Operator's manual

LiftMaster, LiftMaster Sort

TruLaser series 3000/5000/7000
Operator's manual

LiftMaster, LiftMaster Sort

TruLaser series 3000/5000/7000

Original operator's manual

Edition 2011-08-22
 Order Information Please specify when ordering this document:
Operator's manual
LiftMaster, LiftMaster Sort
Edition 2011-08-22
Document number B484EN

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 ...
This operator's manual documents the automation components,
LiftMaster and LiftMaster Sort, for the following TruLaser series:
■ LiftMaster --1530 (1.5 m x 3 m):
− TruLaser 3030
− TruLaser 3530
− TruLaser 5030
■ LiftMaster --2040 (2 m x 4 m):
− TruLaser 3040
− TruLaser 5040
■ LiftMaster --1225 (1.2 m x 2.5 m):
− TruLaser 7025
■ LiftMaster --2540 (2.5 m x 4.m):
− TruLaser 7040

Additional Documentation ■ Replacement parts list for LiftMaster, LiftMaster Sort.

■ Circuit diagram for LiftMaster, LiftMaster Sort.
■ Pneumatic diagram for LiftMaster, LiftMaster Sort.
■ Operator's manual for the laser machine.
■ Programming manual for the laser machine.
■ Operator's manual for the TruFlow-Laser.
■ TruTops Laser software manual.
■ Manual for the storage control system (if there is a storage
system).

B484EN 2011-08-22 Before you proceed ... I

II Before you proceed ... 2011-08-22 B484EN
 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 1-6

4 Hazards 1-8
4.1 Dangers due to the switch cabinet 1-8
4.2 Hazards when dealing with workpieces 1-8
Dangers due to floating loads 1-8
Sharp-edged workpieces 1-9
4.3 Dangers due to the suction frame falling 1-9

5 Measures to be taken by the manufacturer 1-10

5.1 Danger zones and safeguarding device 1-10
5.2 Danger signs on the machine 1-13

6 Measures to be taken by the owner 1-16

6.1 Observing warnings and danger signs 1-16
6.2 Training and instructing operators 1-16
Measures applicable worldwide 1-16
6.3 Adhering to the duty of care when handling 1-16
the machine
6.4 Pay attention to water protection 1-17
6.5 Using spare parts, accessories, software and 1-18
operating materials

7 Overview of residual risks 1-20

8 Disassembly and disposal 1-21

B484EN 2011-08-22 Table of contents 0-1

 Chapter 2 Installation conditions for
LiftMaster, LiftMaster Sort

Who does what? 2-3

1 Planning aid 2-4

2 Installation site 2-5

2.1 Space requirements 2-5
2.2 Floor requirements 2-7
2.3 Weight load 2-9
2.4 Ambient conditions 2-9

3 Electrical supply 2-11

4 Compressed air supply 2-12

5 Transport 2-13
5.1 Transport weight and dimensions 2-13
5.2 Measures to be taken by the customer 2-16

6 Installation 2-18
6.1 TRUMPF service work 2-18
6.2 Unprocessed material station 2-18

Chapter 3 Description

1 Concept 3-3
1.1 Function of LiftMaster (R) and LiftMaster Sort 3-7
1.2 Function of LiftMaster (P) 3-11
1.3 Function of LiftMaster (RP) 3-13

2 Technical data 3-15

2.1 LiftMaster/LiftMaster Sort --1530 3-15
2.2 LiftMaster/LiftMaster Sort --2040 3-16
2.3 LiftMaster --1225/--2540 3-17

0-2 Table of contents 2011-08-22 B484EN

 3 Modules 3-18
3.1 Suction cups 3-20
LiftMaster suction cup arrangement 3-20
Suction cup arrangement of LiftMaster 3-23
Sort
Sheet formats 3-26
Peeler cup 3-27
Separating thin sheets (optional) 3-28
3.2 Double sheet measurement 3-29
Sheet thickness measuring device 3-29
Double sheet detector 3-30
3.3 Rotoscanner 3-31
3.4 Sheet alignment 3-31

4 Pallets 3-33
4.1 Pallet names 3-33
4.2 Auxiliary pallets 3-34

5 Lifting force monitoring 3-35

Chapter 4 Operation of LiftMaster, LiftMaster

Sort --1530/--2040

1 Operating elements 4-3

1.1 Control elements on the complete system 4-3
1.2 Control panel on the LiftMaster's start pedes- 4-5
tal

2 Operating modes 4-11

3 User interface in machines with MMC200X 4-12

control system
3.1 Structure of the user interface 4-12
3.2 Switching TruTops FMC panel on and off 4-16
3.3 User interface: Basic settings 4-16
Calibrate the touchscreen 4-16
Set language, measuring system, date 4-17
and time

B484EN 2011-08-22 Table of contents 0-3

 Open TRUMPF Operating System (TOS) 4-17
3.4 Production (automatic mode) 4-17
3.5 Carrying out technology corrections 4-18
Selecting technology 4-18
Load sheet 4-19
Maxi part separation 4-20
Stack small parts (optional for SortMaster) 4-20
Remove small parts (SortMaster option) 4-21
3.6 Adjusting inventories 4-22
3.7 Manual transporting (semi-automatic cycle) 4-23
3.8 Manual handling (optional) 4-24
3.9 Viewing active store movements 4-25

4 User interface in machines with GritPlus 4-26

control system
4.1 Structure of the user interface 4-26
4.2 Working in semiautomatic cycle 4-28
Loading 4-28
Selecting sheet format 4-29
Unloading 4-30
4.3 Working in automatic mode 4-31
Opening a production plan 4-31
Create sheet job 4-32
Create production plan 4-34
Change sheet job 4-34
Delete sheet job 4-34
Set status 4-34
Prepare and start production 4-35

Chapter 5 Operation of LiftMaster

--1225/--2540

1 Operating elements 5-3

1.1 Control elements on the complete system 5-3
1.2 Control panel on the start post of LiftMaster 5-6
(optional)

0-4 Table of contents 2011-08-22 B484EN

 2 Operating modes 5-9

3 Structure of the user interface 5-10

4 Manual mode 5-12

4.1 Loading 5-12
4.2 Unloading 5-13

5 Working in semiautomatic cycle 5-17

5.1 Loading 5-17
5.2 Selecting sheet format 5-17
5.3 Unloading 5-19

6 Working in automatic mode 5-20

6.1 Opening a production plan 5-20
6.2 Create sheet job 5-20
6.3 Change sheet job 5-21
6.4 Delete sheet job 5-21
6.5 Set status 5-21
6.6 Prepare and start production 5-22
6.7 Working in single-pallet operation 5-22
6.8 Manually loading and unloading within the 5-23
production plan
6.9 Manual intervention in automatic mode 5-23

Chapter 6 Maintenance

1 General guidelines 6-3

2 Maintenance Overview 6-4

3 Lubrication 6-5
3.1 Overview 6-5
3.2 Maintenance Instructions 6-6
Rotary connection to the suction frame 6-6
Linear guides on elevating part 6-7
Lifting chain 6-8

B484EN 2011-08-22 Table of contents 0-5

 Index 6-9
Unloading rake chain 6-9
Ballscrew bearing of unloading rake 6-9
Unloading rake gear motor 6-10
Lift drive 6-11

4 Mechanical elements 6-13

4.1 Overview 6-13
4.2 Maintenance Instructions 6-14
Suction cups 6-14
Index 6-14
Unloading rake chain 6-15
Lifting chain 6-17

5 Electrics 6-19
5.1 Overview 6-19
5.2 Maintenance Instructions 6-19
Heat exchanger door on the switch cabi- 6-19
net

Chapter 7 Index

0-6 Table of contents 2011-08-22 B484EN

 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 1-6

4 Hazards 1-8
4.1 Dangers due to the switch cabinet 1-8
4.2 Hazards when dealing with workpieces 1-8
Dangers due to floating loads 1-8
Sharp-edged workpieces 1-9
4.3 Dangers due to the suction frame falling 1-9

5 Measures to be taken by the manufacturer 1-10

5.1 Danger zones and safeguarding device 1-10
5.2 Danger signs on the machine 1-13

B484EN 2011-08-22 Safety 1-1

 6 Measures to be taken by the owner 1-16
6.1 Observing warnings and danger signs 1-16
6.2 Training and instructing operators 1-16
Measures applicable worldwide 1-16
6.3 Adhering to the duty of care when handling 1-16
the machine
6.4 Pay attention to water protection 1-17
6.5 Using spare parts, accessories, software and 1-18
operating materials

7 Overview of residual risks 1-20

8 Disassembly and disposal 1-21

1-2 Safety 2011-08-22 B484EN

 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.
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. If it is not avoided, it can
result in death and serious injuries.
WARNING Refers to a dangerous situation. If it is not avoided, it
could result in serious injuries.
CAUTION Indicates a potentially dangerous situation. If it is not
avoided, it could result in injuries.
NOTICE If such a situation is ignored, it could result in damage
to property.
Tab. 1-1

B484EN 2011-08-22 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 2011-08-22 B484EN

 2. Terms

In the following, the described automation component is referred

to as the machine. If there are differences or special features
which require further differentiation, the respective product name
will be used.

B484EN 2011-08-22 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.

3.1 Intended use

Machine The operator may use the machine only in the industrial sector.
With the machine, the operator may transport flat and clean
metal sheets for machining on a laser flat-bed machine, as well
as transport away cut sheets and scrap skeletons.
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 following is not allowed:

■ Unauthorized alteration or conversion of the machine by the
operator or personnel.
■ Any working procedure that impairs the safety.
■ Exceeding the permissible workpiece dimensions and weight
limits.
■ Using workpieces with dirty or rough surfaces, e.g.: scaled,
scarred, heavily oiled, rusty or sandblasted workpieces.

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 hydraulic, pneumatic and electrical
modules.

1-6 Operating safety 2011-08-22 B484EN

 − Checking safety elements.
− Disassembling the machine.

B484EN 2011-08-22 Authorized personnel 1-7

 4. Hazards

4.1 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).

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).

4.2 Hazards when dealing with

workpieces

Processing workpieces can be dangerous. These dangers and

measures are different for every workpiece.

Dangers due to floating loads

The automation components move with suspended loads during

loading and unloading.

Unexpected vacuum loss in case of a suctioned workpiece!

DANGER
Risk of fatal injury due to crashing workpieces!
Ø Observe safety regulations for the handling of heavy loads.
Ø Do not enter the danger zone if a workpiece is suctioned.

1-8 Hazards 2011-08-22 B484EN

 Sharp-edged workpieces

Workpieces have sharp edges!

WARNING
Risk of injury!
Ø Wear personal protective gear.

4.3 Dangers due to the suction frame

falling

Risk of fatal injury due to the suction frame falling!

DANGER
The suction frame can fall if the holding brake is defective.
Ø Never stand below the suction frame while it is unsecured.
Ø When performing maintenance work underneath the suction
frame, secure the suction frame with a suitable device (min.
carrying capacity 750 kg).

B484EN 2011-08-22 Dangers due to the suction frame falling 1-9

 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 Deflection mirror for light barrier 2 Operating panel with Emergency 3 Light barrier transmitter
stop impact button and light bar-
rier receiver
Danger zone LiftMaster (highlighted in gray) Fig. 31242

1-10 Measures to be taken by the manufacturer 2011-08-22 B484EN

 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 all operating modes of the machine, the danger zone can
be secured by the safety light barrier.
■ An interrupted light beam triggers a Feed Hold during opera-
tion: All movements of the machine are automatically stop-
ped.
■ When Feed hold is activated, any existing vacuum is main-
tained.

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. 1-2

Note
The machine has a main switch if it has to comply with the elec-
tric IEC regulation (Europe) or NEC regulation (North America).

Emergency stop impact An EMERGENCY STOP leads to the following:

button ■ All axis motions are stopped.
■ All drives are switched off electrically.
■ The 24 V control voltage is maintained.
■ Vacuum remains.

Secure position ■ Safe position with additional locking in the uppermost posi-
tion.

Vacuum The vacuum can only be shut down if the suction frame is in the
lower end position or the unloading rake is closed.

Swivel arm Constructional safety precautions during loading and unloading:

■ The swivel arm can only be lowered to the designated posi-
tions:
− Over the sheet stack.
− Above the pallet changer.
− Above the unloading platform.
■ Swiveling is only possible if the swivel arm is in its final
upper position.

B484EN 2011-08-22 Danger zones and safeguarding device 1-11

 Unloading rake Constructional safety precautions during loading and unloading:
■ It is only possible to open and close the unloading rake when
the suction cups are not in the lower working position.
■ The unloading rake is closed for loading the unprocessed
material during the swiveling movement.

Pallet gripper, only Constructional safety precautions during loading and unloading:
LiftMaster (P) or (RP) ■ The pallet grippers can be opened and closed only in the
lower end position.
■ The closed pallet grippers also remain closed in Emergency
Stop situations and if the compressed air network fails.

Safety devices of the basic In addition, all safety devices of the laser machine are also
machine effective for the automation component:
■ In the event of an emergency stop on the laser machine or
the pallet changer, all motions of the automation components
are stopped.
■ Any applied vacuum is maintained.

1-12 Danger zones and safeguarding device 2011-08-22 B484EN

 5.2 Danger signs on the machine

Danger signs indicate dangers when operating the machine.

Sign positions Fig. 61073

Sign Danger signs

no.
1

Allowed treading surface for maintenance work on the rake

frame
2

Danger due to electrical voltage

3

Hot substances

B484EN 2011-08-22 Danger signs on the machine 1-13

 Sign Danger signs
no.
4

Falling sheet
5

Maximum carrying capacity and sheet thickness LiftMaster

--1530

Maximum carrying capacity and sheet thickness LiftMaster

--2040

1-14 Danger signs on the machine 2011-08-22 B484EN

 Sign Danger signs
no.
5

Maximum carrying capacity and sheet thickness LiftMaster

--1225

Maximum carrying capacity and sheet thickness LiftMaster

--2540
6

Forbidden for persons with pacemakers

Danger signs on the machine Tab. 1-3

B484EN 2011-08-22 Danger signs on the machine 1-15

 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. 1-10).

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.
■ 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.

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

1-16 Measures to be taken by the owner 2011-08-22 B484EN

 operator must replace and put the safety devices into operation
after completing work.

Check the safety light barriers for proper function.

■ Once per shift, preferably before starting the production.
■ If the arrangement of the light transmitters and receivers has
changed.
■ After all maintenance and service work on the safety light
barrier.

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.
■ 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.

Secure the danger zone The user must also safeguard the danger zones caused by a
additionally special shape or larger dimensions.

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

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).

B484EN 2011-08-22 Pay attention to water protection 1-17

 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 Lubricants

Water Hazard Class WHC 2
Volume of water-pollutant materials ≤1000 l
Hazard level of the machine A
Water protection specifications Tab. 1-4

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

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.

1-18 Using spare parts, accessories, software and 2011-08-22 B484EN

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

B484EN 2011-08-22 Using spare parts, accessories, software and 1-19

operating materials
 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 risk Dangerous point Type of danger Measure to be taken by

the operator
Mechanical elements
Crushing Swivel arm Risk of injury Secure danger zone.
Unloading rake Risk of injury Secure danger zone.
Joint Swivel arm Risk of injury Secure danger zone.
Unloading rake Risk of injury Secure danger zone.
Suction frame Risk of injury Secure danger zone.
Gripping or retracting Unloading rake Risk of injury Secure danger zone.
Rake drive Risk of injury Secure danger zone.
Falling loads Load raw material with Risk of injury Secure danger zone.
pallet for LiftMaster (P)
Eject Load raw material with Risk of injury If necessary secure dan-
pallet for LiftMaster (P) ger zone with safety
fence.
Manual removal of work- Pallet changer Risk of injury Before working on the pal-
pieces let changer, remove the
unloading unit from the
danger zone.
Wear protective clothing.
Conversion and installa- Complete machine Risk of injury none
tion, unsuitable means of
transportation
Electrics
Electrical contact and Parts that are normally Risk of fatal injury Assign specially trained
proximity to parts under live personnel for mainte-
high voltage nance, service and
repairs.
Contact with parts that are Risk of fatal injury none
live when in an error
state.
Electrical contact with Frequency converter Risk of fatal injury Assign specially trained
electrically charged parts personnel for mainte-
nance, service and
repairs.
Residual risks Tab. 1-5

1-20 Overview of residual risks 2011-08-22 B484EN

 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. compressed
air line).
■ 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

Hydraulic oil
Gear oil ■
Unloading rake gearbox.
■
Swivel arm lift drive.
■
Swivel drive, swivel arm.
Possible hazardous substances Tab. 1-6

Assemblies with particular ■ The following assemblies/components present a particular

risk potential risk potential during disassembly:

Assembly/component Danger
Swivel arm with suction frame with Suspended assemblies
unloading rake
Assemblies with particular risk potential during disassembly Tab. 1-7

B484EN 2011-08-22 Disassembly and disposal 1-21

 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.

1-22 Disassembly and disposal 2011-08-22 B484EN

 Chapter 2

Installation conditions for

LiftMaster, LiftMaster Sort
Material number 0355 160
Graphic number 67233-030-50.EN

B484EN Installation conditions for LiftMaster, LiftMaster Sort - 2-1

Version 8
 Who does what? 2-3

1 Planning aid 2-4

2 Installation site 2-5

2.1 Space requirements 2-5
2.2 Floor requirements 2-7
2.3 Weight load 2-9
2.4 Ambient conditions 2-9

3 Electrical supply 2-11

4 Compressed air supply 2-12

5 Transport 2-13
5.1 Transport weight and dimensions 2-13
5.2 Measures to be taken by the customer 2-16

6 Installation 2-18
6.1 TRUMPF service work 2-18
6.2 Unprocessed material station 2-18

2-2 Installation conditions for LiftMaster, LiftMaster Sort - B484EN

Version 8
 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 personnel will not be
able to put the system into service.

Note
The main switch on the machine may only be switched on by
TRUMPF service personnel.

TRUMPF Service The machine is put into service by TRUMPF Service technicians.

This includes:
■ Installing, aligning, leveling and securing the machine.
■ Connecting the machine to the supplies (with the exception
of the electrical power supply).
■ Performing a functional test.
■ Instructing personnel.

B484EN Installation conditions for LiftMaster, LiftMaster Sort - 2-3

Version 8
 1. Planning aid

The planning aid provides an overview of the measures and

preparations for which the customer is responsible.
For details, refer to the corresponding subchapters of these
installation conditions.

Time before the delivery Planning criterion Measures

of the machine
15 weeks Personnel and training ■ Appoint a member of staff to be responsible for
preparations for the delivery of the machine.
■ Appoint operating and service personnel and pro-
grammers.
■ Arrange training schedules for specialist personnel.
14 weeks, but no later Installation site ■ Determine the installation site of the machine, taking
than week... into account the space requirements according to
the installation plan.
■ Check floor requirements:
− Floor quality.
− Evenness.
■ Take the weight and dimensions of the machine into
account.
■ Check the requirements for ambient conditions:
− Room temperature.
− Exposure to sunlight.
− Purity of the ambient air.
■ Check transport route:
− Gateway openings.
− Header heights.
− Cable rack heights.
− Room to negotiate around corners etc.
12 weeks, but no later Electrics ■ Install electrical connections at the installation site.
than calendar week ... ■ Lay the conductor cross-section and fuse protection
according to the legal requirements.
12 weeks, but no later Compressed air supply ■ Arrange for the installation of the compressed air
than calendar week ... supply at the installation site.
4 weeks, no later than Transport ■ Provide auxiliary transport equipment.
calendar week ...
Planning aid Tab. 2-1

2-4 Planning aid - Version 8 B484EN

 2. Installation site

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

2.1 Space requirements

See the installation and foundation plan applicable in each case

for the arrangement of the individual parts of the machine and
the space required by the system.
The installation and foundation plan delivered with the system is
always valid.

Machine Type of installation (see (see "Fig. 31103", pg. Installation Foundation
2-7)) plan plan
TruLaser 3030 LiftMaster, symmetric, unprocessed material sta- 93614-5-16 93614-5-16 .1
tion, left
LiftMaster, symmetric, unprocessed material sta- 93614-5-17 93614-5-16 .1
tion, right
TruLaser 3030 --L20 LiftMaster, symmetric, unprocessed material sta- 93730-5-16 93730-5-16.1
tion, left
LiftMaster, symmetric, unprocessed material sta- 93730-5-17 93730-5-16.1
tion, right
TruLaser 5030 LiftMaster, symmetric, unprocessed material sta- 93619-5-16 93619-5-16 .1
tion, left
TruLaser 5030CL
LiftMaster, symmetric, unprocessed material sta- 93619-5-17 93619-5-16 .1
tion, right
TruLaser 3040 LiftMaster, symmetric, unprocessed material sta- 93674-5-16 93674-5-16.1
tion, left
LiftMaster, symmetric, unprocessed material sta- 93674-5-17 93674-5-16.1
tion, right
TruLaser 3040 --L32 LiftMaster, symmetric, unprocessed material sta- 93740-5-16 93740-5-16.1
tion, left
TruLaser 5040 LiftMaster, symmetric, unprocessed material sta- 93678-5-16 93678-5-16.1
tion, left
LiftMaster, symmetric, unprocessed material sta- 93678-5-17 93678-5-16.1
tion, right
TruLaser 3530 LiftMaster, symmetric, unprocessed material sta- 93621-5-16 93621-5-16.1
tion, left
LiftMaster, symmetric, unprocessed material sta- 93621-5-17 93621-5-16.1
tion, right

B484EN Installation site - Version 8 2-5

 Machine Type of installation (see (see "Fig. 31103", pg. Installation Foundation
2-7)) plan plan
TruLaser 7025 LiftMaster left 8751-5-2115 8751-5-2115.1
8751-5-2135
8751-5-2145
TruLaser 7040 LiftMaster right 8753-5-2115 8753-5-2115.1
8753-5-2145 8753-5-2135.1
8753-5-1535 8753-5-2135.1
8753-5-2535 8753-5-2135.1
8753-5-1635
8753-5-2635
8753-5-2735
Installation plans for LiftMaster, LiftMaster Sort Tab. 2-2

2-6 Space requirements - Version 8 B484EN

a Symmetric installation L LiftMaster 1 Position 1: On the very right,
b Installation, left M Laser machine seen from the LiftMaster
c Installation, right P Pallet changer of laser machine 2 Position 2: In the center (pos. c)
or on the left (pos. a, b), seen
B Operator (in front of control
from the LiftMaster
panel for laser machine)
3 Position 3: On the very left (pos.
c), seen from the LiftMaster
Installation versions of LiftMaster and LiftMaster Sort Fig. 31103

2.2 Floor requirements

The minimum requirements have been specified below.

As a basic rule, the required foundation size must be calculated
by a structural analyst.

B484EN Floor requirements - Version 8 2-7

 Evenness ■ The surface used as a base for the machine/system must be
even.
■ The area of the installation site of the machine/system may
not deviate from the level more than a maximum of 12 mm
(½ in) for every 10 m (33 ft).
■ Minor unevenness can be compensated with adjustable legs.

Installation surface ■ A continuous base plate with a smooth surface is required in

the area of the load-bearing points.
■ There should be no hollow spaces below the base plate in
the area of the load-bearing points.
■ 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.

Elastically cushioned base ■ Load capacity:

plate − LiftMaster --1530 and --1225: 30 kN/m2 (4.4 psi).
− LiftMaster --2040 and --2540: 40 kN/m2 (5.7 psi).
■ Minimum thickness 200 mm (8 in).
■ 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).
■ Steel reinforced concrete with the following properties:1
− Characteristic rated value fy ≥435 N/mm2.
− Modulus of elasticity Es ≥200000 N/mm2.
− Upper crosswise reinforcement, 3.7 cm2/m each
(0.075 in2/ft).
− Lower crosswise reinforcement, 3.7 cm2/m each
(0.075 in2/ft).
■ Elastic cushioning of the floor plate on foundation with a min-
imum ballast number of C ≥5000 kN/m3 (loess loam).
■ The following apply for joints in the area of the machine:
− In the area of the fixing points (anchor rods) within a
radius of at least 200 mm (8 in), there must not be
expansion or dummy joints, (which means that the lower
reinforcement is active) neither may there be an edge of
a joint.
− A structural analyst must be consulted for all other joints
and for distances less than the specified minimum clear-
ances.

1 US specification: reinforced with two layers of #5 reinforcing bars 12 in

on center and hooked each way.

2-8 Floor requirements - Version 8 B484EN

Ceiling plate/freely tensioned LiftMaster --1530 LiftMaster --2040
base plate and --1225 and --2540
Load capacity 30 kN/m2 (4.4 psi) 40 kN/m2 (5.7 psi)
Minimum thickness 200 mm (8 in) 300 mm (12 in)
Plates as multiple span girders
Tab. 2-3

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 analysis As a basic rule, the required foundation size must be calculated
by a structural analyst. The structural circumstances at the instal-
lation site and the configuration of the store concerned must also
be taken into account.

The following documents must be made available to the struc-

tural analyst:
■ Installation and foundation plan.
■ Section entitled "Installation site" in the installation conditions.

LiftMaster LiftMaster LiftMaster LiftMaster

--1530 --2040 --2540 --1225
Total weight (including maximum load) Approx. 4850 Approx. 8150 Approx. 7850 Approx. 4350
kg kg kg kg
Overturning moment 97 kNm 190 kNm 190 kNm 66 kNm
Dimensions of LiftMaster base plate 1190x1190 mm 1500x1500 mm 1500x1500 mm 1190x1190 mm
support area
Minimum distance of LiftMaster base 200 mm 200 mm 200 mm 200 mm
plate from edge of foundation plate
Minimum foundation thickness 200 mm 200 mm 200 mm 200 mm
Evenness (maximum difference in 4 mm 5 mm 5 mm 4 mm
height of the support area)
Dimensions of cast base 1310x1310x30 1620x1620x30 1620x1620x30 1310x1310x30
+10 mm +10 mm +10 mm +10 mm
Load values and dimensions at the installation site Tab. 2-4

2.4 Ambient conditions

Ambient Temperature The ambient temperature for the operation of the machine must
be between +10° C (50 °F) and +43° C (109°F). The tempera-

B484EN Weight load - Version 8 2-9

 ture at the installation site may not fall below +5° C (41 °F) while
the system is switched off.
The general ambient conditions required for TRUMPF TruLaser
machines also apply.

2-10 Ambient conditions - Version 8 B484EN

 3. 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.

Line voltage 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. 2-5

The automation component is supplied via a cable with plug from

the machine (see operator's manual for laser machine).

B484EN Electrical supply - Version 8 2-11

 4. 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 is required:

■ For the vacuum ejectors.
■ To blast the suction cups.
■ To lift the suction cups.
■ For the optional shelf storage system: for supplying the stor-
age carts.

Connected loads The LiftMaster is connected directly to the compressed air net-
work.

LiftMaster --1530 LiftMaster --2040 LiftMaster LiftMaster

--2540 --1225
Standard Sort Standard Sort
Nominal width of 16
hose
Network pressure 7 - 14 bar (101 - 203 psi)
Working pressure 6.5 ±0.5 bar (94.3 ±7.3 psi)
∅ Air consumption 13.5 m³/h 22 m³/h 20 m³/h 27 m³/h 22 m³/h 12 m³/h
(12.9 cfm)
(7.9 cfm) (12.9 cfm) (11.8 cfm) (7.1 cfm)
(15.9 cfm)
Minimum flow rate 1000 l/min 1400 l/min 1200 l/min 1700 l/min 1400 l/min 1000 l/min
at the maintenance
(0.59 ft3/s) (0.82 ft3/s) (0.71 ft3/s) (1.00 ft3/s) (0.82 ft3/s) (0.59 ft3/s)
unit2
Tab. 2-6

Note
The same quality criteria apply for the compressed air as for the
TruLaser machine.

Compressed air properties Property Requirement Quality Recommen-

at the tapping point class ISO dation
8573-1
Condensate- Cooled to +7 °C (+44.6 °F) 5 Cold dryer
free (pressure dew point)
Dust-free Maximum particle size: 15 4 Air filter in
µm front of the
system
Maximum particle density: 8
mg/m3
Oil-free Max. oil content: 5mg/m3 4 Oil-free
compacting
compressor
Tab. 2-7

2 For a dynamic pressure of 6 bar (87 psi) .

2-12 Compressed air supply - Version 8 B484EN

 5. Transport

What does the customer You have to make the necessary arrangements and then trans-
need to do? port the automation component from the truck to its final installa-
tion site.

Ensure that you have checked the machine's transport route to

its installation site in good time. The following aspects must be
checked in particular:
■ Door openings.
■ Header heights.
■ Cable racks.
■ Ground suitability for driving with armored rollers and the like.

5.1 Transport weight and dimensions

LiftMaster --1530 LiftMaster --2040 LiftMaster LiftMaster

--2540 --1225
Standard Sort Standard Sort
Total weight Gges3 4200 kg 4200 kg 6850 kg 6850 kg 6495 kg 4000 kg
(9260 lbs) (9260 lbs) (15100 lbs) (15100 lbs) (14320 lbs) (8820 lbs)
Weight of the lifting 300 kg 300 kg 300 kg 300 kg 300 kg 300 kg
beam (660 lbs) (660 lbs) (660 lbs) (660 lbs) (660 lbs) (660 lbs)
Height without cross 2638 mm 2638 mm 2684 mm 2684 mm 2684 mm 2638 mm
beam H1 (104 in) (104 in) (106 in) (106 in) (106 in) (104 in)
Height with cross beam 3080 mm 3080 mm 3120 mm 3120 mm 3120 mm 3080 mm
H2 (121 in) (121 in) (123 in) (123 in) (123 in) (121 in)
Width B (symmetric) 2200 mm 2200 mm 2800 mm 2800 mm 3000 mm -
(87 in) (87 in) (110 in) (110 in) (118 in)
Length L (symmetric) 6060 mm 6060 mm 6800 mm 6800 mm 6800 mm -
(239 in) (239 in) (268 in) (268 in) (268 in)
Width B (left or right) 2300 mm - 2800 mm - - 2200 mm
(91 in) (110 in) (87 in)
Length L (left or right) 5500 mm - 6200 mm - - 4900 mm
(217 in) (244 in) (193 in)
Transport weight and dimensions of LiftMaster/LiftMaster Sort Tab. 2-8

3 Transport weight including transportation equipment and the lifting

beam

B484EN Transport - Version 8 2-13

1 Transport rings 4 Wooden base 7 Support arm position fixation
2 Cross support 5 Frame position fixation 8 Transport aid
3 Cross beam 6 Swivel arm Wto Total weight
t
Transport configuration of LiftMaster --1530, --2040, --2540, symmetric, and LiftMaster Sort Fig. 31270

2-14 Transport weight and dimensions - Version 8 B484EN

1 Transport rings 4 Transport aid 7 Support arm
2 Cross support 5 Support arm position fixation 8 Transport securing devices
3 Cross beam 6 Frame position fixation Wto Total weight
t
Transport configuration of LiftMaster --1530, --2040, left or right Fig. 31313

B484EN Transport weight and dimensions - Version 8 2-15

 5.2 Measures to be taken by the
customer

Every LiftMaster is supplied with transport regulations in three

languages, which are easily visible in a clear plastic envelope
attached to the supporting arm.

Means, Tools, Materials

■ Transport with the forklift is not permissible!
■ Transport to the installation site with a crane truck:
− LiftMaster --1530/--1225: carrying capacity of at least 5 t
(11000 lbs) or higher if a longer lever arm is required due
to conditions on site.
− LiftMaster --2040/--2540: carrying capacity of at least 10 t
(22000 lbs) or higher if a longer lever arm is required due
to conditions on site.
− Eyebolts, shackles and spreader bars are supplied by
TRUMPF. Costs will be reimbursed when the items are
returned.
■ Transport of the LiftMaster to its installation site with armored
rollers:
− Armored rollers (2 x steerable and 2 x non-steerable or 4
x steerable) each with a carrying capacity of 5 t
(11000 lbs). Adjustable height ≤30 mm (≤1.2 in).
− 2 hydraulic jacks each with a carrying capacity of 5 t
(11000 lbs). Adjustable height ≤30 mm (≤1.2 in).
− Hoisting iron 1 m (39 in) with extension.

Checking the LiftMaster on 1. Examine all components for damage caused during transport.
delivery 2. Record visible damage caused during transport on the cargo
note and have the record countersigned by the truck driver.
3. Report any hidden transport damage to the insurance com-
pany and TRUMPF within six days.

Unloading the LiftMaster

from the truck

LiftMaster is not stable on its own.

WARNING
The LiftMaster may tilt!
Ø Before you remove the transport securing device (base),
support the LiftMaster with a crane or forklift until the Lift-
Master has been bolted to the ground.

4. Attach the supplied lifting beam to the LiftMaster.

2-16 Transport weight and dimensions - Version 8 B484EN

 Note
When transporting with a crane truck, a TRUMPF technician
must be present to monitor the attachment of the retaining
straps and the unloading and setting down of the machine.
5. Unload the LiftMaster with the crane truck at the lifting beam.
Transport LiftMaster to 6. Either use a crane truck or armored rollers to transport the
installation site LiftMaster to its installation site. Observe the contact points:

1 Contact points for jack, armored rollers and lift truck

Contact points for LiftMaster with transport securing Fig. 31957
device

B484EN Transport weight and dimensions - Version 8 2-17

 6. Installation

6.1 TRUMPF service work

Putting machine into service The machine is put into service by the TRUMPF Service Depart-
ment. This comprises installing the machine components accord-
ing to the installation plan, connecting the system to the supply
circuit (except for electrics) as well as giving initial instructions to
personnel and checking the machine's functioning.

6.2 Unprocessed material station

To achieve perfect peeling and loading of the unprocessed

sheets, every sheet must touch the stops at a defined position or
be stored on the pallets.
Fastening or positional tolerance: 0+15 mm.
The lower edge of the sheet metal stack must be at least 120
mm above the ground. The customer must therefore either pro-
vide an appropriate platform or use an unprocessed material sta-
tion from TRUMF (optional).

2-18 Installation - Version 8 B484EN

 Chapter 3

Description

1 Concept 3-3
1.1 Function of LiftMaster (R) and LiftMaster Sort 3-7
1.2 Function of LiftMaster (P) 3-11
1.3 Function of LiftMaster (RP) 3-13

2 Technical data 3-15

2.1 LiftMaster/LiftMaster Sort --1530 3-15
2.2 LiftMaster/LiftMaster Sort --2040 3-16
2.3 LiftMaster --1225/--2540 3-17

3 Modules 3-18
3.1 Suction cups 3-20
LiftMaster suction cup arrangement 3-20
Suction cup arrangement of LiftMaster 3-23
Sort
Sheet formats 3-26
Peeler cup 3-27
Separating thin sheets (optional) 3-28

B484EN 2011-08-22 Description 3-1

 3.2 Double sheet measurement 3-29
Sheet thickness measuring device 3-29
Double sheet detector 3-30
3.3 Rotoscanner 3-31
3.4 Sheet alignment 3-31

4 Pallets 3-33
4.1 Pallet names 3-33
4.2 Auxiliary pallets 3-34

5 Lifting force monitoring 3-35

3-2 Description 2011-08-22 B484EN

 1. Concept

The LiftMaster is an automatic loading and unloading system for

flat bed laser machines. The Sort extension (optional) can also
deposit cut large parts and scrap skeletons separately. The inte-
gration of a SortMaster (small part removal and sorting unit,
optional) completes this automation system. Then, the LiftMaster
can be connected to a storage system.

The following versions are possible:

■ • LiftMaster (R): LiftMaster with unloading rake (all LiftMas-
ters).
■ • LiftMaster (P): LiftMaster with auxiliary pallet for loading
and unloading (only LiftMaster --1530 and --2040).
■ • LiftMaster (RP): LiftMaster with unloading rake and auxili-
ary pallet for loading and unloading (only LiftMaster --1530
and --2040).
■ • LiftMaster Sort (R)/(RP): LiftMaster Sort with unloading
rake and auxiliary pallet (only LiftMaster Sort --1530 and
--2040).

B484EN 2011-08-22 Concept 3-3

1 LiftMaster Sort 4 Shelf storage system 7 Pallet changer, laser machine
2 Unloading platform (here for 5 Laser machine 8 Storage pallets for SortMaster
scrap skeleton) 6 Storage container for SortMaster parts
3 Unloading cart (here for maxi parts 9 SortMaster
parts)
Overview example of laser machine with LiftMaster Sort (and SortMaster) and shelf storage Fig. 33873
system

3-4 Concept 2011-08-22 B484EN

1 LiftMaster 3 Deflection mirror for light barrier 5 Deflection mirror for light barrier
2 Start pedestal with EMER- 4 Pulse trigger switch
GENCY STOP impact button
TruLaser 7025 with LiftMaster 1225 Fig. 49092

B484EN 2011-08-22 Concept 3-5

1 TruLaser 7040 4 Laser machine control panel 6 Pallet changer
2 Unloading cart 5 Light barrier 7 LiftMaster lifting stand
3 LiftMaster swivel arm
TruLaser 7040 with LiftMaster 2540 Fig. 53443

3-6 Concept 2011-08-22 B484EN

 Description of the LiftMaster variants:

Unloading rake (R) Unloading rake (R) Auxiliary pallet (P) Unloading rake
and shelf storage and auxiliary pallet
system (RP)
Loading process Swivel mechanism, Swivel mechanism, Swivel mechanism; Swivel mechanism,
unloading rake and unloading rake and suction cylinder and suction cylinders,
suction cylinders as suction cylinders as auxiliary pallet as auxiliary pallet and
means of transporta- means of transporta- means of transporta- unloading rake as
tion. tion. tion. means of transporta-
tion.
Transportation of Transportation of Transportation of
workpiece sheets workpiece sheets workpiece sheets Transportation of
from unprocessed from unprocessed and auxiliary pallets workpiece sheets
material stack to material stack to to the pallet either directly from
pallet changer. pallet changer. changer. the unprocessed
material stack or via
auxiliary pallets to
the pallet changer.
Unloading process Swivel mechanism, Swivel mechanism, Swivel mechanism, Swivel mechanism,
unloading rake and unloading rake and suction cylinder and suction cylinders,
suction cylinders as suction cylinders as auxiliary pallet as unloading rake or
means of transporta- means of transporta- means of transporta- auxiliary pallet as
tion. tion. tion. means of transporta-
tion.
LiftMaster: return of LiftMaster: return of LiftMaster: return of
the finished parts the finished parts finished parts and LiftMaster: return of
and scrap skeletons and scrap skeleton scrap skeletons with the finished parts
with the unloading with the unloading the auxiliary pallet and scrap skeleton
rake. rake from the pallet from the pallet either individually
changer to the changer to the (with auxiliary pallet)
LiftMaster Sort:
unloading cart or fin- unloading cart. or in batches to the
return of finished
ished parts stack. shelf storage sys-
parts with the pro-
tem.
grammable suction LiftMaster Sort:
cylinders; return of return of finished LiftMaster Sort:
scrap skeletons with parts with the pro- return of finished
the unloading rake. grammable suction parts and scrap
cylinders; return of skeletons either indi-
scrap skeletons with vidually (with auxili-
the unloading rake ary pallet) or in
from the pallet batches (with the
changer to the programmable suc-
unloading cart or fin- tion cylinders) into
ished parts stack. the shelf storage
system.
Automation - Automatic connection to a storage system. Expansion of the
capacity of the pallet changer by the addition of storage compart-
ments of a shelf storage system.
Tab. 3-1

1.1 Function of LiftMaster (R) and

LiftMaster Sort

The LiftMaster enables the automatic loading of the laser

machine's pallet changer with workpiece sheets of different sizes
and the removal of the cut parts and of the scrap skeleton. A
swivel arm that holds a suction frame with suction cups transfers

B484EN 2011-08-22 Function of LiftMaster (R) and LiftMaster Sort 3-7

 the workpiece sheets from the unprocessed material station to
the laser machine's pallet changer. The unloading rake is used
to convey finished parts and scrap skeletons from the pallet
changer to the finished parts station (unloading platform or
unloading cart).

Loading and unloading cycle ■ The loading cycle is only carried out when an empty pallet
from the pallet changer is in the changing position.
■ The unloading cycle is only carried out if a pallet is at the
tool change height at which a machined workpiece sheet is
lying.
■ The cycles are enabled from the control system of the
machine.
■ For safety reasons, the swivel arm only swings into the
upper end position.
■ The LiftMaster's suction frame is only lifted and lowered in
the following positions:
− Above the loading station.
− Above the pallet changer.
− Above the unloading station (finished parts and scrap
skeleton).
■ The LiftMaster Sort's suction frame is only lifted and low-
ered in the following positions:
− Above the loading station.
− Above the pallet changer.
− Above the unloading station for finished parts.
− Above the unloading station for scrap skeletons.

Loading cycle ■ The suction cylinders and the armature probe for detecting
the interference contour (stops of the loading station) move
down.
■ The suction frame with the suction cylinders is lowered to the
sheet and the ejectors for generating the vacuum are
switched on.
■ The sheets are raised by the retraction of the suction cylin-
ders, peeled, if necessary and checked (if the peeling func-
tion and the separation of thin sheet and double sheet gauge
were activated).
■ The rake closes.
■ The suction frame moves to the upper end position.
■ During the stroke, the separated sheet is placed on the rake
prongs and the vacuum is switched off (standard procedure;
the "depositing" function can be deactivated in the application
data).
■ If the "sheet alignment" function is available and activated,
the sheet is aligned parallel to the X axis.
■ The suction frame swivels over the pallet changer.
■ The vacuum is switched on and the sheet is lifted off the
rake prongs with the suction cylinders.

3-8 Function of LiftMaster (R) and LiftMaster Sort 2011-08-22 B484EN

 ■ The suction frame is lowered onto the pallet changer and the
rake is opened at the same time.
■ The suction cylinders are extended.
■ The vacuum on the suction cylinders is switched off.
■ The sheet is blasted off the suction cylinders with air.
■ The swivel arm moves into the upper end position.

Unloading cycle LiftMaster:

■ The swivel arm swivels with open unloading rake over the
pallet changer (swiveling with unloading rake closed can be
programmed).
■ The suction cylinders are raised.
■ Armature probe R is extended.
■ The swivel arm is lowered until the loading area of the
unloading rake is under the sheet on the pallet:

1 Unloading rake 3 Pallet of the pallet changer

2 Sheet
Swivel arm descends Fig. 32248

■ The armature probe (R) indicates "bottom" and the rake

closes.

1 Unloading rake 3 Pallett of the pallet changer

2 Sheet
The swivel arm closes Fig. 32249

LiftMaster Sort:
■ The programmable suction cylinders are extended and grasp
the finished parts:

B484EN 2011-08-22 Function of LiftMaster (R) and LiftMaster Sort 3-9

 1 Unloading rake 3 Pallett of the pallet changer
2 Sheet 4 Suction cylinder
Suction of finished parts (sort function) Fig. 33872

■ A test is done with activated pallet monitoring with the help

of the diagonal light barriers, to see if the finished parts and
the waste grid are separated from the support bars. If no
separation is signaled, the cycle will be interrupted with an
error message to this effect.
■ The swivel arm rises and swings in the direction of the
unloading station.
■ The suction frame is lowered over the unloading station to
the depositing position approx. 30 mm above the support
area:

1 Unloading rake 3 Finished part stack

2 Processed sheet 4 Unloading station
The suction frame is lowered above the unloading station. Fig. 32250

LiftMaster :
■ The unloading rake opens. The cut sheet is set down.
■ The swivel arm moves up with the unloading rake open. The
unloading cycle is finished.

LiftMaster Sort:
■ The suction cylinders are raised with the finished parts
attached.
■ The unloading rake opens. The scrap skeleton is deposited.
■ The swivel arm is raised slightly.
■ The rotoscanner is used to check if the finished parts were
separated from the scrap skeleton.
− If that was the case, the cycle is continued.
− If not, the finished parts are deposited on the scrap skel-
eton stack with the scrap skeleton or at a programmed
alternative position.

3-10 Function of LiftMaster (R) and LiftMaster Sort 2011-08-22 B484EN

 ■ The unloading rake closes.
■ The swivel arm moves up and swivels over the finished parts
stack.
■ The unloading rake is opened and lowered.
■ The suction cylinders are extended and the vacuum is
switched off.
■ All parts held on the suction cylinders are dropped and
deposited by blasting with air.
■ The swivel arm ascends with the rake open. The unloading
cycle is ended.

1.2 Function of LiftMaster (P)

The LiftMaster (P) (P = Pallet operation) allows empty and loa-

ded auxiliary pallets to be transferred between the pallet changer
and a compact or universal storage system.
The suction frame of the LiftMaster (P) is equipped with 4 pneu-
matically swiveling hooks that engage when activated in appro-
priate recesses on the long sides of the auxiliary pallet. The aux-
iliary pallet is thus held in place in the suction frame.
Since the sheet lies on an auxiliary pallet without being displaced
during the complete machining process, the sheet remains free
of scratches.

Loading cycle Prerequisite:

■ There are no auxiliary pallets in the pallet changer.
■ There is an auxiliary pallet on the unloading cart.

Sequence:
■ The suction frame is lowered with extended armature probe
P above the auxiliary pallet.
■ Armature probe P sits on the pallet frame.
■ The four hooks on the suction frame grasp the auxiliary pal-
let and close.
■ The swivel arm moves into the upper end position and swiv-
els over the pallet changer.
■ The swivel arm is lowered and the auxiliary pallet is set
down on the pallet changer.
■ The hooks open.
■ The swivel arm moves into the upper end position and waits
for the sheet to be processed in the machine.

Unloading cycle Prerequisite:

■ There is either an auxiliary pallet with a processed workpiece
sheet in the pallet changer or an empty auxiliary pallet.

B484EN 2011-08-22 Function of LiftMaster (P) 3-11

 Sequence:
■ The swivel arm swivels over the pallet changer.
■ Armature probe P is extended.
■ The suction frame descends.
■ The four hooks on the suction frame grasp the auxiliary pal-
let and close with the processed sheet.
■ The swivel arm moves into the upper end position and swiv-
els over the unloading cart.
■ The swivel arm is lowered and the auxiliary pallet is set
down on the pallet changer.
■ The hooks open.
■ The swivel arm moves back into the upper end position.
■ The unloading cart moves to the transfer position in the shelf
storage system.
■ The auxiliary pallet with the machined sheet is transferred to
the shelf servicing device and deposited in a programmed
shelf compartment.

3-12 Function of LiftMaster (P) 2011-08-22 B484EN

 1.3 Function of LiftMaster (RP)

1 Laser machine 6 LiftMaster 10 Control panel for shelf servicing

2 Safety light barrier 7 Loading cart device
3 Pallet changer 8 Unloading cart 11 Storage system
4 Unloading platform (optional) 9 Storage control system 12 Safety barrier
5 Unloading process to unloading 13 Transport cart
cart or unloading platform
Example of LiftMaster (RP) with universal storage system Fig. 16439

The LiftMaster (RP) (R=rake operation, P=pallet operation) ena-

bles the fully automatic production of sheets of different sizes.
This includes the collection of unprocessed sheets from the stor-
age shelf as well as the depositing of finished parts into the stor-
age shelf.

B484EN 2011-08-22 Function of LiftMaster (RP) 3-13

 The LiftMaster (RP) has all functions of LiftMaster (R) and of Lift-
Master (P). There are the following options:
■ A stack of raw sheets can be provided from the shelf storage
system and one sheet conveyed to the machine.
■ A processed sheet which is lying on an auxiliary pallet can
be deposited individually in a shelf compartment.
■ A number of workpieces can be stacked onto a pallet individ-
ually using the rake; the pallet with the stack can then be
transported back to the shelf compartment.

3-14 Function of LiftMaster (RP) 2011-08-22 B484EN

 2. Technical data

2.1 LiftMaster/LiftMaster Sort --1530

LiftMaster LiftMaster Sort

Loading workpiece Maximum weight [kg] 900 900
Minimum size [mm] 2000 x 1000 2000 x 1000
Maximum size [mm] 3000 x 1500 3000 x 1500
Maximum sheet thickness [mm] 25 25
Maximum height of pile [mm] 200 200
Unloading workpiece Maximum weight (with pallet) [kg] 900 900
Minimum size with rake [mm] 150 x 150 150 x 150
Maximum size with rake [mm] 3000 x 1500 3000 x 1500
Maximum sheet thickness (with rake) [mm] 25 25
Maximum sheet thickness (with pallet) [mm] 25 25
Maximum sheet thickness (with suction - 6
cups) [mm]
Minimum size with 24 suction cups [mm] - 600 x 1000
Maximum size with 36 suction cups - 600 x 600
(optional) [mm]
Vertical working Pallet changer transfer height [mm] 840 840
range
Vertical stroke [mm] 1180 1180
Accuracy Positioning accuracy of raw sheet [mm/mm 20/3000 5/3000
sheet length]
Weight Weight [kg] Approx.3900 Approx.3900
Electrical connec- Lifter drive [kW] 3.0 3.0
tions
Swivel drive [kW] 0.37 0.37
Drive, unloading rake [kW] 0.75 0.75
Control voltage [V] 24 24
Compressed air Network pressure [bar] 7-14 7-14
Average air consumption [Nm³/h] 13.5 22
Suction cups Number of suction cups including peeler 18 24 (standard):
cups
23x160 mm,
1x210 mm
36 (optional):
17x160 mm,
1x210 mm,
18x80 mm
Load-bearing capacity [N] 1230 210 mm: 1230
160 mm: 600
80 mm: 270
Loading cart Maximum load-bearing capacity [kg] 3000 3000
(optional)
Stack height [mm] 200 200
Technical data LiftMaster Sort --1530 Tab. 3-2

B484EN 2011-08-22 Technical data 3-15

 2.2 LiftMaster/LiftMaster Sort --2040

LiftMaster LiftMaster Sort

Loading workpiece Maximum weight [kg] 1600 1600
Minimum size [mm] 2000 x 1000 2000 x 1000
Maximum size [mm] 4000 x 2000 4000 x 2000
Maximum sheet thickness [mm] 25 25
Maximum height of pile [mm] 200 200
Unloading workpiece Maximum weight (with pallet) [kg] 1260 1260
Minimum size with rake [mm] 150 x 150 150 x 150
Maximum size with rake [mm] 4000 x 2000 4000 x 2000
Maximum sheet thickness (with rake) [mm] 20 20
Maximum sheet thickness (with pallet) [mm] 25 (for 3000x1500 25 (for 3000x1500
mm) mm)
20 (for 4000x2000 20 (for 4000x2000
mm) mm)
Maximum sheet thickness (with suction - 6
cups) [mm]
Minimum size with 36 suction cups [mm - 600 x 1000
Maximum size with 51 suction cups - 600 x 600
(optional) [mm]
Vertical working Pallet changer transfer height [mm] 840 840
range
Vertical stroke [mm] 1100 1100
Accuracy Positioning accuracy of raw sheet [mm/mm 20/4000 5/4000
sheet length]
Weight Weight [kg] Approx.6550 Approx.6550
Electrical connec- Lifter drive [kW] 4.0 4.0
tions
Swivel drive [kW] 0.55 0.55
Drive, unloading rake [kW] 0.75 0.75
Control voltage [V] 24 24
Compressed air Network pressure [bar] 7-14 7-14
Average air consumption [Nm³/h] 20 28
Suction cups Number of suction cups including peeler 27 36 (standard):
cups
3x160 mm, 35x160 mm,
24x210 mm 1x210 mm
51 (optional):
26x160 mm,
1x210 mm,
24x80 mm
Load-bearing capacity [N] 1230 210 mm: 1230
160 mm: 600
80 mm: 270
Loading cart Maximum load-bearing capacity [kg] 5000 5000
(optional)
Maximum load-bearing capacity [kg] 200 200
Technical data LiftMaster Sort --2040 Tab. 3-3

3-16 LiftMaster/LiftMaster Sort --2040 2011-08-22 B484EN

 2.3 LiftMaster --1225/--2540

LiftMaster --1225 LiftMaster --2540

Loading workpiece Maximum weight [kg] 620 1600
Minimum size [mm] 2000 x 1000 2000 x 1000
Maximum size [mm] 2500 x 1250 4000 x 2500
Maximum sheet thickness [mm] 25 20
Maximum height of pile [mm] 200 200
Unloading workpiece Minimum size with rake [mm] 150 x 150 150 x 150
Maximum size with rake [mm] 2500 x 1250 4000 x 2500
Maximum sheet thickness (with rake) [mm] 25 10
Vertical working Pallet changer transfer height [mm] 925 925
range
Vertical stroke [mm] 1180 1100
Accuracy Positioning accuracy of raw sheet [mm/mm 20/2500 5/4000
sheet length]
Weight Weight [kg] Approx.3700 Approx.6350
Electrical connec- Lifter drive [kW] 3.0 4.0
tions
Swivel drive [kW] 0.37 0.55
Drive, unloading rake [kW] 0.75 0.75
Control voltage [V] 24 24
Compressed air Network pressure [bar] 7-14 7-14
Average air consumption [Nm³/h] 13.5 22
Suction cups Number of suction cups including peeler 12 32
cups
210 mm 210 mm
Load-bearing capacity [N] 1230 1230
Loading cart Maximum load-bearing capacity [kg] - 5000
(optional)
Stack height [mm] - 200
Technical data LiftMaster Sort --1225/--2540 Tab. 3-4

B484EN 2011-08-22 LiftMaster --1225/--2540 3-17

 3. Modules

1 Suction frame 10 Plug B+29-X4 18 Connecting rod or synchronizing

2 Swivel drive 11 Compressed air supply device
3 Swivel arm 12 Plug B+1-X2 19 Unloading rake
4 Index 13 Plug B+1-X1 20 Peeler cup
5 Lift drive 14 Suction cylinder 21 Sheet thickness gauge
6 Elevating part 15 Hook (pallet gripper), not for 22 Sheet alignment (optional for
LiftMaster 1225 / 2540 LiftMaster Sort and LiftMaster
7 Plug B+30-A2
2540)
8 Pedestal 16 Rake guides
23 Rotoscanner (LiftMaster Sort
9 Switch cabinet 17 Rake drive
and LiftMaster 2540)
24 Lifting force monitoring (LiftMas-
ter 2040 with pallet operation)
25 Rotoscanner (LiftMaster Sort
and LiftMaster 2540)
LiftMaster/LiftMaster Sort modules Fig. 33871

3-18 Modules 2011-08-22 B484EN

 Item no.4 Designation Function
1 Suction frame Module on which the suction cylinders are fastened for loading
and unloading.
2 Swivel drive Gear motor for swivel movement drive.
3 Swivel arm Enables the horizontal movement of the complete suction frame
between unprocessed sheet stack, pallet changer and unload-
ing position (unloading platform, unloading cart, storage cart).
4 Index Enables the exact positioning of the suction frame in each swiv-
eling position.
5 Lift drive Drive for the vertical movement of the elevating part via a bevel
gear motor with roller chain.
6 Elevating part Enables the vertical movement of the swivel arm with suction
frame and rake.
7 Plug B+30-A2 Profibus interface.
8 Pedestal Brace and support for the LiftMaster as well as mounting for
the guides and for the lifting component drive.
9 Switch cabinet Electrical supply and control of the LiftMaster.
10 Plug B+29-X4 Control panel interface.
11 Switch cabinet Connection point for the compressed air line, from the laser
machine as standard.
12 Plug B+1-X2 Control voltage 24 V DC.
13 Plug B+1-X1 Power supply.
14 Suction cylinder Vacuum suction plates that are each fastened to a pneumatic
cylinder. They are for transferring the unprocessed sheets.
They are activated according to the sheet format.
15 Hook (pallet gripper) Only on LiftMaster (P) and (RP): Auxiliary pallet transport.
16 Rake guides Enable the opening and closing movements of the rake.
17 Rake drive Opening and closing of the rake via a gear motor with roller
chain.
18 Connecting rod or synchroniz- Ensures that the movement of the suction frame is parallel over
ing device the whole swiveling range.
19 Unloading rake Only on LiftMaster (R) and (RP): Takes finished parts and
waste grid from the pallet changer and transports them to the
unloading position.
20 Peeler cup Specially designed suction cup that enables the separation of
sheets that belong together.
21 Sheet thickness measuring Checking device to detect sheet doubling when loading.
device
22 Sheet alignment Only LiftMaster Sort and LiftMaster --2540: alignment of the
sheet parallel to the X axis and compensation of sheet twisting
(max. sheet thickness: 10 mm)
23 Rotoscanner Only LiftMaster Sort and LiftMaster --2540: checks if finished
parts were separated completely from the scrap skeleton.
24 Lift power monitoring Only for LiftMaster TruLaser 2040 (P) and (RP): prevents any
overload on lifting chain and lift drive.
25 Singling thin sheets Separates raw materials that are difficult to separate, such as
film-coated or oily sheets with a thickness of up to 2 mm.
Description Tab. 3-5

4 See Fig.33871, previous page.

B484EN 2011-08-22 Modules 3-19

 3.1 Suction cups

LiftMaster suction cup arrangement

Suction cup arrangement of LiftMaster --1530 Fig. 31992

3-20 Suction cups 2011-08-22 B484EN

Suction cup arrangement of LiftMaster --2040 Fig. 38398

Suction cup arrangement of LiftMaster --1225 Fig. 48973

B484EN 2011-08-22 Suction cups 3-21

Suction cup arrangement of LiftMaster --2540 Fig. 48974

3-22 Suction cups 2011-08-22 B484EN

 Suction cup arrangement of LiftMaster Sort

Suction cup arrangement of LiftMaster Sort --1530 with 24 suction cups (standard) Fig. 34619

B484EN 2011-08-22 Suction cups 3-23

Suction cup arrangement of LiftMaster Sort --1530 with 36 suction cups (optional) Fig. 34620

3-24 Suction cups 2011-08-22 B484EN

Suction cup arrangement of LiftMaster Sort --2040 with 36 suction cups (standard) Fig. 38400

B484EN 2011-08-22 Suction cups 3-25

Suction cup arrangement of LiftMaster Sort --2040 with 51 suction cups (optional) Fig. 38399

Sheet formats

The appropriate suction cup groups must be activated according

to the sheet format to be transferred.

LiftMaster --1530 LiftMaster --2040 LiftMaster --1225 LiftMaster --2540

Small format 2000x1000 mm 2000x1000 mm 2000x1000 mm 2000x1000 mm
Small format - 1000x2000 mm - 1000x2000 mm
Medium format 2500x1250 mm 2500x1250 mm 2500x1250 mm 2500x1250 mm
Medium format, - - - 1250x2500 mm
transverse
Large format 3000x1500 mm 3000x1500 mm - 3000x1500 mm
Maxi format - 4000x2000 mm - 4000x2000 mm
XXF - - - 4000x2500 mm
LiftMaster/LiftMaster Sort sheet formats Tab. 3-6

3-26 Suction cups 2011-08-22 B484EN

 Sheet formats that deviate from the standard can also be loaded
using individually programmable suction cylinders.

Peeler cup

The peeler cup is used to separate sheets that have stuck

together when sheets are lifted from the sheet stack. The peeler
cup can be used for sheets with a thickness of up to 6 mm.
The peeler cup has a special stripping insert:

1 Pneumatic cylinder for lifting 3 Stripping insert

2 Plate with suction cups
Peeler cup Fig. 53703

By repeated vertical movements of the peeler suction cup, the

corner of the top sheet will be lifted. Air will then get between
the lifted corner and the stack of sheets. The top sheet will be
separated. The number of peeling cycles can be selected via the
control system.

B484EN 2011-08-22 Suction cups 3-27

 Separating thin sheets (optional)

This option is used for unprocessed materials that are difficult to

separate, e.g. foil-coated or oiled sheets with up to 2 mm sheet
thickness.

The option includes two components:

■ Blower device.
■ Peeling device from a bellows-suction grip installed on the
peeler cup.

Operating principle If a vacuum is generated, the bellows-suction grip raises the out-
ermost sheet corner. Each time it is raised during the peeling
procedure, air is blown into the gap that is created between the
sheets that are sticking together.

1 Solenoid valve 3 Air outlet from nozzle 5 Peeling device

2 Pressure accumulator 4 Bellows-suction cup gripper
Singling thin sheets Fig. 46597

3-28 Suction cups 2011-08-22 B484EN

 3.2 Double sheet measurement

Sheet thickness measuring device

Note
The sheet thickness gauge is fitted on all LiftMasters and Lift-
Masters Sort --1530.

The sheet thickness gauge records the thickness of the raised

sheet using an armature probe. This prevents simultaneous lifting
of two or more sheets.
Measuring range: Sheet thicknesses between 0.4 mm and 32
mm.

A Armature probe at home posi- 1 Pneumatic cylinder for Z move- 3 Pneumatic cylinder for lifting /
tion ment swivel movement of the arma-
B Armature probe in measurement 2 Measurement system ture probe
position 4 Armature probe
Sheet thickness gauge Fig. 53705

The sheet thickness gauge is lowered on the sheet using the

pneumatic cylinder. The level of the armature probe is then
below the lower edge of the sheet.

B484EN 2011-08-22 Double sheet measurement 3-29

 The inductive path sensor determines an analog value by swing-
ing in and raising the armature probe till the lower edge of the
sheet. This value is evaluated in the control system.
Subsequently, the armature probe is swiveled back to the home
position and the sheet thickness gauge is brought to the top ini-
tial position.

Double sheet detector

The double sheet detector uses an armature probe to identify the

thickness of a raised sheet. This prevents the simultaneous lifting
of two or more sheets.
Measuring range: Sheet thicknesses between 0.8 mm and 25
mm.

A Armature probe in home posi- B Armature probe in home posi- 1 Armature probe
tion (view from the outside) tion (view from below)
Double sheet detector Fig. 53702

The armature probe swivels from the home position to under the
sheet. The distance between these two measuring points at the
tip of the armature probe is measured in analog form via a
potentiometer. A measuring transducer converts the analog sig-
nals into digital signals, which are evaluated at the laser
machine's control.

3-30 Double sheet measurement 2011-08-22 B484EN

 Then, the armature probe swivels back to the home position.
This movement is performed via toothed belt and swivel cylinder.

3.3 Rotoscanner

The rotoscanner is installed on all LiftMaster Sort devices and on

LiftMaster --2540.

LiftMaster Sort When unloading over the unloading position, it checks if all fin-
ished parts are completely separated from the waste grid.

LiftMaster 2540 Checks during the loading cycle whether the raw material sheet
is sagging before the unloading rake closes.

Function

1 Rotoscanner
Fig. 53042

The rotoscanner uses a rotating mirror over a full circle of 360°

to emit pulsed laser beams. The light pulses are reflected in dif-
fused form by the surrounding objects and are received by a
photo diode in the sensor. As soon as an object is detected in
the monitored range, a signal is emitted and the scrap skeleton
with the finished part is deposited at the alternative position.

3.4 Sheet alignment

The sheet alignment option is available to all LiftMaster Sort

devices and to the LiftMaster --2540.
While the sheet is being transferred to the pallet changer a raw
sheet (with a max. sheet thickness of 10 mm) is aligned parallel

B484EN 2011-08-22 Rotoscanner 3-31

 to the X axis. That ensures that the position of the finished parts
corresponds to the programmed suction cylinders.

1 Draw suction cup 2 Lifting cylinder

Sheet alignment option Fig. 33874

Function ■ The draw suction cup descends.

■ The vacuum is activated.
■ The sheet is pulled in the direction of the strippers.
■ The vacuum is switched off.
■ The draw suction cups rise.
■ If the strippers are not reached, the procedure is repeated.

3-32 Sheet alignment 2011-08-22 B484EN

 4. Pallets

In an automated system with LiftMaster there are up to 3 differ-

ent types of pallets:
■ Machine pallets:
The basic equipment of the flatbed laser machines includes
an automatic pallet changer that generally contains 2
machine pallets.
■ System pallets:
In a plant with automated connection to storage raw sheets
must be transferred out of the storage system and finished
parts transferred back into the storage system. System pal-
lets are required for this, which are suitable for depositing
and moving within the storage system.
■ Auxiliary pallets (not with LiftMaster TruLaser 1225 and
2540): the LiftMaster (P) and LiftMaster (RP) variants require
additional auxiliary pallets.

4.1 Pallet names

Machine pallets The two machine pallets of the pallet changer are labeled A and
B.

System pallets Various system pallets can be selected on the "LiftMaster"

screen under "stock Type":

Designation Description
SP System pallet for transporting unprocessed sheets.
SPm System pallet with base for transferring machined
sheets.
SPh System pallet for transferring auxiliary pallets for hook
operation.
Spr System pallet for transferring auxiliary pallets for rake
operation.
System pallets (see chapter 4) Tab. 3-7

B484EN 2011-08-22 Pallets 3-33

 4.2 Auxiliary pallets

There are two different auxiliary pallets:

■ MPR pallets for rake operation of LiftMaster (RP) with con-
nection to storage. This pallet may only be moved with the
LiftMaster if it is empty.
■ MPH pallet for hook operation of LiftMaster (P) and (RP).
This pallet may be moved with a sheet mounted. Unloading
with the rake is not possible with this pallet.
■ Pallet for pallet operation with LiftMaster (P) and (RP) --2040.
The loading of carrier slats onto the pallet must be selected
according to the sheet properties:

Sheet format 1000 x 2000 1250 x 2500 1500 x 3000 2000 x 4000
Max. sheet thickness with 120 25 mm 25 mm 25 mm 15 mm
carrier strips
Max. loading auxiliary pallet (120 720 kg 720 kg 720 kg 720 kg
carrier strips)
Max. sheet thickness with 60 car- 25 mm 25 mm 25 mm 20 mm
rier strips
Max. loading auxiliary pallet (60 480 kg 480 kg 480 kg 480 kg
carrier strips)
Tab. 3-8

■ Other sheet formats can be calculated as follows:

− Weight (auxiliary pallet + sheet to be transferred) ≤17.5
kN.
− – max. sheet thickness 25 mm.

3-34 Auxiliary pallets 2011-08-22 B484EN

 5. Lifting force monitoring

The lifting force monitoring unit is installed on all LiftMasters (P)

and (RP) --2040.

Function The raised load is checked by a pressure sensor that is fitted

between lifting chain and elevating part.

1 Pressure sensor
Lift power monitoring Fig. 38397

If the permissible value is exceeded, the load is set down and

an error message is displayed. Rating aid for permissible loads
(see "Tab. 3-8", pg. 3-34).

B484EN 2011-08-22 Lifting force monitoring 3-35

3-36 Lifting force monitoring 2011-08-22 B484EN
 Chapter 4

Operation of LiftMaster,
LiftMaster Sort --1530/--2040

1 Operating elements 4-3

1.1 Control elements on the complete system 4-3
1.2 Control panel on the LiftMaster's start pedes- 4-5
tal

2 Operating modes 4-11

3 User interface in machines with MMC200X 4-12

control system
3.1 Structure of the user interface 4-12
3.2 Switching TruTops FMC panel on and off 4-16
3.3 User interface: Basic settings 4-16
Calibrate the touchscreen 4-16
Set language, measuring system, date 4-17
and time
Open TRUMPF Operating System (TOS) 4-17
3.4 Production (automatic mode) 4-17

B484EN 2011-08-22Operation of LiftMaster, LiftMaster Sort --1530/--2040 4-1

 3.5 Carrying out technology corrections 4-18
Selecting technology 4-18
Load sheet 4-19
Maxi part separation 4-20
Stack small parts (optional for SortMaster) 4-20
Remove small parts (SortMaster option) 4-21
3.6 Adjusting inventories 4-22
3.7 Manual transporting (semi-automatic cycle) 4-23
3.8 Manual handling (optional) 4-24
3.9 Viewing active store movements 4-25

4 User interface in machines with GritPlus 4-26

control system
4.1 Structure of the user interface 4-26
4.2 Working in semiautomatic cycle 4-28
Loading 4-28
Selecting sheet format 4-29
Unloading 4-30
4.3 Working in automatic mode 4-31
Opening a production plan 4-31
Create sheet job 4-32
Create production plan 4-34
Change sheet job 4-34
Delete sheet job 4-34
Set status 4-34
Prepare and start production 4-35

4-2 Operation of LiftMaster, LiftMaster Sort --1530/--20402011-08-22 B484EN

 1. Operating elements

1.1 Control elements on the complete

system

1 Main switch 3 Control of laser machine with 5 Storage control system

2 Pulse trigger switch EMERGENCY STOP impact 6 Control panel for shelf storage
button system
4 LiftMaster start pedestal with
EMERGENCY STOP impact
button
Example: LiftMaster with shelf storage system (optional) Fig. 32121

B484EN 2011-08-22 Operating elements 4-3

 Controls Prerequisite Description
None Switches the machine's power supply on or off.

MAIN SWITCH
None Impact button.
Interrupts the power supply of the entire system.

Impact button EMERGENCY STOP

The impact button acts on the following compo-
nents:
■ Laser machine.
■ Laser unit (laser beam is switched off).
■ Pallet changer.
■ Automation component.

The impact button is not effective for the following

components:
■ Suction cups. The existing vacuum is maintained
to prevent attached sheets from being released.
■ 24 V control voltage.
Light barrier was Activate interrupted light barrier.
interrupted

FOOT SWITCH on the start pedes-

tal
Control elements on the complete system Tab. 4-1

4-4 Control elements on the complete system 2011-08-22 B484EN

 1.2 Control panel on the LiftMaster's start
pedestal

1 EMERGENCY STOP impact 9 Illuminated pushbutton RAISE 16 Illuminated pushbutton

button SWIVEL ARM UNLOADING RAKE OPEN/
2 Indicator lamp light barrier inter- 10 Illuminated pushbutton LOWER CLOSED
rupted SWIVEL ARM 17 Illuminated pushbutton
3 Illuminated pushbutton SWIVEL 11 Illuminated pushbutton VACUUM ACKNOWLEDGE THAT PAL-
ARM TO THE RIGHT ON/OFF LET CHANGER LOADED
4 Illuminated pushbutton SWIVEL 12 Illuminated pushbutton RAISE/ 18 Button RESET LIFTMASTER
ARM TO THE LEFT LOWER SUCTION CUPS 19 Illuminated pushbutton DOUBLE
5 Illuminated lock buttonCART 13 Illuminated pushbutton ARMA- SHEET GAUGE
SELECTION TOP/BOTTOM TURE PROBE P 20 LiftMaster status indicator lamp
6 Illuminated lock buttonSELEC- 14 Illuminated pushbutton OPEN/ 21 FEED HOLD illuminated key/
TION OF LOADING/UNLOAD- CLOSE HOOK lock button
ING CART 15 ARMATURE PROBE R illumina- 22 START illuminated key
7 Illuminated pushbuttonLOAD- ted key
ING/UNLOADING CART
TOWARDS THE MACHINE
8 Illuminated pushbuttonLOAD-
ING/UNLOADING CART AWAY
FROM THE MACHINE
LiftMaster / LiftMaster Sort control panel button assignment Fig. 24905

B484EN 2011-08-22 Control panel on the LiftMaster's start pedestal 4-5

Operating element Prerequisite Description
1 None Impact button.
Impact button EMERGENCY Interrupts the power supply of the entire system.
STOP

The impact button acts on the following compo-

nents:
■ Laser machine.
■ Laser unit (laser beam is switched off).
■ Pallet changer.
■ LiftMaster.

The impact button is not effective for the following

components:
■ Suction cups. Existing vacuum is maintained so
that a suction sheet is not released.
■ 24 V control voltage.
2 ■ Light barrier has been Indicator lamp:
interrupted.
Light barrier interrupted Flashes when the safety light barrier which shields
■ The movements of the the pallet changer and LiftMaster is interrupted.
pallet changer and Lift-
Master have been stop- The light barrier is reactivated by pressing the foot
ped. switch.
Continue loading or changing procedures: Press
button 17 or 22.
3 ■ No automatic cycle Illuminated key:
active.
SWIVEL ARM TO THE When the button is pressed, the swivel arm swings
RIGHT
■ No semi-automatic cycle until the position is reached.
has been selected.
Lights up when the final position is reached.
■ Swivel arm up.
■ No EMERGENCY STOP. Flashes as long as the swivel arm is in the inter-
mediate position.
■ No FEED HOLD.
4 ■ No automatic cycle Illuminated key:
active.
SWIVEL ARM TO THE When the button is pressed, the swivel arm swings
LEFT
■ No semi-automatic cycle until the position is reached.
has been selected.
Lights up when the final position is reached.
■ Swivel arm up.
■ No EMERGENCY STOP. Flashes as long as the swivel arm is in the inter-
mediate position.
■ No FEED HOLD.
5 None Illuminated key, lock button:
CART SELECTION TOP/ Button lights up (button pressed): the lower loading/
BOTTOM unloading cart is active and can be moved using
buttons 7 and 8.
Button does not light up (button not pressed): the
upper loading/unloading cart is active and can be
moved using buttons 7 and 8.
6 None Illuminated key, lock button:
SELECTION OF LOADING/ Button lights up (button pressed): the loading cart
UNLOADING CART is active and can be moved using buttons 7 and 8
(optional)
Button does not light up (button not pressed): the
unloading cart is active and can be moved using
buttons 7 and 8

4-6 Control panel on the LiftMaster's start pedestal 2011-08-22 B484EN

Operating element Prerequisite Description
7 ■ No automatic cycle Illuminated key:
active.
LOADING/UNLOADING The "Cart in machine" position is established by
CART TOWARDS THE
■ No semi-automatic cycle pressing the button.
MACHINE has been selected.
Lights up when the position is reached.
■ Swivel arm up.
■ No EMERGENCY STOP. Flashes as long as the cart is in the intermediate
position.
■ No FEED HOLD.

8 ■ No automatic cycle Illuminated key:

active.
LOADING/UNLOADING The "Cart outside machine" position is approached
CART AWAY FROM THE
■ No semi-automatic cycle by pressing the button.
MACHINE has been selected.
Lights up when the position is reached.
■ Swivel arm up.
■ No EMERGENCY STOP. Flashes as long as the cart is in the intermediate
position.
■ No FEED HOLD.

9 ■ No automatic cycle Illuminated key:

active.
LIFT SWIVEL ARM Pressing the button moves the swivel arm into the
■ No semi-automatic cycle upper final position.
has been selected.
Lights up when the position is reached.
■ Swivel arm up.
■ No EMERGENCY STOP. Flashes as long as the swivel arm is in the inter-
mediate position.
■ No FEED HOLD.
■ If vacuum was selected,
the "Vacuum available"
message must be
present.
10 ■ No automatic cycle Illuminated key:
active.
LOWER SWIVEL ARM Pressing the button moves the swivel arm into the
■ No semi-automatic cycle lower end position.
has been selected.
Lights up when the position is reached.
■ Swivel arm in defined
position above removal/ Flashes as long as the swivel arm is in the inter-
deposit position. mediate position.
■ Sensor system for lower
end position (armature
probe P, armature probe
R or suction frame) was
activated.
■ No EMERGENCY STOP.
■ No FEED HOLD.
■ If vacuum was selected,
the "Vacuum available"
message must be
present.

B484EN 2011-08-22 Control panel on the LiftMaster's start pedestal 4-7

Operating element Prerequisite Description
11 ■ No automatic cycle Illuminated key:
active.
VACUUM ON/OFF The first time this is pressed (ON), vacuum is cre-
■ No semi-automatic cycle ated by the ejector on the suction cup.
has been selected.
The next time this is pressed (OFF), the vacuum is
■ With "Vacuum available",
switched off.
the following applies:
− Switching on is The button lights up when vacuum is available.
always possible.
− Switching off is only
possible in the lower
end position.
12 ■ No automatic cycle Illuminated key:
active.
RAISE/LOWER SUCTION Pressing the button will lower the suction cups
CUPS
■ No semi-automatic cycle when they are in the upper position.
has been selected.
Pressing the button will raise the suction cups
■ Swivel arm up.
when they are in the lower position.
■ No EMERGENCY STOP.
Lights up when the suction cups are in the lower
■ No FEED HOLD.
position.
Flashes as long as the suction cups are in the
intermediate position.
13 ■ No automatic cycle Illuminated key:
active.
ARMATURE PROBE P The probe cylinder must be extended for pallet
■ No semi-automatic cycle operation.
has been selected.
Pressing the button will lower the probe cylinder
■ Swivel arm up.
when the armature probe is in the upper position.
■ No EMERGENCY STOP.
Pressing the button will raise the probe cylinder
■ No FEED HOLD.
when the armature probe is in the lower position.
Lights up if the armature probe is on top.
Flashes as long as the armature probe is in the
intermediate position.
14 ■ No automatic cycle Illuminated key:
active.
OPEN/CLOSE HOOK Pressing the button opens the four hooks, if they
■ No semi-automatic cycle were previously closed.
has been selected.
Pressing the button closes the four hooks, if they
■ Swivel arm up.
were previously open.
■ No EMERGENCY STOP.
Lights up if the hooks are open.
■ No FEED HOLD.
Flashes as long as the hooks are in an intermedi-
ate position.
15 ■ No automatic cycle Illuminated key:
active.
ARMATURE PROBE R The probe cylinder must be extended for the rake
■ No semi-automatic cycle operation.
has been selected.
Pressing the button will lower the probe cylinder
■ Swivel arm up.
when the armature probe is in the upper position.
■ No EMERGENCY STOP.
Pressing the button will raise the probe cylinder
■ No FEED HOLD.
when the armature probe is in the lower position.
Lights up if the armature probe is on top.
Flashes as long as the armature probe is in the
intermediate position.

4-8 Control panel on the LiftMaster's start pedestal 2011-08-22 B484EN

Operating element Prerequisite Description
16 ■ No automatic cycle Illuminated key:
active.
OPEN/CLOSE UNLOADING Pressing the button opens the unloading rake, if it
RAKE
■ No semi-automatic cycle was previously closed.
has been selected.
Pressing the button closes the unloading rake, if it
■ No EMERGENCY STOP.
was previously open.
■ No FEED HOLD.
Lights up if the unloading rake is open.
Flashes as long as the unloading rake is in the
intermediate position.
17 Lamp flashes before pallet Illuminated key:
change.
ACKNOWLEDGE THAT If the LiftMaster is deactivated:
PALLET CHANGER LOA-
DED
Pressing the button will resume an interrupted load-
ing or changing operation in the pallet changer, if
the interruption has been previously acknowledged
with the foot switch. Sequence:
■ Light barrier is interrupted.
■ Pallet changer stops.
■ Acknowledge light barrier by pressing the foot
switch.
■ Acknowledge FEED HOLD (button 21 lights up)
with START (button 22).
■ Acknowledge pallet changer with button 17.
If the LiftMaster is activated, button 17 is not effec-
tive since acknowledgement occurs automatically
after the loading operation.
18 None Button:
RESET LiftMaster Compact Pressing this button aborts all active movements
and cycles on the LiftMaster.
An active error message can be deleted by press-
ing the button, once the error has been corrected.

19 ■ No automatic cycle Illuminated key:

active.
DOUBLE SHEET GAUGE Press the button to execute the next possible
■ No semi-automatic cycle movement of the double sheet gauge (lowering,
has been selected. swinging in, swinging out...).
■ No EMERGENCY STOP.
Button lights up when the double sheet gauge is
■ No FEED HOLD. swung out and raised.
20 None Indicator lamp:
Status LiftMaster An active error message on the LiftMaster is indi-
cated by this lamp lighting. The exact error text is
shown on the operating panel of the machine.

B484EN 2011-08-22 Control panel on the LiftMaster's start pedestal 4-9

 Operating element Prerequisite Description
21 None Illuminated key, lock button:
FEED HOLD Pressing the button stops all movements of the pal-
let changer and the LiftMaster. Processing in the
machine continues.
Further movements are not possible while FEED
HOLD is active.
Pressing START deletes an active feed hold.
Button lights up when pressed.
Note:
The FEED HOLD button on the control panel of the
laser machine is effective only for the machine and
the pallet changer, not for the LiftMaster.
22 None Illuminated key:
START Pressing the START button acknowledges feed
hold.
Interrupted movements of the pallet changer and
LiftMaster recommence.
Button flashes when it is released and Feed hold
was not acknowledged.
Note:
No NC program can be started with this button.
Operating elements on the start pedestal of the LiftMaster Tab. 4-2

4-10 Control panel on the LiftMaster's start pedestal 2011-08-22 B484EN

 2. Operating modes

Three operating modes are possible:

■ Manual operation.
■ Semi-automatic cycle.
■ Automatic mode with production plan.
■ Automatic mode with production plan.
■ Single pallet mode.

Manual operation In manual mode all phases of the transport process can be con-
trolled at the LiftMaster's start post (see "Tab. 4-2", pg. 4-10).

Semiautomatic cycle In a semi-automatic cycle, a transport process can be conducted

on the control system of the laser machine.

Automatic mode In automatic mode, the whole loading and unloading procedure
is started using a previously created production plan. The pro-
duction plan is either created by the programming system of the
basic machine (TruTops Laser) or manually on the control sys-
tem interface. Before starting, the defined starting conditions
must always be established.

Single pallet mode In single-pallet operation, only one pallet is used (Pallet A). This
means it is not loading and unloading sheets during productive
time.
Single-pallet operation is recommended when it is necessary to
ensure that parts which are cut free do not fall onto unprocessed
materials lying underneath, which could result in these parts then
causing a collision with the cutting head in the machine. Single-
pallet operation selected and deselected at the control system.

B484EN 2011-08-22 Operating modes 4-11

 3. User interface in machines with
MMC200X control system

3.1 Structure of the user interface

1 TRUMPF logo and login status 3 Status bar 5 Sub-operations

2 Main activities 4 Message line 6 Context buttons
User interface with touch operation Fig. 60848

Status bar Symbol in the Description

status line
The program is running.

Program status: Pause.

The symbol is displayed if the machine is switched off.

There are alarm messages (their quantity is displayed

near the symbol).

4-12 User interface in machines with MMC200X control 2011-08-22 B484EN

system
 Status bar Symbol in the Description
status line
There are warning messages (their quantity is dis-
played near the symbol).

There are information messages (their quantity is

shown next to the symbol).

There is maintenance work.

Status "Manual intervention required": Sheet must be

loaded or unloaded manually, machine control is wait-
ing for acknowledgment.

Status "Manual sorting is ready": Sorting can be done

from the pallet changer or from a platform.

The touchscreen is not active.

The TruTops Message option is active.

There is no connection to the TruTops Message

server (option).

The TruTops Message option is not active.

Tab. 4-3

Note
The status symbols for the production plan are listed in the pro-
duction plan section .
The status symbols for the laser machine are in the laser machi-
nes's operator's manual.

Message line The message line is divided into 4 areas and is used to display
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.

B484EN 2011-08-22 Structure of the user interface 4-13

 TRUMPF logo and login The following information is displayed:
status ■ Logged-on user.
■ Current date.
■ Current time.

By pressing the information displayed, parameters will be dis-

played which can be changed if necessary:
■ Information about the user.
− Language.
− Unit of measurement.
■ Information about the system:
− Date and time.
− Regional settings.

The following actions are possible with the buttons:

■ Exit HMI: closes down the control user interface.
■ Calibrating the touchscreen (see "Calibrate the touchscreen",
pg. 4-16).

4-14 Structure of the user interface 2011-08-22 B484EN

 Main activities

Main activity Functions in the main activity

Production plan:
■ "Production plan" tab:
− Creating and modifying jobs.
− Prepare orders.
− Enabling jobs.
− Starting, interrupting and stopping jobs.
− Deleting jobs with or without the associated program.
− Displaying job details, program details and status of the cell.
− Carry out the technology correction.
■ "Production overview" tab: Having runtimes displayed.
■ "Manual handling" tab (option):
− Work through the production plan with work step carried out man-
ually by the operator. Confirm manual work step.
■ "Stock" tab: create, change or delete stock.
Production:
■ "Program" tab:
− Loading programs.
− Saving programs.
− Deleting programs.
− Correct technology by programs.
■ "Laser machine" tab.
− Having the machine's current job status displayed.
■ "Automation" tab.
− Having the LiftMaster Compact's current job status displayed.
− Transporting manually with the LiftMaster Compact.
− Having active store movements displayed.
Maintenance & commissioning:
See operator's manual for the laser machine.

Diagnosis:
■ Display warnings, alarms and information messages.
■ Sort messages.
■ Open the diagnostics tool.
■ Display software versions.
The Diagnostics button flashes when a new warning or alarm is received.
Help:
■ Search.
■ Index.
■ Bookmark.
Tab. 4-4

List selection On pressing , a list with further options opens.

Sub-operations Each main operation contains one or more sub-operations (tabs).

B484EN 2011-08-22 Structure of the user interface 4-15

 3.2 Switching TruTops FMC panel on and
off

For systems with a separate computer for TruTops FMC, the so-
called TruTops FMC panel, first the machine and then the Tru-
Tops FMC panel must be switched on.
The sequence makes no difference when switching the system
off.

3.3 User interface: Basic settings

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.

Condition
■ Locking the touchscreen may not be pressed.

1. On the user interface, press on the TRUMPF Logo.

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

Calibrate touchscreen: one of the destinations Fig. 38281

4-16 Switching TruTops FMC panel on and off 2011-08-22 B484EN

 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.
5. Press Apply.

Set language, measuring system, date and

time

Adopt changes 1. Press the date on the user interface next to the TRUMPF
logo.
"Settings" is displayed.
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.
Integrated tool management will be shut down and the Win-
dows desktop will be displayed.
5. Restart.
The changes are permanently saved. The user interface is
displayed.

Open TRUMPF Operating System (TOS)

Ø On the user interface, press on the TRUMPF Logo.

− Press "System", Exit HMI.
The user interface is closed. The "TRUMPF Operating
System" (TOS) mask is displayed.

3.4 Production (automatic mode)

The following sequences are described in the operator's manual

for the laser machine in chapter "Operation":
■ Preparing a program.
■ Executing a program automatically

B484EN 2011-08-22 Production (automatic mode) 4-17

 ■ Displaying a program.
■ Stopping a program.
■ Abort the program.
■ Flexible entry in the program.
■ Working with the production plan.
■ Program management.

3.5 Carrying out technology corrections

The technology parameters can be modified, even if a program

has already been started. A modification is saved immediately
and is effective from the next program start.
In addition to the specific technology parameters for the laser
machine, the parameters for loading the sheet can be modified
as well.

Any modification of the technology parameters may result

CAUTION in errors in the manufacturing cell.
Ø Modifications may only be performed after consulting the
programmer.
Ø Modifications should only be made in exceptional cases.

Selecting technology

1. Select Production, "Program", "Storage location" Internal

management, current program, Technology correction.
or
Select Production plan, "Production plan", current program,
Technology correction.
2. Mark the program in which the technology correction is to be
made.
3. Press Technology correction. The "Technology correction:
Select technology" screen is displayed.
4. Select technology that is to be modified:
− "Maxi part separation" (only for Sort extension).
− "Load sheet".
− "Stack small parts" (for SortMaster only).
− "Remove small parts" (for SortMaster only).
5. Press Continue. The corresponding technology is opened
(see the following sections).

4-18 Carrying out technology corrections 2011-08-22 B484EN

 Load sheet

The following parameters can be activated in the SHL technology

table (=SHEET LOAD):

Designation Description
Peeling Separation of sheets sticking together with the peeler
cup.
Double sheet Double sheet measurement with the double sheet
detector.
Sheet alignm. Integrated sheet alignment (of for Sort extension).
Remove Remove intermediate layer (optional)
intermed. store
Spray from Spray tool lubrication (optional).
below
Transport mode Select the desired transport mode.
Suction cup Activate single suction cup selection.
selection
Individual suc- Activate suction cups individually.
tion cup coding
Suction cup Activate preset suction cup groups-
group 1...4
Parameters in SHL Tab. 4-5

1. Open "Load sheet"(see "Selecting technology", pg. 4-18).

2. Click in the desired field.
3. Enter the corresponding number:
− 1: Parameter active.
− 0: Parameter not active.
− The hexadecimal number under "Individual suction cup
coding" is preset by TruTops Laser and should not be
changed.
4. If suction cups are to be programmed individually:
− Mark "Select suction cups" and enter 1
− Press Select single suction cup. "Select single suction
cup" is displayed.
− Mark suction cups which are to be activated with a check
mark.
or
− Press All suction cups on to activate all suction cups.
or
− Press All suction cups off to deactivate all suction cups.
− Press OK.
5. Press Continue or Finish.

B484EN 2011-08-22 Carrying out technology corrections 4-19

 Maxi part separation

The following parameters can be activated in the PAUD technol-

ogy table (=PARTS UNLOAD):

Designation Description
"Individual suc- Activate suction cups individually with hexadecimal
tion cup coding" code (not recommended).
"Transport Select the desired transport mode.
mode"
"Reserve" Reserve bit for programmers and developers. Please
do not change.
Parameter in PAUD for maxi parts Tab. 4-6

1. Open "Maxi part separation"(see "Selecting technology", pg.

4-18).
2. Click in the desired field.
3. Enter the corresponding number.
4. If suction cups are to be programmed individually: (see "Load
sheet", pg. 4-19).
5. Press Continue or Finish.

Stack small parts (optional for SortMaster)

Note
See also operator's manual for SortMaster.

The following parameters can be activated in the technology

tablePAPA:

Designation Description
"X position" and Removal position, measured between the center of the
"Y position" SortMaster suction plate and the center of gravity of
the part to be removed.
"Angle" C axis rotation angle (optional).
"Suction cup Extendable suction cup slats (for the optional C axis
slat" with extendable suction cup slats):
■ 0: suction cup slat inactive.
■ 1: suction cup slat active.
■ -1: suction cup slat is not present.
"Pos. suction Position of the extendable suction cup slats in [mm]
cup slat 1...4" (for optional C axis with extendable suction cup slats).
"Rotation circle Maximum outer radius when rotating the C axis with a
radius" part sucked on and attached (for optional C axis and
extendable suction cup slats).

4-20 Carrying out technology corrections 2011-08-22 B484EN

 Designation Description
"Removal test" SortMaster checks if the part to be removed was
picked up using suction:
■ 1: Test active.
■ 0: Test not active.
"Reserve" Reserve bit for programmers and developers. Please
do not change.
Parameter in PAPA for stacking small parts with SortMaster Tab. 4-7

1. Open "Remove small parts"(see "Selecting technology", pg.

4-18).
2. Click in the desired field.
3. Enter the corresponding number.
4. Press Continue or Finish.

Remove small parts (SortMaster option)

Note
See also operator's manual for SortMaster.

The following parameters can be activated in the technology

tablePAUD:

Designation Description
"Target selec- Depositing place:
tion" ■ 2: bucket on the unloading platform on the length-
wise side of the pallet changer.
■ 3...6: Depositing places on pallets.
"X offset (tar- X and Y coordinates of the depositing position, relative
get)" and "Y off- to the zero point of the depositing unit.
set (target)"
"Rotation" Deposit angle = angle of rotation of the C axis
(optional) with the part to be deposited on the depos-
iting unit.
"Unloading Depositing type:
mode" ■ 1: Depositing
■ 2: Dropping from maximum stack height preset by
TruTops.
■ 3: Dropping from above (highest gripper position).
■ 4: Dynamic dropping (dropping always takes place
2 cm above the current stack height).
"Stack no." number of the stack to which the selected part
belongs.
"Max. stack The upper limit of the stack height is preset by Tru-
height" Tops.
"Acceleration" Start-up acceleration of the SortMaster axes.

B484EN 2011-08-22 Carrying out technology corrections 4-21

 Designation Description
"Speed" Speed of the SortMaster axes.
"Reserve" Reserve bit for programmers and developers. Please
do not change.
Parameter in PAPA for stacking small parts with SortMaster Tab. 4-8

1. Open "Stack small parts"(see "Selecting technology", pg.

4-18).
2. Click in the desired field.
3. Enter the corresponding number.
4. If suction cups are to be programmed individually: (see "Load
sheet", pg. 4-19).
5. Press Continue or Finish.

3.6 Adjusting inventories

Material or pallet inventories from FMC locations can, but need

not, be updated in TruTops FMC. The system will also function
without inventory updating. Any warnings which may appear can
be ignored.

Note
Only inventories from FMC locations can be adjusted in TruTops
FMC. Storage stations must be modified in the storage software
(e.g. TruTops Fab).

Create stock 1. Press Production plan, "Stock".

All inventories which are known in TruTops FMC are listed.
Inventories which are currently located in the production
cycle are also displayed.
2. Press Create. The "Create/modify stock" screen will be dis-
played.
3. Open the Stock type with .
4. Mark the desired stock type in the selection list:
5. Enter the "Designation" and the "Quantity".
6. Open the location with .

Note
Storage stations cannot be created or modified at this point.
Storage stations need to be modified in the warehouse man-
agement feature.
7. Select the location at which the new inventory is to be found.
8. Enter "Length in X [mm]", "Length in Y [mm]", "Batch num-
ber" and, if desired, "Comments".

4-22 Carrying out technology corrections 2011-08-22 B484EN

 9. Press Apply.
Change inventory 10. Press Production plan, "Stock".
All inventories which are known in TruTops FMC are listed.
Inventories which are currently located in the production
cycle are also displayed.
11. Press Modify. The "Create/modify stock" screen is displayed.
12. See "Create stock" for the subsequent procedure.

3.7 Manual transporting (semi-automatic

cycle)

On the "LiftMaster" or "LiftMaster Sort" tab, the transport process

with the LiftMaster can be executed manually at the laser control
system.

1. Open Production, "Automation", "LiftMaster" or "LiftMaster

Sort".
2. Press Manual transport.
The "Manual transport" screen will open.
3. Use to select "Source location", "Target location",
"Transport type" and "Suction cup":

"Location" Location at which the sheet to be transported is

available, e.g.
■ Pallet changer of the machine (Laser out-
side).
■ In the unloading rake (LiftMaster rake).
■ At the pallet hooks (LiftMaster hooks).
■ At the suction cups (LiftMaster suction cup).
■ Unprocessed sheet stack (raw sheet).
■ Skeleton stack (scrap skeleton).
"Target location" Location to which the sheet is to be transferred,
e.g. skeleton stack (scrap skeleton).

B484EN 2011-08-22 Carrying out technology corrections 4-23

 "Transport type" Type of transport with which the sheet is to be
transported, e.g.
■ Suction cup transport by activating individual
suction cups (Individual suction cup).
■ Transport by activating Suction cup groups.
■ Transport with auxiliary pallet on hook.
■ In the Rake
■ Maxi part separation with maxi part on the
suction cups and scrap skeletons in the
unloading rake.
"Suction cups"/"Suc- Definition of the suction cup/suction cup groups
tion cup groups" selected in the transport type.
The sheet format can be selected under "Suc-
tion cup groups".
Individual suction cups can be activated directly
under "Individual suction cup coding".
Transport types Tab. 4-9

4. If available and necessary, specify the "Options" and sheet

properties in "Sheet" for manual transport:
− "Peeling": to separate sheets which have stuck together.
− "Align sheet": Integrated sheet alignment in the rake (only
for the sort extension).
− "Double-sheet check": check for double sheets using a
sheet thickness tester.
5. Press . The transport is carried out.
or
Press if the LiftMaster is to move to its home position.
or
Press for the LiftMaster swivel arm to be swiveled (the
swivel arm must be in the upper end position).
6. Press to close the dialog.

3.8 Manual handling (optional)

For systems equipped with the manual handling option, the oper-
ator can apply one of the LiftMaster processing steps in the pro-
duction plan for a corresponding sequence list. If the sequence
list contains the "Unload manually" step, for example, the system
will pause while the operator manually removes the cut sheet
from the pallet changer
If the sequence list in the production plan contains the step
"Manual load", then the operator must first load a sheet onto the
pallet changer before the processing of the production plan can
continue.

4-24 Carrying out technology corrections 2011-08-22 B484EN

 Conditions
■ Production plan in automatic mode.
■ In the job details, a sequence list with manual loading or
unloading has been selected and is being processed, e.g.
Cut suction cup/rake, manual sorting.
Production will stop when the "Manual unloading" sequence step
is pending.

1. If TruTops FMC prompts the operator to manually unload the

cut parts at the specified location.
2. Press Transport completed , once the manual step has been
completed. The next step in the production plan will be car-
ried out.

3.9 Viewing active store movements

Ø Open Production, "Automation", "Active store movements".

All of the currently running store movements will be shown
which belong to the job sequence.

B484EN 2011-08-22 Carrying out technology corrections 4-25

 4. User interface in machines with
GritPlus control system

4.1 Structure of the user interface

1 Menu bar 5 Goods description 9 Loading mode

2 Machine location 6 Number of parts 10 Softkeys
3 Item number for inventories 7 Supply pallet 11 Symbols for system status
4 Type of the goods to be trans- 8 Unloading pallet 12 Program status and status of
ported production plan
The structure of the GritPlus control user interface Fig. 56709en

4-26 User interface in machines with GritPlus control 2011-08-22 B484EN

system
Name Description
Machine location The following locations are possible:
■ Loading cart/unprocessed material table.
■ Unloading cart/unloading platform.
■ Pallet changer outside.
■ Pallet changer inside.
Note:
The configuration options of the machine locations depend on the configuration stage of the
system.
No Item number for different inventories at the same location.
Stock type BT: sheet not machined.
NCP: sheet machined (NC program).
MPR: machine pallet or auxiliary pallet for rake operation.
MPH: machine pallet or auxiliary pallet for hook operation.
SP: system pallet for transporting unprocessed sheets.
SPm: system pallet with base for transferring machined sheets.
SPh: system pallet for transferring auxiliary pallets for hook operation.
SPr: system pallet for transferring auxiliary pallets for rake operation.
Stock ID Any description can be selected.
Quantity Quantity of the parts listed in the goods type at the machine location, e.g. "10 unprocessed
sheets".
VP Supply pallet.
System pallet SP, SPm or SPr for BT or MPR type goods. The number of the supply pallet
is entered. If -1 is entered in the column, the system pallet is not relevant or not available.
EP Unloading pallet.
System pallet SP, SPm, SPh, or SPr for NCP, MPR or MPH type goods. The number of
the unloading pallet is entered. If -1 is entered in the column, the system pallet is not rele-
vant or not available.
BA Loading mode.
Program status The following program status displays are possible:
■ Program stopped
■ Program running before PC (PC = pallet changer)
■ Program running after PC

B484EN 2011-08-22 Structure of the user interface 4-27

Name Description
Production plan The following displays to execute the production plan are possible:
status ■ active.
■ not active.
■ is suspended (when Production stop is selected).
Symbols Symbols for system status. Which symbols are displayed depends on the configuration
stage of the system.

Top line:
Status of the components for loading.
Middle line:
Status of pallet changer and automation component.
Bottom line:
Status of the components for unloading.
Tab. 4-10

4.2 Working in semiautomatic cycle

Loading

Conditions
■ Defined position of the swivel arm available:
− above the unprocessed material station or
− above the pallet changer or
− above the finished parts station.
■ The pallet in the pallet changer is empty.
■ The pallet is in the change position.
■ No emergency stop or feed hold.

1. At the machine control, select >Operation (1) >Production (1)

>LiftMaster (7).
2. Press Load. "Load LiftMaster motion order" is opened.
3. Make entries in the fields "Loading type", "Start point", "Des-
tination", "Sheet thickness" and "Sheet format" (see "Select-
ing sheet format", pg. 4-29).

4-28 Working in semiautomatic cycle 2011-08-22 B484EN

 Designation Description
Cancel Exit screen.
Sheet alignment Activates the sheet alignment option (see chapter 3).
Peeler cup Supplies the peeler cup with vacuum (see chapter 3).
Double sheet Opens the production plan.
check
Peeling Activates peeling.
Perform loading Starts the loading cycle.
Buttons for loading the motion order Tab. 4-11

Selecting sheet format

Both standard sheet formats and user-defined formats can be

entered in the "Sheet format" field.

Select suction cup groups 1. Select "Sheet format", other format. The fields of the suction
cup groups are displayed.
2. Activate the desired suction cup groups:
− 1: Suction cup group active.
− 0: Suction cup group not active.
− 3: Suction cup group for maxi part separation (Sort exten-
sion).

Format Suction cup group Suction cup group Suction cup group Suction cup group
1 2 3 4 (peeler cups)
Small format 1 0 0 1
Medium format 1 1 0 1
Large format 1 1 1 1
Maxi format 1 1 3 1
Suction cup groups activated for standard formats Tab. 4-12

Select individual cup 3. Select "Sheet format", Individual suction cup activation. The
individual suction cups are displayed, grouped into 4 sections
(1-16, 17-32, 33-48, 49-63).

LiftMaster Programmable suction cups

LiftMaster --1530 1-18
LiftMaster Sort --1530 1-18 and 34-51
LiftMaster --2040 1-27
LiftMaster Sort --2040 1 -27 and 34 - 57
Programmable suction cups Tab. 4-13

4. Enter individual suction cups in hexadecimal code.

B484EN 2011-08-22 Working in semiautomatic cycle 4-29

 or
Press the MAGNIFYING GLASS button at the laser machine
control. "Select individual suction cup" is opened.
− Click on the desired suction cup or
− Jump from suction cup to suction cup using the cursor
keys until the individual suction cup required is outlined in
red.
− Press Switch over suction cup to activate the marked
suction cup.
− Press OK to confirm the selection.
5. Press OK. The suction cup selection will be accepted.

Designation Description
Cancel Exit screen.
Deselect all Deactivate all suction cups.
Select all Activate all suction cups.
Reverse selec- Activates all deactivated suction cups and vice versa.
tion
Switch over suc- Activate or deactivate highlighted suction cup.
tion cup
OK Apply selection.
Buttons for selecting individual suction cups Tab. 4-14

Unloading

Without maxi part separation 1. At the machine control, select >Operation (1) >Production (1)
>LiftMaster (7).
2. Press Unload. "Unload LiftMaster motion order" is opened.
3. Make entries in the fields "Loading type", "Start point", "Des-
tination", "Destination of maxi parts" and "Sheet thickness".
4. Press Unload to start the unloading cycle.
or
Press Values from stock if the program was previously abor-
ted.
The value from the database will be used if the program had
previously been programmed with a programming system.
With maxi part separation 5. At the machine control, select >Operation (1) >Production (1)
>LiftMaster (7).
6. Press Unload. "Unload LiftMaster motion order" is opened.
7. Make entries in the fields "Loading type", "Start point", "Scrap
skeleton destination", "Maxi parts destination", "Sheet thick-
ness" and "Sheet format"(see "Selecting sheet format", pg.
4-29).
8. Press Unload to start the unloading cycle.

4-30 Working in semiautomatic cycle 2011-08-22 B484EN

 or
Press Values from stock if the program was previously abor-
ted.
The value from the database will be used if the program had
previously been programmed with a programming system.

4.3 Working in automatic mode

An automatic cycle is always started via a production plan.

Exactly one NC program is allocated to each sheet job. A sheet
job consists of a defined number of program runs of the NC pro-
gram.
The production plan thus determines which NC programs are to
be executed at the machine and in which order. Sheet jobs can
only be generated from programs which are in the NC archive.
See chapter "Operation" in the operator's manual for the laser
machine.

Opening a production plan

Ø On the laser machine's control system, open >Operation (1),

>Production (1), >Production plan (6).
The following parameters are displayed:

Name Description
Sequence Serial number of the sheet job. The sheet jobs are
(="seq.") executed in the same order as their serial numbers.
"Status" Job status. Job complete, disabled or free.
"Name" Description of the sheet job.
"Program name" Name of the NC program.
"Required" Quantity of sheets to be processed.
"Actual" Quantity of sheets already processed.
"Deposit loca- Location at which the completes parts of the job are
tion" stored.
Job data production plan Tab. 4-15

Designa- Description Note

tion
0 Not set. -
1 Suction cup/rake. Loading with suction cups; unloading with rake
or suction cups and rake (maxi part separation).
2 Hook operation without separation. -

B484EN 2011-08-22 Working in automatic mode 4-31

 Designa- Description Note
tion
3 Hook operation without separation or SortMaster -
use.
4 Unassigned. -
5 Hook operation with separation. -
6 Hook operation with separation and SortMaster -
use.
7 Suction cup/rake and SortMaster use. -
8 Suction cup/rake with intermediate layer. An intermediate layer is placed between each of
the unloaded parts.
9 Suction cup/rake with intermediate layer and -
SortMaster use.
Loading types Tab. 4-16

Create sheet job

Condition
■ The "Production plan" screen is open.

1. Press Create sheet job. All stored NC programs will be dis-

played.

Designation Description
Find program Look for a particular program.
Select program Open a previously marked program.
Create a sheet Opens the dialog to create a sheet job.
job
Production plan Opens the production plan.
All programs / Changeover switch:
NCU
Either shows all programs in the list of programs or
only programs which are in the control system.
Next Opens the program notes where optional comments
on the program can be entered.
Check program This does a syntax check. Amongst other things, it
checks whether all of the tables and subroutines are
contained in the program. If not, then the program sta-
tus will be set to "incomplete". After being corrected,
"Check program" must again be run.
Create sheet job button Tab. 4-17

2. Select the desired program with the cursor key.

3. Press Create sheet job. "Create production plan" is opened:
4. For entering parameters.
Note:

4-32 Working in automatic mode 2011-08-22 B484EN

 Loading pallets and stock IDs can be programmed either
selectively or simultaneously. This also applies to unloading
pallets and group type. When both parameters are program-
med simultaneously, the pallet is processed first.
If only the system pallets are programmed, the production
plan stops after the pallets have been processed.

Parameters:

Designation Description
"Sequence" Serial number of the sheet job. The sheet jobs are
executed in the same order as their serial numbers.
"Designation" Description of the sheet job.
"Required quan- Quantity of sheets to be processed.
tity"
"Actual quantity" Quantity of sheets already processed.
"Sort small Sorting small parts with SortMaster (optional) is active.
parts"
"Loading type" Type of loading operation (see "Tab. 4-16", pg. 4-32).
"Supply" Location from which the unprocessed sheets will be
supplied.
"Loading pallet" Number of the system pallet, on which the raw materi-
als sheets to be processed are lying. This is offered
only if a storage position had been previously selected
as a supply location.
"Unloading pal- Number of the system pallet, on which the finished
let" parts should be stored. This is offered only if a stor-
age position had been previously selected as an
unloading location.
"Group type" Type of pallet, e.g. system pallet with floor SPm.
"Stock ID" Description of the type of raw sheet that is to be used
for this job.
Create production plan, parameters Tab. 4-18

Buttons for creating a production plan:

Designation Description
Abort Exit screen.
Cleaning With SortMaster option: clean suction cups and
machine pallet (see operator's manual for SortMaster)
Unprocessed Select unprocessed sheets.
material
Storage pallets With connection to storage: display and select inven-
tory.
Buttons for creating a production plan Tab. 4-19

5. Press Create sheet job. The sheet job is created.

B484EN 2011-08-22 Working in automatic mode 4-33

 Create production plan

1. In the "NC program"screen, press Production plan.

2. Press Unprocessed material, to select the required unpro-
cessed sheets:
− Select the material type using the cursor keys.
− Accept selection with Select stock.
3. Press Storage pallets when the inventory is to be displayed
and programmed for a particular pallet:
− Select the storage location with the cursor keys.
− Adopt a storage location using one of the softkeys, e.g.
Supply pallet
− Press the Back softkey to return to the "Create produc-
tion plan" mask.
4. Press Create sheet job to create the sheet job. The mask
with the overview of the NC programs will be displayed
again.

Change sheet job

1. Select the sheet job to be modified in the "Production plan"

mask using the cursor keys.
2. Press Modify/info sheet job. "Modify production plan" will be
opened.
− "New sequence": sequence number can be changed.
3. Modify sheet job (see "Create sheet job", pg. 4-32).

Delete sheet job

1. Select one or more sheet jobs in the "Production plan" mask

using the cursor keys.
2. Press Delete sheet job. All marked sheet jobs will be
deleted.

Set status

A free sheet job can be disabled or enabled with Set status.

1. Select one or more sheet jobs in the "Production plan" mask

using the cursor keys.

4-34 Working in automatic mode 2011-08-22 B484EN

 2. Press Set status, until the required status is shown in the
production plan. The following parameters can be set:
− Free.
− Blocked: the sheet job will not be scheduled for execution
within the production plan.

Under "Status" the production plan also includes displayed val-

ues allocated by the system which give additional status informa-
tion which cannot be set by the operator:

Designation Description
No file A particular file is missing, which should have been gener-
ated when the complete file was split up.
Active The program is currently running.
Ended Enough parts have been produced.
Incomplete A database table that is required holds no entry for the
selected program (error in NC program).
Notes Notes have been generated for the program.
Prog. error Undefined error in the program.
No material Raw material required in order to execute the job has not
been specified or is unavailable.
No removal Unloading pallet or unloading location is undefined.
Data incon- Incorrect definition of data, e.g.: unloading station is
sistency defined as supply station.
Ready The measures required in preparation for processing the
job, such as the loading operation have been performed.
Res.Err. Materials reservation error in the storage system.
Status information Tab. 4-20

Prepare and start production

Ø See operator's manual for laser machine, chapter "Opera-

tion".

B484EN 2011-08-22 Working in automatic mode 4-35

4-36 Working in automatic mode 2011-08-22 B484EN
 Chapter 5

Operation of LiftMaster
--1225/--2540

1 Operating elements 5-3

1.1 Control elements on the complete system 5-3
1.2 Control panel on the start post of LiftMaster 5-6
(optional)

2 Operating modes 5-9

3 Structure of the user interface 5-10

4 Manual mode 5-12

4.1 Loading 5-12
4.2 Unloading 5-13

5 Working in semiautomatic cycle 5-17

5.1 Loading 5-17
5.2 Selecting sheet format 5-17

B484EN 2011-08-22 Operation of LiftMaster --1225/--2540 5-1

 5.3 Unloading 5-19

6 Working in automatic mode 5-20

6.1 Opening a production plan 5-20
6.2 Create sheet job 5-20
6.3 Change sheet job 5-21
6.4 Delete sheet job 5-21
6.5 Set status 5-21
6.6 Prepare and start production 5-22
6.7 Working in single-pallet operation 5-22
6.8 Manually loading and unloading within the 5-23
production plan
6.9 Manual intervention in automatic mode 5-23

5-2 Operation of LiftMaster --1225/--2540 2011-08-22 B484EN

 1. Operating elements

1.1 Control elements on the complete

system

1 LiftMaster 3 Deflection mirror for light barrier 5 Control panel for laser machine
2 Start pedestal with EMER- 4 Pulse trigger switch
GENCY STOP impact button
TruLaser 7025 with LiftMaster --1225 Fig. 49092

B484EN 2011-08-22 Operating elements 5-3

1 TruLaser 7040 4 Laser machine control panel 6 Pallet changer
2 Unloading cart 5 Deflection mirror for light barrier 7 LiftMaster
3 LiftMaster swivel arm
TruLaser 7040 with LiftMaster --2540 (example) Fig. 53443

5-4 Control elements on the complete system 2011-08-22 B484EN

 Controls Prerequisite Description
None Switches the machine's power supply on or off.

MAIN SWITCH
None Impact button.
Interrupts the power supply of the entire system.

Impact button EMERGENCY STOP

The impact button acts on the following compo-
nents:
■ Laser machine.
■ Laser unit (laser beam is switched off).
■ Pallet changer.
■ Automation component.

The impact button is not effective for the following

components:
■ Suction cups. The existing vacuum is maintained
to prevent attached sheets from being released.
■ 24 V control voltage.
Light barrier was Activate interrupted light barrier.
interrupted

FOOT SWITCH on the start pedes-

tal
Control elements on the complete system Tab. 5-1

B484EN 2011-08-22 Control elements on the complete system 5-5

 1.2 Control panel on the start post of
LiftMaster (optional)

1 EMERGENCY STOP impact 3 Illuminated pushbutton START 5 Indicator lamp light barrier inter-
button 4 Illuminated lock button FEED rupted
2 Illuminated pushbutton HOLD
ACKNOWLEDGE LOADING OF
PALLET CHANGER
Control panel button assignment of LiftMaster --1225/--2540 Fig. 49095

5-6 Control panel on the start post of LiftMaster 2011-08-22 B484EN

(optional)
Operating element Prerequisite Description
1 None Impact button.
Impact button EMERGENCY Interrupts the power supply of the entire system.
STOP

The impact button acts on the following compo-

nents:
■ Laser machine.
■ Laser unit (laser beam is switched off).
■ Pallet changer.
■ LiftMaster.

The impact button is not effective for the following

components:
■ Suction cups. Existing vacuum is maintained so
that a suction sheet is not released.
■ 24 V control voltage.
2 Lamp flashes before pallet Illuminated key:
change.
ACKNOWLEDGE THAT If the LiftMaster is deactivated:
PALLET CHANGER LOA-
DED
Pressing the button will resume an interrupted load-
ing or changing operation in the pallet changer, if
the interruption has been previously acknowledged
with the foot switch. Sequence:
■ Light barrier is interrupted.
■ Pallet changer stops.
■ Acknowledge light barrier by pressing the foot
switch.
■ Acknowledge FEED HOLD (button 21 lights up)
with START (button 22).
■ Acknowledge pallet changer with button 17.
If the LiftMaster is activated, button 17 is not effec-
tive since acknowledgement occurs automatically
after the loading operation.
3 None Illuminated key:
START Pressing the START button acknowledges feed
hold.
Interrupted movements of the pallet changer and
LiftMaster recommence.
Button flashes when it is released and Feed hold
was not acknowledged.
Note:
No NC program can be started with this button.

B484EN 2011-08-22 Control panel on the start post of LiftMaster 5-7

(optional)
 Operating element Prerequisite Description
4 None Illuminated key, lock button:
FEED HOLD Pressing the button stops all movements of the pal-
let changer and the LiftMaster. Processing in the
machine continues.
Further movements are not possible while FEED
HOLD is active.
Pressing START deletes an active feed hold.
Button lights up when pressed.
Note:
The FEED HOLD button on the control panel of the
laser machine is effective only for the machine and
the pallet changer and not for LiftMaster.
5 ■ Light barrier has been Indicator lamp:
interrupted.
Light barrier interrupted Flashes when the safety light barrier which shields
■ The movements of the the pallet changer and LiftMaster is interrupted.
pallet changer and Lift-
Master have been stop- The light barrier is reactivated by pressing the foot
ped. switch.
Continue loading or changing procedures: Press
button 2 or 3.
Operating elements on the start pedestal of the LiftMaster Tab. 5-2

5-8 Control panel on the start post of LiftMaster 2011-08-22 B484EN

(optional)
 2. Operating modes

Three operating modes are possible:

■ Manual operation.
■ Semi-automatic cycle.
■ Automatic mode with production plan.
■ Automatic mode with production plan.
■ Single pallet mode.

Manual operation In manual mode all phases of the transport process can be con-
trolled at the laser machine's control panel (see "Manual mode",
pg. 5-12).

Semiautomatic cycle In a semi-automatic cycle, a transport process can be conducted

on the control system of the laser machine.

Automatic mode In automatic mode, the whole loading and unloading procedure
is started using a previously created production plan. The pro-
duction plan is either created by the programming system of the
basic machine (TruTops Laser) or manually on the control sys-
tem interface. Before starting, the defined starting conditions
must always be established.

Single pallet mode In single-pallet operation, only one pallet is used (Pallet A). This
means it is not loading and unloading sheets during productive
time.
Single-pallet operation is recommended when it is necessary to
ensure that parts which are cut free do not fall onto unprocessed
materials lying underneath, which could result in these parts then
causing a collision with the cutting head in the machine. Single-
pallet operation selected and deselected at the control system.

B484EN 2011-08-22 Operating modes 5-9

 3. Structure of the user interface

Note
LiftMaster of TruLaser series 7000 is operated using the operat-
ing panel of the laser machine. Users can use the start pedestal
to intervene in the operation of the LiftMaster only to a certain
extent.

Example: semiautomatic mode

1 Menu bar 5 Goods description 9 Loading mode

2 Machine location 6 Number of parts 10 Softkeys
3 Item number for inventories 7 Supply pallet 11 Symbols for system status
4 Type of the goods to be trans- 8 Unloading pallet 12 Program status and status of
ported production plan
The structure of the GritPlus control user interface Fig. 49096en

Name Description
Machine location The following locations are possible:
■ Loading cart/unprocessed material table.
■ Unloading cart/unloading platform.
■ Pallet changer outside.
■ Pallet changer inside.
Note:
The configuration options of the machine locations depend on the configuration stage of the
system.
No Item number for different inventories at the same location.

5-10 Structure of the user interface 2011-08-22 B484EN

Name Description
Stock type BT: sheet not machined.
NCP: sheet machined (NC program).
MPR: machine pallet or auxiliary pallet for rake operation.
MPH: machine pallet or auxiliary pallet for hook operation.
SP: system pallet for transporting unprocessed sheets.
SPm: system pallet with base for transferring machined sheets.
SPh: system pallet for transferring auxiliary pallets for hook operation.
SPr: system pallet for transferring auxiliary pallets for rake operation.
Stock ID Any description can be selected.
Quantity Quantity of the parts listed in the goods type at the machine location, e.g. "10 unprocessed
sheets".
VP Supply pallet.
System pallet SP, SPm or SPr for BT or MPR type goods. The number of the supply pallet
is entered. If -1 is entered in the column, the system pallet is not relevant or not available.
EP Unloading pallet.
System pallet SP, SPm, SPh, or SPr for NCP, MPR or MPH type goods. The number of
the unloading pallet is entered. If -1 is entered in the column, the system pallet is not rele-
vant or not available.
BA Loading mode.
Program status The following program status displays are possible:
■ Program stopped
■ Program running before PC (PC = pallet changer)
■ Program running after PC
Production plan The following displays to execute the production plan are possible:
status ■ active.
■ not active.
■ is suspended (when Production stop is selected).
Symbols Symbols for system status. Which symbols are displayed depends on the configuration
stage of the system.

Top line:
Status of the components for loading.
Middle line:
Status of pallet changer and automation component.
Bottom line:
Status of the components for unloading.
Tab. 5-3

B484EN 2011-08-22 Structure of the user interface 5-11

 4. Manual mode

4.1 Loading

Conditions
■ The sheet is on the loading station.
■ The unloading cart is in the parking position in the store.
■ LiftMaster is on the loading platform.
■ The light barrier has been acknowledged using the foot
switch on the operating panel.

1. , open selection.
2. Use the cursor keys to select "LiftMaster manual function" for
the switch element.
3. Press .
The following switch elements are available for selection:

Switch element Description

1. Swivel Activates the swivel arm for moving to the work-
ing positions using the JOG buttons ( and .
see operator's manual for the laser machine).
2. Vacuum Switches the vacuum on or off.
3. Rake Opens or closes the unloading rake.
4. Armature probe R Moves the sensor system for the rake drive to
the active or inactive position.
5. Suction cup unit Moves the suction cup to the upper or the lower
position.
6. Stroke speed Toggles the speed of the motion unit between the
creep or rapid feedrate.
7. Lifting motion Activates the LiftMaster's lifting unit for moving up
and down using the JOG buttons ( and .
see operator's manual for the laser machine).
8. Feed hold/start Triggers a feed hold or deletes an active feed
LiftMaster hold after acknowledgement with the foot-oper-
ated switch.
9. RESET LiftMaster Reset for the LiftMaster only. All movements will
be stopped.
Switch elements for LiftMaster manual functions Tab. 5-4

4. Click on the desired switch elements.

or
At the keyboard click on the digits of the desired switch ele-
ments (see "Tab. 5-6", pg. 5-12).

5-12 Manual mode 2011-08-22 B484EN

 Switch ele- Sequence
ment
3 Open unloading rake.
5 Move suction cylinder to the bottom position.
7 Activate elevating part.
- Move the elevating part down until the suction cylinders
are seated on the sheet.
2 Generate vacuum. The sheet is sucked and picked up.
5 Move suction cylinder to the top position.
7 Activate elevating part.
+ Move elevating part with sheet into the upper end posi-
tion.
3 Close unloading rake.
1 Activate swivel arm.
+ or - Move the swivel arm over the pallet changer.
4 Move armature probe R down.
7 Activate elevating part.
- Move the elevating part down until the light barrier inter-
rupts the movement of the armature probe.
3 Open unloading rake.
5 Open unloading rake.
2 Vacuum goes off. The sheet is deposited.
7 Activate elevating part.
+ Move elevating part with sheet into the upper end posi-
tion.
Sheet loading sequence Tab. 5-5

Tip
If a feed hold is triggered while a movement is in progress,
press the foot-operated switch on the control panel first and then
the switch element "8. Feed hold/start LiftMaster".

4.2 Unloading

Conditions
■ The cut sheet is on the pallet changer.
■ The unloading cart is in the parking position in the store.
■ LiftMaster is above the pallet changer.
■ The light barrier has been acknowledged using the foot
switch on the operating panel.

Removing the sheet 1. , open Selection.

2. Use the cursor keys to select "LiftMaster manual function" for
the switch element.

B484EN 2011-08-22 Manual mode 5-13

 3. Press .
The following switch elements are available for selection:

Switch element Description

1. Swivel Activates the swivel arm for moving to the work-
ing positions using the JOG buttons ( and .
see operator's manual for the laser machine).
2. Vacuum Switches the vacuum on or off.
3. Rake Opens or closes the unloading rake.
4. Armature probe R Moves the sensor system for the rake drive to
the active or inactive position.
5. Suction cup unit Moves the suction cup to the upper or the lower
position.
6. Stroke speed Toggles the speed of the motion unit between the
creep or rapid feedrate.
7. Lifting motion Activates the LiftMaster's lifting unit for moving up
and down using the JOG buttons ( and .
see operator's manual for the laser machine).
8. Feed hold/start Triggers a feed hold or deletes an active feed
LiftMaster hold after acknowledgement with the foot-oper-
ated switch.
9. RESET LiftMaster Reset for the LiftMaster only. All movements will
be stopped.
Switch elements for LiftMaster manual functions Tab. 5-6

4. Click on the desired switch elements.

or
At the keyboard click on the digits of the desired switch ele-
ments (see "Tab. 5-6", pg. 5-12).

Switch ele- Sequence

ment
3 Open unloading rake.
4 Move armature probe R down.
7 Activate elevating part.
- Move the elevating part down until the light barrier inter-
rupts the movement of the armature probe.
3 Close unloading rake.
7 Activate elevating part.
+ Move elevating part with sheet into the upper end posi-
tion.
1 Activate swivel arm.
+ or - Move the swivel arm over the unloading position.
4 Move armature probe R down.
7 Activate elevating part.
- Move the elevating part down until the light barrier inter-
rupts the movement of the armature probe.
3 Open unloading rake.
5 Open unloading rake.

5-14 Manual mode 2011-08-22 B484EN

 Switch ele- Sequence
ment
2 Vacuum goes off. The sheet is deposited.
7 Activate elevating part.
+ Move elevating part with sheet into the upper end posi-
tion.
Sheet unloading sequence Tab. 5-7

Moving the cart at the 5. , open Selection.

LiftMaster 6. Use the cursor keys to select "LiftMaster manual function" for
the switch element.
7. Press .
The following switch elements are available for selection:

Switch element Description

1. L/D cart Not available in this configuration stage.
2. L/U cart Not available in this configuration stage.
3. U/D cart Not available in this configuration stage.
4. U/U cart The unloading cart is on the unloading platform.
5. Feed hold/start Triggers a feed hold or deletes an active feed
LiftMaster hold after acknowledgement with the foot-oper-
ated switch.
6. RESET LiftMaster Reset for the LiftMaster only. All movements will
be stopped.
Switch elements for LiftMaster cart Tab. 5-8

8. Select switch element 4. The cart moves from the park posi-
tion at the storage system above the loading platform in front
of the machine.
Depositing the sheet 9. , open Selection.
10. Use the cursor keys to select "LiftMaster manual function" for
the switch element.
11. Press .
The following switch elements are available for selection:
12. Click on the desired switch elements.
or
At the keyboard click on the digits of the desired switch ele-
ments (see "Tab. 5-6", pg. 5-12).

Switch ele- Sequence

ment
4 Move armature probe R down.
7 Activate elevating part.
- Move the elevating part down until the light barrier inter-
rupts the movement of the armature probe.
3 Close unloading rake.

B484EN 2011-08-22 Manual mode 5-15

 Switch ele- Sequence
ment
7 Activate elevating part.
+ Move elevating part with sheet into the upper end posi-
tion.
Sheet depositing sequence Tab. 5-9

5-16 Manual mode 2011-08-22 B484EN

 5. Working in semiautomatic cycle

5.1 Loading

Conditions
■ Defined position of the swivel arm available:
− above the unprocessed material station or
− above the pallet changer or
− above the finished parts station.
■ The pallet in the pallet changer is empty.
■ The pallet is in the change position.
■ No emergency stop or feed hold.

1. At the machine control, select >Operation (1) >Production (1)

>LiftMaster (7).
2. Press Load. "Load LiftMaster motion order" is opened.
3. Make entries in the fields "Loading type", "Start point", "Des-
tination", "Sheet thickness" and "Sheet format" (see "Select-
ing sheet format", pg. 4-29).

Designation Description
Cancel Exit screen.
Sheet alignment Activates the sheet alignment option (see chapter 3).
Peeler cup Supplies the peeler cup with vacuum (see chapter 3).
Double sheet Opens the production plan.
check
Peeling Activates peeling.
Perform loading Starts the loading cycle.
Buttons for loading the motion order Tab. 5-10

5.2 Selecting sheet format

Both standard sheet formats and user-defined formats can be

entered in the "Sheet format" field.

Select suction cup groups 1. Select "Sheet format", other format. The fields of the suction
cup groups are displayed.
2. Activate the desired suction cup groups:
− 1: Suction cup group active.
− 0: Suction cup group not active.
− 3: Suction cup group for maxi part separation (Sort exten-
sion).

B484EN 2011-08-22 Working in semiautomatic cycle 5-17

 Format Suction cup group Suction cup group Suction cup group Suction cup group
1 2 3 4 (peeler cups)
Small format 1 0 0 1
Medium format 1 1 0 1
Large format 1 1 1 1
Maxi format 1 1 3 1
Suction cup groups activated for standard formats Tab. 5-11

Select individual cup 3. Select "Sheet format", Individual suction cup activation. The
individual suction cups are displayed, grouped into 4 sections
(1-16, 17-32, 33-48, 49-63).

LiftMaster Programmable suction cups

LiftMaster --1530 1-18
LiftMaster Sort --1530 1-18 and 34-51
LiftMaster --2040 1-27
LiftMaster Sort --2040 1 -27 and 34 - 57
Programmable suction cups Tab. 5-12

4. Enter individual suction cups in hexadecimal code.

or
Press the MAGNIFYING GLASS button at the laser machine
control. "Select individual suction cup" is opened.
− Click on the desired suction cup or
− Jump from suction cup to suction cup using the cursor
keys until the individual suction cup required is outlined in
red.
− Press Switch over suction cup to activate the marked
suction cup.
− Press OK to confirm the selection.
5. Press OK. The suction cup selection will be accepted.

Designation Description
Cancel Exit screen.
Deselect all Deactivate all suction cups.
Select all Activate all suction cups.
Reverse selec- Activates all deactivated suction cups and vice versa.
tion
Switch over suc- Activate or deactivate highlighted suction cup.
tion cup
OK Apply selection.
Buttons for selecting individual suction cups Tab. 5-13

5-18 Working in semiautomatic cycle 2011-08-22 B484EN

 5.3 Unloading

1. At the machine control, select >Operation (1) >Production (1)

>LiftMaster (7).
2. Press Unload. "Unload LiftMaster motion order" is opened.
3. Make entries in the fields "Loading type", "Start point", "Des-
tination" and "Sheet thickness".
4. Press Unload to start the unloading cycle.
or
Press Values from stock if the program was previously abor-
ted.
The value from the database will be used if the program had
previously been programmed with a programming system.

B484EN 2011-08-22 Working in semiautomatic cycle 5-19

 6. Working in automatic mode

An automatic cycle is always started via a production plan.

Exactly one NC program is allocated to each sheet job. A sheet
job consists of a defined number of program runs of the NC pro-
gram.
The production plan thus determines which NC programs are to
be executed at the machine and in which order. Sheet jobs can
only be generated from programs which are in the NC archive.
See chapter "Operation" in the operator's manual for the laser
machine.

6.1 Opening a production plan

Ø On the laser machine's control system, open >Operation (1),

>Production (1), >Production plan (6).
The following parameters are displayed:

Designation Description
Sequence Serial number of the sheet job. The sheet jobs are
(="seq.") executed in the same order as their serial numbers.
"Status" Job status. Job complete, disabled or free.
"Designation" Description of the sheet job.
"Program name" Name of the NC program.
"Required" Quantity of sheets to be processed.
"Actual" Quantity of sheets already processed.
Job data production plan Tab. 5-14

Description of softkeys: see the following sections.

6.2 Create sheet job

Condition
■ The "Production plan" screen is open.

1. Press Create sheet job. All stored NC programs will be dis-

played.

Designation Description
Find program Look for a particular program.
Select program Open a previously marked program.

5-20 Working in automatic mode 2011-08-22 B484EN

 Designation Description
Create a sheet Opens the dialog to create a sheet job.
job
Production plan Opens the production plan.
All programs / Changeover switch:
NCU
Either shows all programs in the list of programs or
only programs which are in the control system.
Next Opens the program notes where optional comments
on the program can be entered.
Check program This does a syntax check. Amongst other things, it
checks whether all of the tables and subroutines are
contained in the program. If not, then the program sta-
tus will be set to "incomplete". After being corrected,
"Check program" must again be run.
Create sheet job button Tab. 5-15

2. Select the desired program with the cursor key.

3. Press Create sheet job. "Create production plan" is opened:
4. For entering parameters.
5. Subsequent course (see "Create sheet job", pg. 4-32).

6.3 Change sheet job

1. Select the sheet job to be modified in the "Production plan"

mask using the cursor keys.
2. Press Modify/info sheet job. "Modify production plan" will be
opened.
− "New sequence": sequence number can be changed.
3. Modify sheet job (see "Create sheet job", pg. 4-32).

6.4 Delete sheet job

1. Select one or more sheet jobs in the "Production plan" mask

using the cursor keys.
2. Press Delete sheet job. All marked sheet jobs will be
deleted.

6.5 Set status

A free sheet job can be disabled or enabled with Set status.

B484EN 2011-08-22 Working in automatic mode 5-21

 1. Select one or more sheet jobs in the "Production plan" mask
using the cursor keys.
2. Press Set status, until the required status is shown in the
production plan. The following parameters can be set:
− Free.
− Blocked: the sheet job will not be scheduled for execution
within the production plan.

Under "Status" the production plan also includes displayed val-

ues allocated by the system which give additional status informa-
tion which cannot be set by the operator:

Designation Description
No file A particular file is missing, which should have been gener-
ated when the complete file was split up.
Active The program is currently running.
Ended Enough parts have been produced.
Incomplete A database table that is required holds no entry for the
selected program (error in NC program).
Notes Notes have been generated for the program.
Prog. error Undefined error in the program.
No material Raw material required in order to execute the job has not
been specified or is unavailable.
No removal Unloading pallet or unloading location is undefined.
Data incon- Incorrect definition of data, e.g.: unloading station is
sistency defined as supply station.
Ready The measures required in preparation for processing the
job, such as the loading operation have been performed.
Res.Err. Materials reservation error in the storage system.
Status information Tab. 5-16

6.6 Prepare and start production

Ø See operator's manual for laser machine, chapter "Opera-

tion".

6.7 Working in single-pallet operation

In single-pallet operation only the top pallet is used.

Selecting single pallet mode 1. Store the required material in the correct sequence.
2. Enter the material in the production plan in the appropriate
sequence.

5-22 Working in automatic mode 2011-08-22 B484EN

 3. On the laser machine's control system, open >Operation (1),
>Production (1), >Production plan (6).
4. Press Options. The "Options" screen appears
5. Press Single pallet mode.
If single pallet mode is not active, the LiftMaster runs in the
operating mode defined in the "Sheet loading" technology
table.
Entering single pallet mode 6. At the laser machine's control, open >Operation (1), >Produc-
in the Sheet loading table tion (1), >Tables (5), Load sheet (3).
(SHEET LOAD) 7. Select the desired "program name" and "table name".
8. In the "Loading unit" field enter the value 7 for single pallet
mode. Single pallet mode is active.

6.8 Manually loading and unloading

within the production plan

Condition
■ The "Production plan" is open.

1. Press Options. The "Options" are opened.

2. Press Manual unloading or Manual loading
3. In the field "Alternative position of LiftMaster during manual
unloading (loading)" select the position, e.g. Unloading cart/
platform.

6.9 Manual intervention in automatic

mode

Material damage or collision due to manual intervention in

CAUTION automatic mode.
Ø Always check any manual intervention in automatic mode
carefully before starting.
Ø Adjust manual intervention in the production plan.

Inventory management Pallet changer inventory management takes place automatically

and ensures that the automatic operating mode on the LiftMaster
runs properly.

B484EN 2011-08-22 Manual intervention in automatic mode 5-23

 The following basically applies:
■ The operator can only manually adjust machine stocks at the
laser machine's control.
■ Inventories at the storage stations must be entered into the
storage software.
■ Inventories on the platforms are not controlled.

Manual intervention After manual intervention stock management is not automatically

updated. Manual intervention may be e.g.:
■ Manually loading or unloading pallet changers.
■ Transferring the unprocessed sheet manually from the supply
pallet to the pallet changer
■ Manually unloading the unloading platform.
■ ...

Updating inventory If any manual intervention resulted in faulty states, the stock
management must be checked and updated. If that is not done, errors could
occur when restarting the production plan, e.g.:
■ An empty pallet enters the working range of the machine.
■ An unprocessed sheet which is awaiting processing is unloa-
ded without being processed.

5-24 Manual intervention in automatic mode 2011-08-22 B484EN

 Chapter 6

Maintenance

1 General guidelines 6-3

2 Maintenance Overview 6-4

3 Lubrication 6-5
3.1 Overview 6-5
3.2 Maintenance Instructions 6-6
Rotary connection to the suction frame 6-6
Linear guides on elevating part 6-7
Lifting chain 6-8
Index 6-9
Unloading rake chain 6-9
Ballscrew bearing of unloading rake 6-9
Unloading rake gear motor 6-10
Lift drive 6-11

4 Mechanical elements 6-13

4.1 Overview 6-13

B484EN 2011-08-22 Maintenance 6-1

 4.2 Maintenance Instructions 6-14
Suction cups 6-14
Index 6-14
Unloading rake chain 6-15
Lifting chain 6-17

5 Electrics 6-19
5.1 Overview 6-19
5.2 Maintenance Instructions 6-19
Heat exchanger door on the switch cabi- 6-19
net

6-2 Maintenance 2011-08-22 B484EN

 1. General guidelines

Correct maintenance is essential for maintaining the quality of

the machine. It prevents operational malfunctions and their con-
sequences.

Risk of fatal injury during maintenance work with the

DANGER machine switched on!
Unless expressly stated otherwise:
Ø Switch off the MAIN SWITCH.
Ø Lock the MAIN SWITCH.
Ø Pull out the key.
Ø Strictly observe the safety regulations.

Danger of accidents caused by maintenance work high up!

WARNING
Ø Do not carry out maintenance or repair work at height your-
self.
Ø Place an order with TRUMPF's service department for main-
tenance and service work at height.

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:
■ Do not leave filler and drainage caps open for longer than
necessary and keep them clean.
■ Drain 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.

B484EN 2011-08-22 General guidelines 6-3

 2. Maintenance Overview

Interval/ Maintenance point Maintenance work Page

operating
hours
160 Suction cups Check the rubber inserts 6-14
500 Rotary connection to the suction frame Lubricate four-point bearing (ISA) 6-6
500 Index Check the pin and the pressure roller 6-14
500 Unloading rake chain Checking the chain tension 6-15
500 Lifting chain Check lifting chains for wear 6-17
1000 Rotary connection to the suction frame Grease gear rim 6-6
1000 Linear guides on elevating part Lubricate linear guide (INA) 6-7
1000 Lifting chain Clean lifting chain 6-8
1000 Index Lubricating the index 6-9
1000 Unloading rake chain Clean and lubricate the chain 6-9
1000 Lifting chain Check the elongation of the lifting chain 6-17
1000 Heat exchanger door on the switch cabi- Check the air gap of the disc brake 6-20
net
2000 Ballscrew bearing of unloading rake Lubricating the ballscrew bearings 6-9
Annually Lifting chain Replace the lubricant container and the 6-8
battery
Every 5 years Unloading rake gear motor Changing the lubricant 6-10
Every 5 years Lift drive Changing the lubricant 6-11
Every 5 years Lift drive Changing the lubricant 6-12
As needed Unloading rake chain Retighten the chain 6-16
As needed Heat exchanger door on the switch cabi- Clean the fins of the heat exchanger 6-19
net

For single shift operation the following relations hold:

160 operating hours monthly

500 operating hours every 3 months
1000 operating hours every 6 months
2000 operating hours annually
Annually regardless of the number of operat-
ing hours
Every 5 years regardless of the number of operat-
ing hours

6-4 Maintenance Overview 2011-08-22 B484EN

 3. Lubrication

3.1 Overview

1 Chain for unloading rake 5 Unloading rake gear motor 8 Lift chain
2 Swivel drive 6a Index, swivel part (optional for 9 Lift drive
3 Ballscrew bearing of unloading extended swivel range with syn- 10 Lubricant container
rake chronous chain)
4 Rotary connection to suction 6b Index, elevating part
frame 7 Linear guide for elevating part
LiftMaster lubrication plan
B484EN 2011-08-22 Lubrication 6-5
Fig. 31268
 Lubrication point Quan- Recommended lubricants TRUMPF Identifi- Viscosity
tity material no. cation
Linear guide - ESSO Beacon EP2 0356 701 KP2N-2 NLGI 2
5
Ballscrew bearing of - ESSO Beacon EP2 0356 701 KP2N-2 NLGI 2
unloading rake 5
Index, rotary connection - ESSO Beacon EP2 0356 701 KP2N-2 NLGI 2
5
CASTROL LZV-EP 0064 569
KHPL2
SHELL Alvania EP grease 2 0096 544
R
KP2K
Lifting chain - IWIS special chain lubricant SP 0348 947 - NLGI 00
6-Kombi superplus as a spray
Unloading rake chain - IWIS special chain lubricant SP 0348 947 - NLGI 00
6-Kombi superplus as a spray
Lift drive 8.2 l Aral Degol BG 680 0133 520 CLP VG 680
Swivel drive 3.1 l Aral Degol BG 680 0133 520 CLP VG 680
Drive, unloading rake 1.2 l Aral Degol BG 680 0133520 CLP VG 680
Lubricants Tab. 6-1

Note
Approved lubrication agents of the same quality from other man-
ufacturers can also be used.

3.2 Maintenance Instructions

Rotary connection to the suction frame

(see "Overview", pg. 6-5)

105749: Maintenance interval: 500 operating hours

Lubricate four-point bearing
(ISA)
Ø Use the grease gun to press grease into all grease nipples
until a crown of fresh grease forms on both sealing lips.

105750: Maintenance interval: 1000 operating hours

Grease gear rim
1. Remove cover plate on LiftMaster with connecting rod.
2. Grease gear rim with a brush.

6-6 Lubrication 2011-08-22 B484EN

 Linear guides on elevating part

(see "Overview", pg. 6-5)

105753: Maintenance interval: 1000 operating hours

Lubricate linear guide (INA)
Condition
■ Linear guides are at operating temperature.

LiftMaster Total quantity of Number of lubrica-

grease [cm³]/carriage tion cycles
--1225, --1530 7 2
--2040, --2540 11 3
Lubricating cycles for linear guide Tab. 6-2

1 grease nipples 2 2 Guide carriage

Fig. 38840

1. Lubricate the 4 grease nipples of the guide carriage with half

(LiftMaster --1225/--1530) or a third (LiftMaster --2040/--2540)
of the lubricating grease.
2. Perform a lowering and lifting motion with maximum distance.
3. Repeat the lubricating process twice (LiftMaster
--1225/--1530) or three times (LiftMaster --2040/--2540).

B484EN 2011-08-22 Lubrication 6-7

 Lifting chain

(see "Overview", pg. 6-5)

105751: Maintenance interval: 1000 operating hours

Clean lifting chain
1. Move swivel arm to the lowest position.
2. Clean lifting chain with a hard brush (do not use benzene or
kerosene).

105752: Maintenance interval: Annually

Replace the lubricant
container and the battery
Ø Replace the lubricant container (mat. no. 0375 516) and bat-
tery (mat. no. 0375 517):

1 Battery for lubricant container 2 Battery for lubricant container

Fig. 53411

6-8 Lubrication 2011-08-22 B484EN

 Index

(see "Overview", pg. 6-5)

105754: Maintenance interval: 1000 operating hours

Lubricating the index

Ø Grease index using grease gun until grease oozes out.

Unloading rake chain

(see "Overview", pg. 6-5)

105500: Maintenance interval: 1000 operating hours

Clean and lubricate the
chain
1. Clean chain with a hard brush (do not use benzene or kero-
sene).
2. Lubricate the chain.

Ballscrew bearing of unloading rake

(see "Overview", pg. 6-5)

105501: Maintenance interval: 2000 operating hours

Lubricating the ballscrew
bearings

1 grease nipples 3 Rake prongs

2 Guide carriage
Ballscrew bearing Fig. 38841

B484EN 2011-08-22 Lubrication 6-9

 Ø Using a grease gun, grease both guide carriages on the four
ballscrew bearings.
− Total quantity of grease / carriage: 2 cm³.
Number of lubrication cycles: 1.

Unloading rake gear motor

(see "Overview", pg. 6-5)

105503: Maintenance interval: Every 5 years

Changing the lubricant

1 Air bleeding and filler nozzle 2 Oil drain plug

Unloading rake gear motor Fig. 31791

1. Place container under the oil drain plug.

2. Open the bleed screw.
3. Drain waste oil via the oil drain plug.
4. Close oil drain plug.
5. Seal screw plug with Loctite 573.
6. Fill new oil through the air bleeding hole.
7. Close the bleed opening.
8. Seal screw plug with Loctite 573.

6-10 Lubrication 2011-08-22 B484EN

 Lift drive

(see "Overview", pg. 6-5)

105755: Maintenance interval: Every 5 years

Changing the lubricant

1 Air bleeding and filler nozzle 2 Oil drain plug

Lift drive gearbox Fig. 31790

1. Place container under the oil drain plug.

2. Open the bleed screw.
3. Drain waste oil via the oil drain plug.
4. Close oil drain plug.
5. Seal screw plug with Loctite 573.
6. Fill new oil through the air bleeding hole.
7. Close the bleed opening.
8. Seal screw plug with Loctite 573.

B484EN 2011-08-22 Lubrication 6-11

 105756: Maintenance interval: Every 5 years
Changing the lubricant

1 Air bleeding and filler nozzle 2 Oil drain plug

Swivel drive gearbox Fig. 31789

1. Place container under the oil drain plug.

2. Open the bleed screw.
3. Drain waste oil via the oil drain plug.
4. Close oil drain plug.
5. Seal screw plug with Loctite 573.
6. Fill new oil through the air bleeding hole.
7. Close the bleed opening.
8. Seal screw plug with Loctite 573.

6-12 Lubrication 2011-08-22 B484EN

 4. Mechanical elements

4.1 Overview

1 Unloading rake chain: check 3 Suction plate suction cups: 5 Pressure sensor, lifting force
chain tension every 500 operat- Check for wear every 160 oper- monitoring (only LiftMaster (RP)
ing hours ating hours --2040): replace battery every 2
2 Recirculating ball guides, 4 Index: check pins and pressure years
unloading rake: every 2000 roller every 500 operating hours 6 Lifting chain: check rollers and
operating hours pins every 500 operating hours
Mechanical maintenance points Fig. 31269

B484EN 2011-08-22 Mechanical elements 6-13

 4.2 Maintenance Instructions

Suction cups

(see "Overview", pg. 6-13)

105757: Maintenance interval: 160 operating hours

Check the rubber inserts

1. Check all rubber inserts for wear.

2. Replace suction plate if necessary.

Suction cup diameter Material number

210 mm 0352 225
160 mm 0352 946
80 mm 0352 963
Tab. 6-3

Index

(see "Overview", pg. 6-13)

: Maintenance interval: 500 operating hours

Check the pin and the
pressure roller
1. Swivel the swivel arm between two positions.
2. Actuate the corresponding valves manually to extend the pin.
3. Check clearance between roller and pin. Maximum permissi-
ble clearance: 0.3 mm.

1 Roller 2 Bolt
Index, top view Fig. 31794

6-14 Mechanical elements 2011-08-22 B484EN

 4. If the clearance exceeds 0.3 mm, replace the roller and pin.

Unloading rake chain

(see "Overview", pg. 6-13)

105491: Maintenance interval: 500 operating hours

Checking the chain tension

Ø Load lower chain strand with 10 N.

The top chain strand must be able to move 5 mm in each
direction:

Checking the chain tension Fig. 31795

B484EN 2011-08-22 Mechanical elements 6-15

 105492: Maintenance interval: As needed
Retighten the chain

1 Lock nut 2 Eccentric shaft

Retensioning the chain of the unloading rake Fig. 31796

1. Release the lock nut.

2. Rotate eccentric shaft until the specified chain tension has
been reached.
3. Replace the chain, if the specified chain tension can not be
attained.

6-16 Mechanical elements 2011-08-22 B484EN

 Lifting chain

(see "Overview", pg. 6-13)

105758: Maintenance interval: 500 operating hours

Check lifting chains for wear

1 Bolt 2 Link plate

Lifting chain on LiftMaster Fig. 38842

1. Move the swivel arm to the lowest position until the lifting
chain is slack:
− Position the wooden plank or similar under the swivel
arm.
− Move the swivel arm to the wooden plank until the "lifting
chain slack" switch triggers.
2. Check the lifting chain over its working range for the follow-
ing criteria:
− The chain pins must not be seized in the flange.
− The rollers must not have any radial play.
− The link plates may not be deformed.
− There must be no hairline cracks in the flanges.
− The lifting chain must be supple.
− There may be no frictional corrosion or pitting corrosion
on the lifting chain.
3. Replace the lift chain, if any one of these criteria is not fulfil-
led. Otherwise the chain could break.

105759: Maintenance interval: 1000 operating hours

Check the elongation of the
lifting chain
1. Move the swivel arm to the lowest position until the lifting
chain is taut.

B484EN 2011-08-22 Mechanical elements 6-17

 L Length "L" = measured length over "n" links
Number of measuring elements of lifting chain Fig. 31788
2. In the working range of the lifting chain, measure the length
"L" for "n" links from outer pin to outer pin.

LiftMaster Lifting Mat. no. Measured length L0 (length when new) L max
chain [number of links n]
--1225 16 B-3 0147 204 20 516 mm 531 mm
--1530
--2040 20 B-3 0147 609 16 518 mm 533 mm
--2540
Tab. 6-4

3. If L≥Lmax, have the chain replaced. Otherwise the chain could

break.
Note
In none of the individual links should the distance of outer
pin to outer pin exceed:
- 34.2 mm for 16 B-3.
- 42.6 mm for 20 B-3.

6-18 Mechanical elements 2011-08-22 B484EN

 5. Electrics

5.1 Overview

1 Brakes on lifting and swivel 2 Switch cabinet with air condi-

drive tioning door
Overview of maintenance work on electrical components Fig. 31267

5.2 Maintenance Instructions

Heat exchanger door on the switch cabinet

(see "Overview", pg. 6-19)

105484: Maintenance interval: As needed

Clean the fins of the heat
exchanger
1. Switch off the system.
2. Remove the front side (with vanes) from cooling device.
3. Pull out the plug from the display.
4. Clean front side vanes with compressed air.
5. Reassemble the chiller in reverse order.

B484EN 2011-08-22 Electrics 6-19

 Chiller on the air conditioning door Fig. 33609

105760: Maintenance interval: 1000 operating hours

Check the air gap of the
disc brake

A Air gap between the brake discs

Lift drive (see SEW manufacturer's documentation) Fig. 38402

1. Check the air gap A between the brake discs.

6-20 Electrics 2011-08-22 B484EN

 Drive LiftMaster Permissible air gap
Swivel drive All 0.25-0.6 mm
Lift drive --1225 0.25-0.6 mm
--1530
--2040 0.3-1.2 mm
--2540
Tab. 6-5

In general, the air gap will not exceed the permissible value.
2. If the air gap should however be bigger, determine the cause
of the excessive wear and remedy this.
3. Replace the brake discs.

B484EN 2011-08-22 Electrics 6-21

6-22 Electrics 2011-08-22 B484EN
Index
Double sheet check .......................4-29, 5-17
Double sheet detector .............................3-30

A
Abort ........................................................4-33
Acceleration .............................................4-21
E
Accessories .............................................1-18 EC Declaration of Conformity ...................1-3
Active .............................................4-35, 5-22 Emergency stop impact button ...............1-11
Active store movements ..........................4-25 Ended .............................................4-35, 5-22
Align sheet ...............................................4-24 EP ..................................................4-27, 5-11
All programs / NCU .......................4-32, 5-21 Evenness ...................................................2-8
Angle ........................................................4-20
Automation ...............................................4-15

F
B Find program .................................4-32, 5-20

BA ..................................................4-27, 5-11
Blocked ..........................................4-35, 5-22
Button ................................4-6–4-10, 5-7, 5-8 G
GritPlus user interface ...................4-26, 5-10

C
Calibrate ..................................................4-16 H
Cancel .........................4-29, 4-30, 5-17, 5-18
Help .........................................................4-15
CE marking ................................................1-3
Home position .........................................4-24
Check program ..............................4-32, 5-21
Cleaning ...................................................4-33
Close ........................................................4-24
Control panel
LiftMaster .......................................4-5, 5-6
I
Controls Incomplete ......................................4-35, 5-22
Entire system .................................4-4, 5-5 Individual suction cup ..............................4-24
Create ......................................................4-22 Individual suction cup coding .................4-20
Create sheet job ..................4-32, 5-20, 5-21 Installation conditions
Weight loading ......................................2-9
Intended use ..............................................1-6

D
Danger signs ...........................................1-13
Danger zone
L
Safeguarding device ...........................1-10 Language .................................................4-17
Data inconsistency .........................4-35, 5-22 Laser machine .........................................4-15
Date .........................................................4-17 Laser outside ...........................................4-23
Delete sheet job ............................4-34, 5-21 Liability disclaimer ...................................1-18
Deselect all ....................................4-30, 5-18 Lifting force monitoring ............................3-35
Diagnosis .................................................4-15 LiftMaster hooks ......................................4-23
Double-sheet check .................................4-24 LiftMaster rake .........................................4-23

B484EN 2011-08-22 Index 7-1

LiftMaster suction cup .............................4-23 Production ................................................4-15
List selection ............................................4-15 Production overview ................................4-15
Location ...................................................4-23 Production plan ....................4-15, 4-32, 5-21
Production plan status ...................4-28, 5-11
Prog. error ......................................4-35, 5-22
Program ...................................................4-15
M Program status ..............................4-27, 5-11
PT ...................................................4-27, 5-11
Machine location ............................4-27, 5-10
Maintenance
Electrical system .................................6-19
Lubrication .............................................6-5
Mechanical system ..............................6-13
Q
Maintenance & commissioning ...............4-15 Quantity ..........................................4-27, 5-11
Manual handling ............................4-15, 4-24
Manual operation .............................4-11, 5-9
Manual transport .....................................4-23
Max. stack height ....................................4-21 R
Maxi part separation ...............................4-24
Measuring system ...................................4-17 Raw sheet ...............................................4-23
Mode, automatic ..............................4-11, 5-9 Ready .............................................4-35, 5-22
Modify ......................................................4-23 Removal test ...........................................4-21
Modify/info sheet job .....................4-34, 5-21 Res.Err. ..........................................4-35, 5-22
Modules ...................................................3-18 Reserve ..........................................4-21, 4-22
MPH ...............................................4-27, 5-11 Residual risks ..........................................1-20
MPR ...............................................4-27, 5-11 Reverse selection ..........................4-30, 5-18
Rotation ...................................................4-21
Rotation circle radius ..............................4-20
Rotoscanner ............................................3-31
N
NCP ................................................4-27, 5-11
No ...................................................4-27, 5-10 S
No file .............................................4-35, 5-22
No material ....................................4-35, 5-22 Safety light barrier ...................................1-11
No removal ....................................4-35, 5-22 Scrap skeleton .........................................4-23
Notes ..............................................4-35, 5-22 Select all ........................................4-30, 5-18
Select program ..............................4-32, 5-20
Select stock .............................................4-34
Semiautomatic cycle ........................4-11, 5-9
O Set status ...................4-34, 4-35, 5-21, 5-22
Sheet alignment ...................3-31, 4-29, 5-17
Open TRUMPF Operating System (TOS) .... Sheet thickness measuring device .........3-29
4-17 Single pallet mode ...........................4-11, 5-9
Software ...................................................1-18
SP .........................................3-33, 4-27, 5-11
Spare parts ..............................................1-18
P Speed ......................................................4-22
SPh .......................................3-33, 4-27, 5-11
Pallets
SPm ......................................3-33, 4-27, 5-11
Machine pallets ...................................3-33
SPr ........................................3-33, 4-27, 5-11
System pallets .....................................3-33
Stack no. .................................................4-21
Peeler cup ............................3-27, 4-29, 5-17
Stock .....................................4-15, 4-22, 4-23
Peeling ..................................4-24, 4-29, 5-17
Stock ID .........................................4-27, 5-11
Perform loading .............................4-29, 5-17
Stock type ......................................4-27, 5-11
Pos. suction cup slat 1...4 ......................4-20
Storage pallets ........................................4-33

7-2 Index 2011-08-22 B484EN

Suction cup arrangement of
LiftMaster --1225 .................................3-21
LiftMaster --1530 .................................3-20
LiftMaster --2040 .................................3-21 V
LiftMaster --2540 .................................3-22
LiftMaster Sort --1530 (24 suction cups) ... VP ..................................................4-27, 5-11
3-23
LiftMaster Sort --1530 (36 suction cups) ...
3-24
LiftMaster Sort --2040 (36 suction cups) ...
W
3-25 Water protection ......................................1-17
LiftMaster Sort --2040 (51 suction cups) ... Weight loading ...........................................2-9
3-26
Suction cup groups .................................4-24
Suction cup slat .......................................4-20
Suction cups ............................................4-24 X
Switch over suction cup ................4-30, 5-18
Switching TruTops FMC panel on and off .... X offset (target) .......................................4-21
4-16 X position .................................................4-20
Swivel ......................................................4-24

Y
T Y offset (target) .......................................4-21
Target location .........................................4-23 Y position .................................................4-20
Target selection .......................................4-21
Technical data .........................................3-15
LiftMaster --1225/--2540 ......................3-17
LiftMaster --1530 .................................3-15
LiftMaster --2040 .................................3-16
Technology correction .............................4-18
Thin sheets, separating ...........................3-28
Time .........................................................4-17
Touchscreen
Calibrate ..............................................4-16
Transport .................................................4-24
Transport completed ...............................4-25
Transport mode .......................................4-20
Transport to the installation site .............2-16
Transport type .........................................4-24

U
Unloading mode ......................................4-21
Unprocessed material ....................4-33, 4-34
User interface
Login status .........................................4-14
Main activities ......................................4-15
Message line .......................................4-13

B484EN 2011-08-22 Index 7-3

7-4 Index 2011-08-22 B484EN