH, lock it and pull out the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.
3. Screw out the filter housing.
4. Replace the filter element.
5. Assemble the filter housing.

Microfilter (only with the compressed-air

cutting option)

(see "Overview", pg. 6-25)

103806: Maintenance interval: 2000 operating hours

Replace the filter element

1. Shut down the machine properly. Switch off the MAIN

SWITCH, lock it and pull out the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.
3. Screw out the filter housing.
4. Replace the filter element.
5. Assemble the filter housing.

B743en 2011-10-07 Pneumatics 6-31

 Activated carbon filter 1 (only for the
compressed-air cutting option)

(see "Overview", pg. 6-25)

100965: Maintenance interval: 500 operating hours

Checking the filter element
[47]
1. Shut down the machine properly. Switch off the MAIN
SWITCH, lock it and pull out the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.
3. Screw out the filter housing.
4. Check the filter element and replace it if it has a slight brown
discoloration or if it smells of oil (mat. no. 123676).
5. Reassemble the filter housing.

100928: Maintenance interval: As needed

Replacing the filter element
[47]
1. Switch off the machine in the correct way, switch off the
MAIN SWITCH, lock it, and remove the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.
3. Screw out the filter housing.

Note
Generally, the filter element from activated carbon filter 2 can
be used in activated carbon filter 1. A new filter element
(mat. no. 123676) must be used if the filter element in activa-
ted carbon filter 2 is slightly colored brown or smells of oil.
4. Replace the filter element.
5. Assemble the filter housing.

Activated carbon filter 2 (only for the

compressed-air cutting option)

(see "Overview", pg. 6-25)

100929: Maintenance interval: 500 operating hours

Checking the filter element
[48]
1. Shut down the machine properly. Switch off the MAIN
SWITCH, lock it and pull out the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.

6-32 Pneumatics 2011-10-07 B743en

 3. Screw out the filter housing.
4. Check the filter element and replace it if it has a slight brown
discoloration or smells of oil (see below for procedure).
5. Reassemble the filter housing.

100930: Maintenance interval: As needed

Replacing the filter element
[48]
1. Shut down the machine properly. Switch off the MAIN
SWITCH, lock it and pull out the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.
3. Screw out the filter housing.
4. Check the filter element and replace it if it is colored brown
or smells of oil. Otherwise, insert the filter element in the
activated carbon filter 1.
5. Assemble the filter housing.

B743en 2011-10-07 Pneumatics 6-33

 Spraying equipment

1 Quick filler 4 Filler plug 6 Container pressure correction

2 Level indicator 5 Manual operation unit screw
3 Pressure gauge container pres- 7 Compressed air shut-off valve
sure
Fig. 33245

100931: Maintenance interval: As needed

Refilling the spraying agent
[92]
The spraying agent container must be refilled with spraying
agent when the level indicator (2) shows the "min. level".

In the following cases, the supply line must be filled or bled:

■ If the container has drained completely.
■ If the spraying equipment is not spraying evenly.

Note
As specified on the sign on the spraying agent container, only
the TRUMPF-approved spraying agent, TRUMPF CutFluid,
should be used (1 l packing drum mat. no. 356258, 5 l - packing
drum mat no. 356259).
When using TRUMPF CutFluid, observe that its service life is
limited to about 6-9 months as printed on the barcode of the
container.

6-34 Pneumatics 2011-10-07 B743en

 In older systems, where a different spraying agent is still in use
(e.g. Wisura Akamin), the container must be removed and
cleaned before CutFluid can be used.
On the TruLaser 2525, 3030, 3040 and 3060, the container can
be removed and cleaned by the customer.
For the TruLaser 5030 and 5040, consult TRUMPF customer
service before removing and cleaning the spraying equipment.

1. Shut off the compressed air supply by means of the com-

pressed air shut-off valve (7) if the main switch is ON. The
container pressure displayed on the pressure gauge (3)
drops back to "0".
2. The compressed air supply does not have to be shut off if
the main switch is OFF.
3. Open the filler plug (4).
4. Use a funnel to fill the container with spraying agent up to
the maximum mark (2).
5. Close the filler plug (4).
6. If the original pressure is not reached:
Ø Press the compressed air shut-off valve.
The container pressure displayed on the pressure gauge
(3) rises to the original pressure.
or
Ø To fill the container pressure quickly:
Ø Open the quick oil filler by turning it approx. one turn
counterclockwise with an Allen key (see Fig. 33245).
7. Use a screwdriver to turn the manual operation unit (5) to the
ON position.

B743en 2011-10-07 Pneumatics 6-35

 7. Machine cooling circuit

7.1 Maintenance Instructions

Process cooler

105384: Maintenance interval: When indicated by the control system

Replacing the filter mat

1 Cover 2 Filter mat

Cooling unit Fig. 59550

1. At the switch cabinet: switch off and lock the MAIN SWITCH,
pull out the key.
2. Remove knurled screws and take off the cover (1).
− Remove filter mat (2).
3. Insert a new filter mat and mount the cover.

105410: Maintenance interval: 500 operating hours

Checking the filling level

Means, Tools, Materials

■ Easy-Kit Al-1.
■ Demineralized water with a conductivity of ≤10 μS.
■ Protective gloves.

1. At the switch cabinet: switch off and lock the MAIN SWITCH,
pull out the key.

6-36 Machine cooling circuit 2011-10-07 B743en

 2. Read off the cooling water level on the level indicator (2),
(see "Fig. 59558", pg. 6-39).

Note
If more than half the volume of the water tank is filled with
demineralized water, one bottle of the corrosion protection
"Water Care Aluminum" (light blue bottle lid) will have to be
added to the cooling water.

Cooling water and cooling water additives are aggressive!

WARNING
Injuries to skin and eyes.
Ø Avoid direct skin contact with cooling water and cooling
water additives.
Ø Wear protective gloves and safety glasses when working
with cooling water and cooling water additives.

3. Fill up the cooling water or replace all the cooling water if the
minimum marking on the level indicator or if the maintenance
interval for all the cooling water has been reached.

1 Screws
Process cooler, tank cover Fig. 59727
4. At the switch cabinet: switch off and lock the MAIN SWITCH,
pull out the key.
5. Remove two screws (1) and take off the tank cover.

B743en 2011-10-07 Machine cooling circuit 6-37

 1 Tank
Process cooler Fig. 59733
6. To fill the cooling water:
− Take off the tank cap from tank (1).
− Fill demineralized water until the max. marking on the
level indicator is reached.
− If more than half the volume of the water tank is filled
with demineralized water: Add corrosion protection "Water
Care Aluminum" (light blue bottle lid) to the cooling water.
7. Mount the tank cap and tank cover.

105383: Maintenance interval: Annually

Replacing cooling water
Means, Tools, Materials
■ Easy-Kit Al-1.
■ Conductivity measuring device.
■ Pump (included in the scope of delivery of the machine).
■ Approx. 140 l demineralized water with a conductivity of
≤10 μS.
■ Collecting container.
■ Protective gloves.

Cooling water and cooling water additives are aggressive!

WARNING
Injuries to skin and eyes.
Ø Avoid direct skin contact with cooling water and cooling
water additives.
Ø Wear protective gloves and safety glasses when working
with cooling water and cooling water additives.

6-38 Machine cooling circuit 2011-10-07 B743en

1 Tank filling 3 Tank drain valve 4 Yellow seal cap
2 Level indicator
Cooling unit Fig. 59558

Executing the cleaning cycle 1. At the switch cabinet: switch off and lock the MAIN SWITCH,
pull out the key.
2. Add the cleaning biocide (red bottle lid) from Easy-Kit Al-1 to
the used cooling water via the tank filling (1), (see "Fig.
59558", pg. 6-39).
− Perform a 2-hour cleaning cycle (the process cooler
pump must be running).
3. At the switch cabinet: switch off and lock the MAIN SWITCH,
pull out the key.
Pumping off the cooling 4. On the "Tank emptying" connection, remove the yellow seal
water cap (4).
− Mount the reducer 1/2-3/3'' to the cock piece.
− Engage a hose.
− Connect the suction side of the pump to the hose.
5. Engage another hose on the pressure side of the pump and
connect to the collecting container on hand.
6. Provide a collecting container for used cooling water.
7. Open tank drain valve (3).
8. Put a drilling machine on the pump and pump off the cooling
water into the collecting container.
− To empty completely: Tilt the process cooler.
9. Close the tank drain valve.
Filling cooling water 10. Connect the pressure side of the pump to the drain cock of
the process cooler.
11. Connect the suction side of the pump to the container for
demineralized water.

B743en 2011-10-07 Machine cooling circuit 6-39

 12. Open the tank drain valve.
13. Fill demineralized water until the max. marking on the level
indicator (2) is reached.
14. Close the tank drain valve.
15. Switch on the MAIN SWITCH on the switch cabinet. and
allow the pump to run for 30 minutes.
16. At the switch cabinet: switch off and lock the MAIN SWITCH,
pull out the key.

Measure conductivity

1 Screws
Process cooler, tank cover Fig. 59727
17. Remove two screws (1) and take off the tank cover.

1 Tank
Process cooler Fig. 59733
18. To measure the conductivity of the cooling water:

6-40 Machine cooling circuit 2011-10-07 B743en

 − Take off the tank cap from tank (1).
− Measure the conductivity of the cooling water.
The conductivity of the cooling water in the tank must be
≤20 μS.
19. If the conductivity is >20 μS:
− As described: re-drain the cooling water and repeat the
purging process until the required conductivity is ach-
ieved.
Adding corrosion protection 20. If the conductivity is ≤20 μS:
− Add the "Water Care Aluminum" corrosion protection
(light blue bottle lid) from Easy-Kit Al-1 to the cooling
water via the tank filling (1)(see "Fig. 59558", pg. 6-39).
− Close the tank filling.
21. Mount the tank cap and tank cover, dismantle the pump and
accessories.

B743en 2011-10-07 Machine cooling circuit 6-41

 8. External cooling circuit laser

8.1 Maintenance Instructions

External laser process cooler

105793: Maintenance interval: Annually

Replace cooling water

Means, Tools, Materials

■ Easy-Kit Cu-4.
■ Conductivity measuring device.
■ Pump (included in the scope of delivery of the machine).
■ Approx. 480 l demineralized water with a conductivity of
≤10 μS.
■ Collecting container.
■ Protective gloves.

Cooling water and cooling water additives are aggressive!

WARNING
Injuries to skin and eyes.
Ø Avoid direct skin contact with cooling water and cooling
water additives.
Ø Wear protective gloves and safety glasses when working
with cooling water and cooling water additives.

1. Perform cleaning cycle; procedure see manufacturer's docu-

mentation from Riedel.
2. Pump out cooling water; procedure see manufacturer's docu-
mentation from Riedel.
3. Fill up cooling water; procedure see manufacturer's docu-
mentation from Riedel.
Measure conductivity 4. To measure the conductivity of the cooling water.
− Take off the tank cap from tank.
− Measure the conductivity of the cooling water.
The conductivity of the cooling water in the tank must be
≤20 μS.
5. If the conductivity is > 20 μS:
− As described: re-drain the cooling water and repeat the
purging process until the required conductivity is ach-
ieved.
Adding corrosion protection 6. If the conductivity is ≤20 μS:
− Add the corrosion protection "Water Care Copper" (yellow
bottle lid) from Easy-Kit Cu-4 to the cooling water via the
tank filling.
− Close the tank filling.

6-42 External cooling circuit laser 2011-10-07 B743en

 7. Close process cooler again.

B743en 2011-10-07 External cooling circuit laser 6-43

 9. Electrics

9.1 Maintenance Instructions

Switch cabinet

100995: Maintenance interval: 1000 operating hours

Cleaning the fan [64]
Condition
■ The main switch on the switch cabinet is switched off and is
secured against being switched on again.

Warning of electrical voltage

DANGER
Ø Work in the switch cabinet may only be carried out by elec-
tricians or persons instructed in carrying out electrical work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is switched off and is no
longer live.

1 Fan
Fan , cover removed Fig. 46925

1. At the switch cabinet: switch off and lock the MAIN SWITCH,
pull out the key.
2. Open the switch cabinet door.
3. Remove the cover.
4. Pull out the fan.

6-44 Electrics 2011-10-07 B743en

 5. Clean the fan (1) with a dry brush.
6. Lock the fan into place.
7. Close the switch cabinet door.

103517: Maintenance interval: Every 3 years

Replacing the battery pack
of the UPS
UPS stands for Uninterruptible Power Supply.

Condition
■ The main switch on the switch cabinet is switched off and is
secured against being switched on again.

Means, Tools, Materials

■ Battery pack (mat. no. 0364944).

Electrical voltage!
DANGER
Danger to life due to electric shock!
Ø Work in the switch cabinet may only be carried out by elec-
tricians or persons instructed in carrying out electrical work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is switched off and is no
longer live.

Risk of injury due to the contents of the rechargeable

WARNING battery pack in the event of skin or eye contact!
Ø As described below: load the rechargeable battery pack only
when it is fitted.
Ø Do not use force to open the rechargeable battery pack.
Ø Do not throw rechargeable battery packs into fire.
Ø Dispose of rechargeable battery packs correctly.

B743en 2011-10-07 Electrics 6-45

 1 Battery pack 3 Plug
2 Fixing screws
Fig. 58623

1. At the switch cabinet: switch off and lock the MAIN SWITCH,
pull out the key.
2. Open the switch cabinet door.
3. Undo 2 screws on the plug (3) and pull out the plug.
4. Remove the 4 fixing screws (2).
5. Remove the old battery pack (1).
6. Install a new battery pack.
7. Insert the plug of the battery pack.
8. Close the switch cabinet door.

Note
The new battery is not charged. Loading time approx. 5 h at
2.5 Ah.
9. To charge the new rechargeable battery pack: leave the
MAIN SWITCH on for at least 5 hours.

103518: Maintenance interval: Every 3 years

Replacing the buffer battery
for the real time clock
Condition
■ The main switch on the switch cabinet is switched off and is
secured against being switched on again.

Means, Tools, Materials

■ Recommended batteries: Varta CR2025, Panasonic BR2020.

6-46 Electrics 2011-10-07 B743en

 Notes
■ The battery must be replaced with an identical battery or one
recommended by the manufacturer.
■ The service life of a 170 mAh battery (VARTA CR2025) is 5
to 6 years, at an ON time of 8 hours a day and an ambient
temperature of 30 °C. This value depends on the actual
ambient temperature and on the ON duration.
To make sure that the battery is not discharged prematurely,
it is recommended that you replace it after 3 to 5 years.

Electrical voltage!
DANGER
Danger to life due to electric shock!
Ø Work in the switch cabinet may only be carried out by elec-
tricians or persons instructed in carrying out electrical work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is switched off and is no
longer live.

Risk of injury in the case of contact with skin and eyes!

WARNING
Ø Do not charge the battery.
Ø Do not use force to open batteries.
Ø Do not throw batteries into fire.
Ø Dispose of the battery properly.

Electrostatic charge!
CAUTION
Plug-in cards can get damaged.
Ø A ground strap must be worn for work on the plug-in cards.
The ground strap is in the switch cabinet.

B743en 2011-10-07 Electrics 6-47

1 Screws on the plug-in card 2 Buffer battery
Location of the buffer battery Fig. 55500

1. Open the switch cabinet door.

2. Remove all wires from the plug-in card.
3. Undo 4 screws (1) on the plug-in card.
4. To pull out the plug-in unit:
− Push the white lever down.
− Push the black lever down.
5. Pull out the plug-in card approx. 6 cm.

Note
Do not touch the cooling element. The cooling element can
be very hot.
6. Remove the old buffer battery.
7. Insert the new buffer battery:
− The positive pole must point outwards.
− Do not touch the contact surfaces.
8. Insert the plug-in card until it touches the bus at the back.
9. To connect the plug-in card to the bus at the back:
− Lock the lever into place and press it up.
− Insert the screws.
10. Plug in all cables, fit all covers.
11. Close the switch cabinet.

6-48 Electrics 2011-10-07 B743en

 Note
Replacing the buffer battery stops the real time clock.
12. At the user interface: reset the time and date.

Safety light barrier

100933: Maintenance interval: 500 operating hours

Cleaning the safety light
barrier [51]
Note
Soft rag or cotton pad
30% alcohol
Ø Clean the mirror surfaces.

B743en 2011-10-07 Electrics 6-49

 10. Optic

10.1 Overview

General guidelines Utmost cleanliness and the greatest care must be ensured when
handling optical components. A clean environment, a clean work
station, and clean additional equipment are absolutely essential.
■ All work involving the removal, installation and cleaning of
optical components, as well as the adjustment of the laser
beam after cleaning, if necessary, may only be carried out by
trained personnel.
■ All work involving the removal, installation, and cleaning of
optical components should be performed in clean rooms and
not in the vicinity of the machine itself.
■ The protective glass must be placed on a soft and lint-free
surface for cleaning. Make sure your hands are clean and/or
wear lint-free gloves.
■ Only use the additional equipment that is listed.

Additional equipment, tools, ■ Optics cleaning kit compl. (TRUMPF order no. 1675885).
material: ■ Rubber bellows (TRUMPF order no.: 0779473).
■ Optical square (TRUMPF order no.: 0779446)
■ Tweezers (TRUMPF order no.: 0779464).
■ Lint-free cloth and gloves.
■ Bottle with pipette (TRUMPF order no.: 0779463).
■ Polyester swab, knitted (TRUMPF order no.: 0989843)
■ Methanol, bottle (TRUMPF order no.: 1246182).
■ Hook wrench (TRUMPF order no.: 1655965).

10.2 Maintenance Instructions

Cartridge in the cutting unit

105263: Maintenance interval: As needed

Check the cartridge, clean if
necessary [01]
Check the protective glass for contamination and clean it if nec-
essary.

Note
If the contamination on the protective glass cannot be removed
completely, the glass must be replaced.

6-50 Optic 2011-10-07 B743en

 Danger of poisoning due to methanol!
WARNING
Ø Do not breathe in or ingest methanol fumes.
Ø Make sure there is plenty of fresh air.
Ø Wash your hands after the cleaning process.

Fire hazard due to methanol!

NOTICE
Ø Keep methanol away from ignition sources.
Ø Do not smoke.

1 Air blast nozzle 4 Union nut

2 Nozzle 5 Protective glass
3 Knurled nut with groove for
hook wrench
Cutting unit cartridge Fig. 59873

Cleaning the protective 1. Undo the knurled nut using the hook wrench and unscrew it
glass [01], sealing surfaces, completely.
and interior space of the 2. Pull out the cartridge down out of the cutting unit.
cartridge
3. Unscrew the union nut.
4. Remove the protective glass and clamp it with tweezers.

B743en 2011-10-07 Optic 6-51

 Protective glass clamped with tweezers Fig. 58596

5. Remove loose dirt with a bellows.

Cleaning protective glass with bellows Fig. 58583

Note
The swab must always be stored so that it is not in directly
contact with the table surface or the like. This avoids con-
tamination of the swab, which could cause the protective
glass to be scratched. The swab must generally be disposed
of after use.
6. Drip methanol over the swab. Shake out excess methanol.

6-52 Optic 2011-10-07 B743en

 Dripping methanol over the swab Fig. 58582

7. Hold the tweezers with the protective glass in front of a black

background to identify the contamination easily.

Protective glass in front of a black background Fig. 58581

8. Remove coarse dirt by rubbing with the moistened swab.

B743en 2011-10-07 Optic 6-53

 Cleaning the protective glass with the swab Fig. 58580

9. Remove fine contamination with the flat side of the swab by

evenly drawing it across the surface from one edge to the
other. Do not put the swab down on the protective glass, as
this might cause residue on the protective glass.
10. Turn the protective glass over and clean the other side as
described above.
11. Clean the sealing surfaces, the inside of the cartridge and
the thread with the swab while it is still wet.
12. Dispose of the swab. The swab may not be used to clean
the protective glass again.
13. Insert the protective glass into the cartridge. Make sure that
the O-ring the protective glass rests on is present and not
damaged.
14. Screw in the union nut and tighten as much as possible.
15. Insert the cartridge and tighten the knurled nut with the hook,
until the arrow is exactly below the lock symbol (see Fig.
59872).

1 Lock symbol 2 Arrow

Arrow marking in the cutting unit Fig. 59872

Checking nozzle and air 16. Check the nozzle for deformations, scratches near the mouth
nozzle of the nozzle and that it is fitted firmly.

6-54 Optic 2011-10-07 B743en

 17. Check the air blast nozzle for deformations and blockages.

B743en 2011-10-07 Optic 6-55

6-56 Optic 2011-10-07 B743en
 Chapter 7

Safety light barrier

1 Safety light barrier SICK M 4000 7-2

2 Installation of safety light barrier 7-3

2.1 Installing mirror columns 7-3
2.2 Aligning mirror columns 7-3

B743en 2011-10-07 Safety light barrier 7-1

 1. Safety light barrier SICK M 4000

The SICK M 4000 safety light barrier consists of the following

individual parts:

■ Safety light barrier transmitter M40S-025010AR0 with trans-

parent display pane.
■ Safety light barrier receiver M40E-025010RR0 with integrated
laser alignment aid.
■ Deflecting mirror columns suitable for M40S-025010AR0 and
M40E-025010RR0.
■ Equipment columns.
■ Alignment template for mirror.
■ Alignment template for transmitter.
The laser alignment aid integrated in the receiver is primarily
used to align the deflecting mirror columns and their individual
mirrors properly.

The laser alignment aid corresponds to laser class 2!

WARNING
Laser radiation can cause permanent damage to the eyes.
Ø Never look directly into the laser beam.

7-2 Safety light barrier SICK M 4000 2011-10-07 B743en

 2. Installation of safety light barrier

2.1 Installing mirror columns

Means, Tools, Materials

■ Screwdriver
■ Allen wrench SW 3
■ Size 4 Allen key
■ Size 6 Allen key
■ Open-end wrench, size 17
■ Drilling machine with 10 mm drilling machine
■ Hammer
■ Spirit level

Note
The number of mirror columns and the appropriate installation
site depend on the respectively applicable installation plan.

1. Set the transmitter and receiver at a vertical position and at

the same height over floor using the equipment columns or a
swiveling bracket.
2. Mark the operating range of the machine (protection field)
with a marking pen (chalk) or with a piece of string on the
floor according to the installation plan.
3. Place the transmitter, receiver and deflection columns in the
respective corners of the protected field, align them roughly
and screw them tight.

2.2 Aligning mirror columns

Condition
■ Mirror columns are mounted and roughly aligned with one
another.

Note
The laser alignment aid is automatically activated when the
safety light barrier is switched on, if the light beams are not yet
adjusted or the light path is interrupted.
If the laser alignment aid is not automatically activated, please
refer to the M 4000 instruction manual.

1. Use a spirit level to check whether the columns and mirrors

are installed in a vertical position.

B743en 2011-10-07 Installation of safety light barrier 7-3

 2. Check to see whether the mirrors are at the same height.
3. Loosen the clamping screw of the safety light barrier.
4. Glue the alignment template for the mirrors to the lower mir-
ror of the first deflection column (starting from the point of
view of the receiver).

Fig. 42294

5. Activate the laser alignment aid by switching on the power

supply or by using one of the two configuration buttons at the
receiver.
6. Turn the receiver until the alignment beam goes through the
center of the hole in the alignment template.
7. Use the alignment template to align the mirrors of further
deflection columns.
8. Remove the alignment template for mirrors.
9. Stick the transmitter alignment template on the lower mirror
of the transmitter.

Fig. 42295

10. Align the mirror of the last deflection column to the transmit-
ter.
The transparent display pane of the transmitter lights up if
the transmitter is aligned properly.
11. Check whether further adjustment is required, using the 7-
segment display of the receiver. Refer to Chapter 7 of the M
4000 operating manual, Putting the Machine into Service.

7-4 Installation of safety light barrier 2011-10-07 B743en

 Chapter 8

Test certificate on the noise

level of the TruLaser 5030
(L41)

1 Test certificate 8-2

2 Measurement result 8-4

3 Position of the measuring points 8-5

B743en 2011-10-07 Test certificate on the noise level of the TruLaser 8-1
5030 (L41)
 1. Test certificate

Noise measurements according to DIN 45635 part 1

Location, date of measurement Ditzingen, 2010-05-10
Measurement room Testing ground for machine tools, machine hall
Accuracy class 2
Machine
Manufacturer TRUMPF Werkzeugmaschinen GmbH & Co. KG
Machine(Q2, Type) TruLaser 5030 (L41)
Serial number and year of manufac- A0231A0003; year of manufacture 2010
ture
Type Solid-state laser-flatbed machine
Dimensions of the plant Basic machine: 9.35 mm x 2.98 mm x 2.38 mm (L x W x H)
Laser and cooler: 4.56 mm x 0.95 mm x 1.70 mm (L x W x H)
Installation Process cooler and laser separate from the machine
Laser TruDisk 3001
Measuring device
Sound level meter Brüel & Kjaer, type 2250, serial no. 2645064
Microphone Brüel & Kjaer, type 4189, serial no. 2631420
Measuring points
Measuring point arrangement According to DIN 45635, part 1, fig. 1.3 , p. 19
Dimensions of the reference cube, 7.89 m x 4.98 m x 3.38 m (L x W x H)
basic machine
Dimensions of the reference cube, 6.56 m x 2.45 m x 2.70 m (L x W x H)
laser and process cooler
Number and position of the measur- 48; position see Fig.
ing points, basic machine
Number and position of the measur- 12; position see Fig.
ing points, laser and cooler
Index of the measuring surface S, 126.3 m2
basic machine
Index of the measuring surface S, 64.7 m2
laser and process cooler
Measuring distance d = 1.0 m
Extraneous noise adjustment K1A 0 dB
Ambience correction K2A machine 0.7 dB
Ambience correction K2A laser and 1.4 dB
process cooler
A-rated measuring surface sound 66.8 dB
level LpA basic machine
A-rated measuring surface sound 72.9 dB
level LpA laser and process cooler
A-rated workplace-related sound 65.9 / 64.1 dB
pressure level at control panel /
light barrier
A-class acoustic power level LWA 88.0
basic machine
A-class acoustic power level LWA 91.0
laser and process cooler

8-2 Test certificate 2011-10-07 B743en

Sound pressure level L'pi See following table
Dimensions of the measuring sur- a = 9.9 m
face b = 8.7 m
c = 3.1 m
Number of measuring points 86
Position of the measuring points
Averaging time Punching: 35 s
Low pressure laser cutting: 28 s
High pressure laser cutting: 25 s
Measuring surface S = 205 m2
Measuring surface level Ls = 23.1 dB
Correction values
Extraneous noise adjustment K1: 0 dB
Environmental adjustment K2A: 1.9 dB

at K2A = 10 lg(1 + 4 S/A) dB

A = Total area SV x sound absorption coefficient α
A = 8570 m2x 0.15 = 1285 m2
S = 205 m2 (measuring surface)
Tab. 8-1

B743en 2011-10-07 Test certificate 8-3

 2. Measurement result

Measur- Measur- L'pi Measur- Measur- L'pi Measur- L'pi Measur-

ing path ing point ing path ing point ing path ing point
1 1 65.7 3 21 67.5 5 41 68.9
2 65.8 22 68.1 42 68.1
3 64.7 23 65.2 43 66.5
4 66.2 24 66.3 44 73.3
5 67.9 25 68.7 45 69.0
6 69.9 26 70.7 46 65.3
7 69.9 27 66.1 6 47 70.9
8 67.7 28 66.4 48 68.6
9 65.1 29 65.5
10 67.5 30 67.6
2 11 64.4 4 31 66.7
12 62.1 32 66.9
13 64.8 33 65.5
14 63.9 34 64.9
15 67.4 35 66.6
16 66.3 36 67.0
17 68.3 37 68.5
18 70.3 38 64.6
19 64.7 39 65.6
20 65.8 40 66.0
Basic machine: values of the sound pressure level L'pi Tab. 8-2

Measur- Measur- L'pi Measur- Measur- L'pi

ing path ing point ing path ing point
1 1 72.3 2 7 71.6
2 72.7 8 72.5
3 74.1 9 74.1
4 79.6 10 75.4
5 72.6 11 74.0
6 71.6 12 72.5
Laser and process cooler: values of the sound pressure Tab. 8-3
level L'pi

8-4 Measurement result 2011-10-07 B743en

 3. Position of the measuring points

Basic machine: position of the measuring points, view from above Fig. 60039

Basic machine: position of the measuring points, view from the left Fig. 60040

Basic machine: position of the measuring points, view from the right Fig. 60041

B743en 2011-10-07 Position of the measuring points 8-5

Basic machine: position of the measuring points; left: view from the rear left; right: view from Fig. 60042
the front

Laser and process cooler: position of the measuring points; top: view from the right; second Fig. 60045
row from left to right: view from the front, top, and behind; bottom: view from the left

8-6 Position of the measuring points 2011-10-07 B743en

 Chapter 9

Automatic nozzle changer

and adjustment mechanism,
automatically center beam
to nozzle
1. The automatic nozzle changer ..................................... 9-3

2. The structure .................................................................. 9-3

2.1 The replacement procedure ............................................ 9-4

3. Restrictions .................................................................... 9-4

4. Nozzle changer operation ............................................. 9-5

4.1 Manual actuation of the nozzle changer .......................... 9-5
Translating axes ......................................................... 9-5
Manual functions ........................................................ 9-6
4.2 Nozzle management ........................................................ 9-7
Nozzle holder allocation ............................................. 9-8
4.3 Tooling dialog in the production plan ............................. 9-10
4.4 Defining the service life of the nozzles .......................... 9-11
4.5 Loading nozzle changers ............................................... 9-13
4.6 Canceling an automatic nozzle change ......................... 9-14

B743EN The automatic nozzle changer 9-1

 5. Adjustment mechanism "Automatically center
beam to nozzle" ........................................................... 9-15
5.1 Maintenance of the beam centering mechanism ........... 9-15

6. Nozzle changer maintenance ..................................... 9-17

Ceramic bodies and nozzle thread ........................... 9-17
Nozzle holders, calibration plate and nozzle-
cleaning brushes ...................................................... 9-17
Drive unit cover plate ................................................ 9-18

7. Minimizing and/or preventing malfunctions and

failures .......................................................................... 9-19
Examples of damaged nozzles and ceramic
bodies ....................................................................... 9-20
Example of a damaged nozzle holder ...................... 9-22

9-2 The automatic nozzle changer 2011-09-16 B743en

 1. The automatic nozzle changer

Function With the nozzle changer, nozzles are removed from the laser
cutting head and replaced with different ones.
The nozzle changer can be used in the following cases:
 Changeover to different material thicknesses.
 Changes of materials.
 Nozzle changes controlled by a program to prevent worn-out
nozzles from being used.
 Other applications which necessitate nozzle replacements.

2. The structure

1 Nozzle-cleaning brush 3 Nozzle holder

2 Calibration plate 4 Nozzle changer extension

Fig. 61830

 The nozzle changer has 18 nozzle holders for automatic

nozzle change.
 Positioning and lift movements use the machine axes.
 The motion for screwing the nozzle holders in and out is
generated by a central drive and a toothed belt.
 The 18 nozzle holders are arranged linearly in 3 lines on the
nozzle changer.
 The screwing-in motion of the nozzle into the ceramic body is
torque controlled.

B743EN The automatic nozzle changer 9-3

  The nozzle changer travels to the right to the parking position
after the replacement procedure, to ensure easier access to
the pallet for the operator.

2.1 The replacement procedure

The sequence of a replacement cycle is described below:

Prerequisites  The nozzle changer is loaded.
 A nozzle is screwed into the cutting head.
 ControlLine is calibrated.

Sequence  The “Brush nozzle" function is performed (nozzle changer is

retracted).
 The nozzle changer moves to the change position.
 The monitoring height of the nozzle is determined using the
calibration plate.
 The new nozzle and the nozzle holder station of the previous
nozzle are blown out/cleaned.
 The previous nozzle is screwed out the nozzle holder.
 The new nozzle is screwed in.
 The monitoring height of the new nozzle is measured and
checked using the calibration plate.
 The nozzle changer moves to the parking position.

3. Restrictions

For automatic nozzle changes, the 2D ceramic M12 nozzle holder,

mat. no. 1591594, is needed.

9-4 Restrictions B743EN

 4. Nozzle changer operation

4.1 Manual actuation of the nozzle changer

Translating axes

Fig. 57461

 If the nozzle changer was previously extended using the switch

elements, the nozzle holders can be turned manually via the
nozzle changer axis C1 by selecting "Set-up Axes motion“
and using the + and - keys.

B743EN Nozzle changer operation 9-5

 Manual functions

Fig. 57462

The following nozzle changer position can be selected and

approached manually by selecting "Set-up Manual functions“:
 Nozzle changer position: The nozzle changer station is
extended and retracted using this function.
 Tooling position: The nozzle changer station is extended and
the nozzle changer axis is rotated to zero using this function.
Nozzles can be changed or checked in this position.

Note
Only screw nozzles in or out of the laser cutting head using the
nozzle tool.

Nozzle tool Fig. 57463

9-6 Nozzle changer operation B743EN

 4.2 Nozzle management

Nozzles, which are in the nozzle changer and in the cutting head,
are managed using the "Technology - Nozzle changer" function.

The mask offers the following functions:

 Display of the magazine allocation (status, position, nozzle
types, remaining service life).
 Manual intervention in allocation and service life.
 Setting the status to “Nozzle changer active“.
 Activation of the “Continue working during nozzle failure"
option.

The column next the "Nozzle type" indicates the Fig. 57464
remaining service life of the nozzle

Nozzles in the nozzle changer and the laser cutting head are
managed using the function Technology >Nozzle changer.

B743EN Nozzle changer operation 9-7

 Nozzle holder allocation

If there is no symbol in the status column, then the magazine

station is free (the nozzle type column is empty) or occupied (there
is an entry in the nozzle type column).

Status symbols Nozzle in the laser cutting head

This status indicates that the nozzle from this position
is in the laser cutting head and that the corresponding
nozzle holder is empty.

Nozzle holder station disabled

A nozzle cannot be allocated to this nozzle holder
station and queries regarding the nozzle allocation of
this station will be ignored.
Tool change height
This symbol indicates that a nozzle change is currently
being performed. As soon as the nozzle changer starts
screwing a nozzle in or out, the status changes from
"Nozzle in the cutting head" to "Tool change height",
once the nozzle changer has successfully completed
the nozzle change, the status changes to "Magazine
station occupied".

Tab. 1

Context buttons If a magazine station (empty or occupied) has

been selected in the table, it is possible to switch
between the status disabled and enabled.

The nozzle service life of the selected magazine

station can be set to the default value of 4 hours,
regardless of the previous value.

9-8 Nozzle changer operation B743EN

 The laser cutting head can be adjusted with this
button.

A dialog box appears.

When a nozzle is being changed manually, it is possible to enter

information here about which nozzle is in the cutting head or that
the cutting head is empty when the nozzle is being screwed out
manually. Only loaded magazine stations are listed in the
magazine station field.

The nozzle changer is moved to the tooling

position by pressing this button, so that the
operator can access the nozzle holders more
easily.
Note
When the tooling position was approached using
the Tooling position button, the End tool setup
operation button is active and when this button
is pressed the machine travels back to its
previous position from before the tooling position
was selected. The End tool setup operation
button is inactive if the tooling position was not
approached using this button.
The tool setup is completed by pressing this
button.

This button deletes all the nozzles via the

Technology → Nozzle changer function, except
for the magazine station with the status Nozzle in
the cutting head.

Tab. 2

B743EN Nozzle changer operation 9-9

 4.3 Tooling dialog in the production plan

Fig. 57459

The nozzles required for the selected program or for the production
plan which are not yet in the magazine are displayed in this mask.
Status Here it is not possible to modify the nozzle changer status (check
box is grayed out).
The check box “Continue working during nozzle failure“ can be
activated so that a program will run to the end even if the service
life has expired. If this check box has not been activated, when the
nozzle service life has expired, the machine will stop at the end of
a contour.
When the nozzle service life has expired, a corresponding
message stating the corresponding magazine station is displayed
in the message line.

9-10 Nozzle changer operation B743EN

 This message is displayed until the service life has been managed
accordingly.

Message in the message line “Service life of the Fig. 57460

nozzle in the magazine station has expired“

4.4 Defining the service life of the nozzles

The service life of the nozzles depends on the programs to be run

and the corresponding operating times.
Program run times are usually known. Approximate service lives
can be calculated on the basis of these known values according
the following formula:

Formula Service life = program run time x 80% x program repetitions

The value of "80 %" is a result of the assumption that when a
program has run 100 %, the average "beam on" time is 80 %.

Example  Program run 1 h.

 The program should run 5x.
 Nozzle, Ø 1.7 mm.

This therefore results in the following according to the formula:

Service life 240 min = 60 min x 80% x 5 program repetitions.
In this example, the service life entered in the tooling dialog is 240
min = 4 h. When the service life expires, the nozzle is changed
automatically as long as there is another identical nozzle available
in the nozzle changer.

B743EN Nozzle changer operation 9-11

 Tip
During day to day operation, the operator can, depending on the
nozzle diameter, material, material thickness, gas type and the
operating mode (manless or with operator), define the service life
as he sees fit or according to known values.
A tool change is carried out after 3 h if the operator enters a
service life of 3 h in the tooling dialog for the nozzle given this
example; this is referred to as preventative nozzle replacement.
The operator is thus able to define the number of nozzle changes
or a preventative nozzle replacement via the service time entered.
If the "Continue working during nozzle failure" function has been
selected, the machine continues cutting even when the entered
service life has expired.
If there is no further nozzle in the nozzle changer, a nozzle change
can therefore not be performed, the machine will stop after the
entered service life has expired.

9-12 Nozzle changer operation B743EN

 4.5 Loading nozzle changers

Inserting the nozzle  Insert the new nozzle so that it does not cant and so that it lies
horizontally with a little play in the nozzle holder.

Fig. 57453

Removing the nozzle Note

Nozzles can jam when being screwed in, should this be the case,
push the nozzle holder down and then release it, it should spring
back up and also release the nozzle.

 Remove the nozzle from the nozzle holder.

Fig. 57454

B743EN Nozzle changer operation 9-13

 4.6 Canceling an automatic nozzle change

In automatic mode, a nozzle change can be canceled as follows:

 Press the RESET button.
 Press the MACHINE OFF button .
 Press the EMERGENCY STOP button.

Case 1 A nozzle was not screwed in or out when the nozzle change was
canceled
 The machine can then be moved back to the home position.

Case 2  The operation of screwing a nozzle in or out was canceled, the

nozzle therefore does not have a clear status, or it has the
status “Tool change height“.
 Approaching the home position does result in the machine and
mechanics of the nozzle changer returning to the home
position, the “Home position reached LED does, however, not
light up.
 The message “The nozzle in the cutting head is at tool change
height and needs to be checked“ appears
 Modify the status in the nozzle administrative table (either "in
the cutting head“ or “in the magazine“).
The machine in back at the home position.

9-14 Nozzle changer operation B743EN

 5. Adjustment mechanism "Automatically
center beam to nozzle"

1 Adjustment mechanism for 2 Nozzle centering sensor

beam centering

Fig. 61717

Function With the adjustment mechanism, the beam can automatically be

centered in the nozzle.
The adjusting screws on the cutting head are operated via two
motors. The centering is controlled by the integrated sensor for the
center of the nozzle.

5.1 Maintenance of the beam centering

mechanism

Checking Maintenance interval: 500 operating hours.

Check the two bellows couplings on the adjustment unit and the
two adjuster screws on the cutting head and have them replaced if
worn or damaged.
Note
If the plastic part of the adjuster screws on the cutting head are
worn away or if the bellows coupling is broken on the adjustment
mechanism, then it must be presumed that the concentric
alignment of the axes is no longer correct. In this case we
recommend that a TRUMPF service technician replaces the
damaged parts.

B743EN Adjustment mechanism "Automatically center beam to 9-15

nozzle"
 Lubricate Maintenance interval: 2000 operating hours

Lubricating nipple on the adjusting mechanism Fig. 61716

 Grease the two lubricating nipples on the adjusting mechanism

using Klüber Microlube GB 00 (see the lubricant table in the
chapter on the maintenance of the machine).

9-16 Adjustment mechanism "Automatically center beam to B743EN

nozzle"
 6. Nozzle changer maintenance

Ceramic bodies and nozzle thread

Checking Maintenance interval: eight operating hours

1. Check ceramic bodies and nozzle thread for wear.

2. Check the condition of all of the nozzles.
3. Replace nozzles as necessary and enter the desired nozzle
service life or default value at the control system.

Checking the nozzle holders Maintenance interval: 1000 operating hours.

1. Check the nozzle holders for damage.

2. Check whether all of the nozzle holders can be pushed down
equally. If this should not be the case, replace the
corresponding nozzle holder(s).
3. Clean the nozzle holders.
4. Clean the upper side of the cover plate.

Nozzle holders, calibration plate and nozzle-

cleaning brushes

Check and clean Maintenance interval: 500 operating hours

1. Blow out the nozzle holders and clean with a cleaning cloth
and with cleaning agent if necessary.
2. Clean the calibration plate.
3. Check the nozzle-cleaning brushes, clean and exchange if
necessary.

B743EN Nozzle changer maintenance 9-17

 Drive unit cover plate

Maintenance interval: 2000 operating hours

Cleaning 1. Remove the cover plate and clean the drive unit area (see Fig.
57676. Pos. 1) under the cover plate.

1 The area of the drive unit

Fig. 57576

2. Check the bellows for damage (see Fig. 57669. Pos. 1).

1 Bellows

Fig. 57669

Lubricate After removing the cover plate, lubricate the linear guide grease
nipples (4x) underneath the bellows.

9-18 Nozzle changer maintenance B743EN

 7. Minimizing and/or preventing
malfunctions and failures

The following points should be observed when inserting the nozzle

changer:
 Use original TRUMPF nozzles and ceramic bodies.
 The nozzle administration has, among other things, to be
corrected in the following cases via the “Technology – Nozzle
changer“ function, so that the nozzle holder allocation
corresponds to the actual state:
– After manual intervention.
– After changing the laser cutting head.
– After canceling nozzle change.
 When using a production plan, check the availability of the
nozzles via “Production - Production plan - Prepare“.

Fig. 57455

 There may not be any spatter on the nozzles (outer area of the
tapered surface), as they also form the support areas in the
nozzle chuck.
 The following damage to the nozzle can result in the nozzle
change being canceled:
– The hexagonal on the nozzle has been deformed or
damaged by being overtigthened manually or as a result of
a collision.
– The thread, and in particularly the start of thread, has
become damaged due to having been overtightened
manually or due to the nozzle having been dropped on a
hard surface.

B743EN Minimizing and/or preventing malfunctions and 9-19

failures
 – The thread or the sealing surface is not clean which leads
to increasing abrasion in the magazine stations and
particularly in the ceramic insulator.
– The nozzle changer should, as a rule, be kept clean and
maintenance work should be performed according to the
maintenance plan.

Examples of damaged nozzles and ceramic

bodies

Damaged nozzle surface Fig. 57465

Hexagonal surfaces rounded, squashed or broken off Fig. 57466

9-20 Minimizing and/or preventing malfunctions and B743EN

failures
 Thread damaged Fig. 57467

Cracked ceramic body Fig. 57469

Ripped 2D ceramic M12 nozzle holder Fig. 61718

B743EN Minimizing and/or preventing malfunctions and 9-21

failures
 Example of a damaged nozzle holder

Area with a large amount of wear Fig. 61720

The nozzle holders are subject to wear which varies according to

use.
If there is excessive wear and/or cracking, the corresponding
nozzle holders must be replaced.
The transfer position of the cutting head must also be checked.
Fig. 61720 shows the area which is most subject to wear (6 x per
nozzle holder).
The lower macro photo shows a possible damage pattern.

Pressure point and crack in the nozzle holder.

Fig. 61719

9-22 Minimizing and/or preventing malfunctions and B743EN

failures