Operator's Manual 11-17-17 PDF

Operator's manual
TruLaser Cell 8030 (L60)

Operator's manual
Original operator's manual

Edition 2017-11-17
Order Information Please specify when ordering this document:
Operator's manual
Edition 2017-11-17
Document number B836en
TRUMPF GmbH + Co. KG

Address for orders Technische Redaktion
Johann-Maus-Straße 2
D-71254 Ditzingen
Fon: +49 7156 303 - 0
Internet: http://www.trumpf.com
E-Mail: docu.tw@de.trumpf.com
For "partly completed machinery" in accordance with the EC

Machinery Directive, this document corresponds to the
assembly instructions.
© TRUMPF GmbH + Co. KG

Before you proceed ...
This operator's manual documents the laser processing machine
TruLaser Cell 8030 (L60), machine serial release S04. The beam
source is a laser device TruDisk.
The operator's manual is intended not only for the user (owner)
and the operator of the machine, but also for the maintenance
personnel. It should be made accessible to all of these people.
The machine documentation ■ TruLaser Cell 8030 Operator's manual

includes the following ■ Supplements to operator's manual: Configurable control inter-
documents: face KSS (option)
■ Supplements to operator's manual: Automation interface
(option)
■ "TruTops Cell Basic" manual (option)
■ Programming manual for the TruLaser Cell 8030
■ Data collection for the TruLaser Cell 8030
■ Electronic spare parts catalog for TruLaser Cell 8030
■ Schematics set for the TruLaser Cell 8030 with fluid plans
■ Documentation for Laser TruDisk from TRUMPF Laser
Schramberg:
− Operator's manual for the TruDisk
− Spare parts catalogue for the TruDisk
− Manual for TruControl 1000
− Circuitry documents and interface description
■ Supplier documents (electronic on DocOnCD_MA836):
− Compact dust extractor (Herding)
− Scrap conveyor (Kabelschlepp)
− Sick laser scanner
− Safety light curtain from Sick
Indication of hazards
The entire machine documentation contains important safety
information on the prevention of injuries and potential hazards to
life and health. Such information is marked by warning symbols.
Read the Safety chapter.
Online help The online help of the operator's manual on the machine's user
interface is an excerpt from the operator's manual.
B836en 2017-11-17 Before you proceed ... I

II Before you proceed ... 2017-11-17 B836en
Table of contents
Chapter 1 Safety
Delivery variants 1‐4
1 For your safety 1‐5
2 Terms 1‐7
3 Operational safety 1‐8

3.1 Intended use 1‐8
3.2 Authorized personnel 1‐9
4 Hazards 1‐10
4.1 Overview of laser classes 1‐10
Laser classes of the machine 1‐11
Laser classes of laser device and compo- 1‐11
nents
4.2 Hazards due to laser radiation 1‐11
4.3 Fire hazard 1‐13
Extinguishing the fire in the compact dust 1‐14
extractor (Herding) without fire extinguisher
extractor (Herding) with the CO2 fire extin-
guisher
extractor (Herding) with the argon fire extin-
guisher
Machining highly reactive materials 1‐17
Machining heavily oiled workpieces 1‐18
4.4 Dangers from magnetic fields 1‐19
Magnetic coupling of the processing optics 1‐19
4.5 Dangers due to the open electrical cabinet 1‐20
4.6 Dangers due to live parts 1‐21
4.7 Danger from handling hot components 1‐22
4.8 Dangers due to configured movement sequen- 1‐22
ces
4.9 Dangers when handling clamping fixtures 1‐23
B836en 2017-11-17 Table of contents 0‐1

4.10 Dangers due to quickly-rotating rotational 1‐24
changer
4.11 Dangers due to quickly turning rotary indexing 1‐25
table (option)
4.12 Hazard risks due to the scrap conveyor 1‐26
4.13 Dangers due to a suspended axis 1‐26
4.14 Danger while teaching 1‐27
4.15 Dangers in the work area due to a bright 1‐27
source of light.
4.16 Dangers of slipping, tripping or falling 1‐27
4.17 Dangers handling workpieces 1‐28
Sharp-edged workpieces 1‐28
Hot workpieces 1‐28
Suspended loads when setting up workpie- 1‐28
ces
4.18 Hazards due to collisions in the work area 1‐29
4.19 Dangers when working with the 1‐29
Smart Optics Setup station
4.20 Hazards due to escaping coolant or cooling 1‐30
water
4.21 The risks of no switch cabinet cooling 1‐30
4.22 Dangers due to Teleservice 1‐31
4.23 Dangers when using the MobilelControl app 1‐31
4.24 Hazardous materials 1‐32
Dusts, exhaust air 1‐32
Hazardous materials due to cutting oils 1‐33
Hazardous substances derived from poly- 1‐33
ethylene films
5 Measures to be taken by the manufacturer 1‐34

5.1 Danger zones and safeguarding device 1‐34
5.2 Warning signs at the machine 1‐44
6 Organizational measures to be taken by the 1‐48

user
6.1 Observe warnings and warning signs 1‐48
6.2 Training and instructing operators 1‐48
Measures applicable worldwide 1‐48
Protection against radiation: information for 1‐49
Germany
Protection against radiation: additional 1‐50
measures for the USA
6.3 Duty of care when handling the machine 1‐50
6.4 Pay attention to water protection 1‐52
0‐2 Table of contents 2017-11-17 B836en

6.5 Observe the fire safety rules 1‐53
6.6 Using spare parts, accessories, software and 1‐53
operating materials
6.7 Safety data sheet on hazardous materials 1‐54
7 Overview of residual risks 1‐55
8 Machines without complete safety equip- 1‐59

ment
8.1 Operating safety 1‐59
8.2 Suction system in the work area 1‐60
8.3 Laser safety 1‐61
8.4 Secondary radiation 1‐61
8.5 Overview of residual risks 1‐62
9 Disassembly and disposal 1‐67
Chapter 2 Installation conditions TruLaser Cell

8030 (L60)
To what does this apply? 2‐4
1 Planning aid 2‐5
2 Installation site 2‐9

2.1 Space requirements 2‐9
2.2 Floor requirements 2‐9
2.3 Weight load 2‐11
2.4 Ambient conditions 2‐12
2.5 Installation of compact dust extractor 2‐15
2.7 Installation of the process cooler 2‐17
External cooling circuit 2‐18
2.8 Cable racks for laser light cables 2‐24
2.9 Customer screen options 2‐25
Installing the monitor 2‐27
3 Gas supply 2‐28

3.1 Cutting gases 2‐29

Purity 2‐29
Cutting gas consumption 2‐29
Supply lines for cutting gas supply 2‐30
Requirements on the connection point of 2‐31
the machine
Cutting gas supply with cylinders or bundles 2‐31
Cutting gas supply with gas tank 2‐32
4 Electric power supply 2‐34

4.1 Electrical connection 2‐34
4.2 Power supply 2‐36
4.3 Connected load and fuse protection 2‐37
Central power supply 2‐37
Decentralized power supply 2‐38
4.4 Teleservice 2‐42
4.5 Network connection 2‐42
5 Compressed air supply 2‐43
6 Operating materials 2‐46

6.1 Gases 2‐46
6.2 Cooling water 2‐46
6.3 Dispensing material for MultiCoater 2‐49
7 Transport 2‐50
7.1 Dimensions and weights of the transport units 2‐52
7.2 Transporting machine and machine compo- 2‐56
nents
Transporting basic machine with truck 2‐57
Loading and unloading container 2‐59
Transporting the basic machine to the 2‐60
installation site
Transport TruDisk laser device 2‐61
Transport rotational changer with a crane or 2‐62
forklift
Transporting rotary indexing table with 2‐63
crane or forklift truck
Transporting the safety cabin 2‐64
Transportation of scrap conveyor 2‐65
Transporting the compact dust extractor 2‐65
(Herding)
Transporting process cooler 2‐66

7.3 Installing the system 2‐66
Preparing the factory floor 2‐66
Chapter 3 Description
1 Machine concept 3‐3
2 Coordinate system and working range 3‐4

2.1 Coordinate system 3‐4
2.2 Working range 3‐6
3 Machine components 3‐8

3.1 Sub-assemblies of the basic machine 3‐10
Machine body 3‐11
Motion unit 3‐11
Hydroforming package (option) 3‐11
Beam guidance 3‐12
Dynamic cutting optics 3‐13
3.2 Laser protection device 3‐19
3.3 Exhaust system and filtering installation 3‐21
3.4 Workpiece changer 3‐25
3.5 Clamping fixture 3‐29
Clamping fixture for hot-formed parts 3‐34
Clamping fixture for inner high-pressure 3‐37
(IHU) formed workpieces
3.6 Solid-state lasers 3‐43
4 Technical data 3‐45
Chapter 4 Operation
1 Description of the controls and indicators 4‐8

1.1 The machine's main switch 4‐11
1.2 Control panel 4‐14

1.3 MobileControl 4‐19
Installing the MobileControl app 4‐22
Activate MobileControl at the machine. 4‐23
Switching between control and observation 4‐27
mode
Exiting MobileControl 4‐28
1.4 Access Control Key System user management 4‐29
1.5 Decentral control panel 4‐34
1.6 Status indicators 4‐37
1.7 Scrap conveyor 4‐38
1.8 Compact dust extractor 4‐40
1.9 Acknowledge the danger zone 4‐41
1.10 Mechanically lock the door 4‐42
2 Operating modes of the machine 4‐43
3 Operating the machine 4‐44

3.1 Entering the work area 4‐45
3.2 Switching the machine on and off 4‐46
Switching on the machine 4‐46
Switching off the machine 4‐48
3.3 Shutting down the machine in the event of a 4‐50
malfunction/emergency
Tripping the EMERGENCY STOP 4‐50
Cancelling the EMERGENCY STOP 4‐50
Trip the extinguisher with a manual alarm 4‐50
3.4 Check safety functionality 4‐52
Manually start the safety test 4‐53
Issue user consent 4‐54
3.5 Eliminate malfunction 4‐55
Triggering FEED HOLD 4‐55
Acknowledging FEED HOLD after opening 4‐55
the door
Acknowledging FEED HOLD after a colli- 4‐55
sion involving the nozzle
Restarting processing after knocking off the 4‐56
processing optics
3.6 Operating the workpiece changer 4‐57
Manual functions 4‐59
Rotating workpiece changer in setup mode 4‐59
RSTAcknowledge the loading operation in 4‐60
automatic mode

RW: Acknowledge the loading operation in 4‐60
automatic mode
Acknowledging malfunction 4‐61
Acknowledging clamping error 4‐61
3.7 Operate scrap conveyor 4‐62
Starting the conveyor belt 4‐63
Stopping the conveyor belt 4‐63
Starting the conveyor belt in reverse mode 4‐64
Eliminate malfunction 4‐64
4 Description of the user interface 4‐65
5 System settings 4‐71

5.1 Setting data and time 4‐71
5.2 Selecting language and measuring system 4‐71
5.3 Activate the on-screen keyboard 4‐72
5.4 Open TRUMPF Operating System (TOS) 4‐73
5.5 Close user interface 4‐73
5.6 Switching to the TruControl interface 4‐74
6 User administration 4‐75

6.1 Log on user group 4‐76
6.2 Change password 4‐77
6.3 Deleting the password 4‐77
7 Production plan 4‐78

7.1 Creating and editing a production plan 4‐81
Creating a new production plan 4‐82
Editing job data 4‐84
Disable job 4‐84
Delete the order in the production plan 4‐84
Delete programs and orders 4‐85
Deleting a production plan 4‐85
7.2 Production with the production plan 4‐86
Starting a production plan (manual loading) 4‐87
Starting a production plan (automatic load- 4‐89
ing)
Changing the program sequence 4‐90
Modifying the number of program runs 4‐91
Stopping the production plan with "Stop 4‐92
after cycle end"

Starting to run empty, ending the production 4‐93
plan
7.3 Exporting order 4‐93
7.4 Starting step-by-step cycle 4‐94
7.5 Loading and workpiece status 4‐94
Displaying the loading and workpiece status 4‐96
Changing the loading and workpiece status 4‐98
Acknowledging workpiece status with man- 4‐99
ual loading
Acknowledging the workpiece status with 4‐99
automatic loading
7.6 Remaining time display 4‐101
Configuring the remaining time display 4‐105
8 Production 4‐115
8.1 Current program 4‐115
Start program 4‐115
Pause program 4‐116
Aborting a program 4‐116
Switch screen view 4‐116
Display Switching over the axis positions 4‐117
Display NC simulation 4‐117
8.2 Preparing programs 4‐118
Import master file 4‐118
Prepare program 4‐119
8.3 Manual functions 4‐120
Call manual functions 4‐122
Activating marking test mode 4‐123
Activating STOP after single contour 4‐124
Display the workpiece counter 4‐124
Resetting the workpiece counter 4‐124
8.4 Utility tools 4‐125
Starting utility programs 4‐125
9 Setup 4‐126
9.1 Moving the axes manually 4‐126
Moving the axis continuously 4‐126
Moving the axis incrementally 4‐126
Requesting the laser in the laser network 4‐131
Enabling the laser in the laser network 4‐131

Enabling the dynamic distance control sys- 4‐132
tem
Deactivating the dynamic distance control 4‐132
system
Positioning the additional axis 4‐133
Activating distance regulation 4‐133
ControlLineRecord characteristic curve 4‐134
Switching the kinematic transformation on 4‐134
or off
Park axes 4‐135
Displaying and resetting workpiece counter 4‐135
Running a warm start 4‐136
Focal position without FocusLine setting 4‐136
9.3 MDA 4‐138
Execute the NC blocks in the following 4‐138
block
Execute the NC blocks in a single block 4‐138
9.4 Configuration 4‐139
Configure loading and unloading place 4‐141
10 Programming 4‐144
10.1 Program management 4‐144
Selecting program 4‐146
Creating a new program 4‐146
Copying a program 4‐147
Editing a program in the text editor 4‐147
Create subroutine 4‐148
Number program 4‐150
Exporting program 4‐150
Importing program 4‐151
Delete program 4‐151
Show setup plan 4‐152
Show PDF file 4‐152
10.2 Creating and managing subroutine macros 4‐153
Creating a subroutine macro 4‐154
Processing a subroutine macro 4‐155
Deleting the subroutine macro 4‐156
Inserting the Subroutine macro 4‐156
10.3 Transformation 4‐159
Applying the actual position as the zero 4‐161
point

Moving zero point incrementally 4‐162
Select Frame and fill transformation accu- 4‐162
mulator
Deleting transformation accumulator 4‐163
10.4 Operate KSS 4‐163
Start KSS configuration 4‐163
Activate module and load module data 4‐164
Deactivating the module 4‐164
10.5 Programming system 4‐165
Starting TruTops Cell Basic 4‐165
Call up advanced shop floor programming 4‐165
11 Technology 4‐166
11.1 Laser cutting 4‐167
Selecting the setting for the "Table" selec- 4‐168
tion field
Creating a cutting table 4‐168
Edit the cutting table 4‐169
11.2 Ramp cycles 4‐170
Programming ramp cycles 4‐170
11.3 Managing the tooling status 4‐171
Activate setup state 4‐172
Creating a new setup state 4‐173
Editing the tooling level 4‐174
Deleting a setup state 4‐175
12 Maintenance 4‐177
12.2 Partial backup 4‐177
Backing up data 4‐177
12.3 File manager 4‐178
Edit and save file 4‐179
13 Diagnostics 4‐180
13.1 Displaying all messages 4‐180
13.3 Displaying the software version 4‐181
13.4 Display I/O monitor 4‐181
13.5 Logging the process data for service purposes 4‐182
13.6 Starting Teleservice 4‐182
13.7 Visual Online Support (VOS) 4‐184

Starting Visual Online Support 4‐185
14 Help 4‐189
14.1 Starting online help 4‐190
14.2 Editing bookmarks 4‐190
14.3 Starting context-sensitive help 4‐191
15 Teachen 4‐192
15.1 Teach panel 4‐194
15.2 Description of the user interface 4‐201
15.3 Activating TEACHIN operating mode 4‐203
15.5 Setting basic functions 4‐204
Automatically replacing the zero point 4‐204
Activate the imperial (inch) measuring sys- 4‐205
tem
Activate and set the NC axes 4‐205
Setting threshold values for determination of 4‐206
the geometry deviation
Configure the function for F1 and F2 but- 4‐208
tons
Configure the cycle selection for the F1 key 4‐209
Delete the configuration for the F1 key 4‐210
15.6 Recording teach points 4‐211
Teaching a straight line 4‐211
Teaching the arc with CIP 4‐212
Teaching the macro center 4‐213
Teaching macro help point 4‐213
Teaching circular contour 4‐214
Teaching a rectangle contour (square) 4‐215
Teaching oblong hole 4‐217
15.7 Creating new program 4‐219
Setting the zero point 4‐220
Approach edge incrementally. 4‐220
Incorporating the contour 4‐223
15.8 Editing a program 4‐224
Searching and replacing NC text 4‐225
Insert and process cycles 4‐225
Select value for the name variable laser 4‐226
technology table.
Selecting the laser technology table 4‐227

Inserting block numbering 4‐227
15.9 Testing and correcting the program 4‐227
Correcting the zero point 4‐228
Inserting H word 4‐228
Correct path 4‐229
Testing the program 4‐230
Chapter 5 Setting work
Safety notes 5‐3
1 Overview of setting work 5‐4

1.1 Overview of cutting process setting work 5‐4
2 Tooling the processing optics 5‐6

2.1 Removing the processing optics 5‐6
2.2 Installing processing optics 5‐7
3 Checking the C and B axes and referencing 5‐10

manually
3.1 Checking the B and C axes 5‐10
3.2 Referencing the C and B axes manually 5‐13
4 Test sheet holder 5‐14
5 Smart Optics Setup 5‐17

5.1 Swiveling the test sheet holder into the setup 5‐22
position and mounting a test sheet
5.2 Swiveling the test sheet holder into the parking 5‐23
position
5.3 Approaching the start or reference position 5‐24
5.4 Resetting the reference position 5‐25
6 Wizard 5‐27
6.1 Test sheet holder: Starting the utility program 5‐29
6.2 Smart Optics Setup station: Starting the utility 5‐31
program
6.3 Defining new reference optics 5‐33

7 Cutting process setting work 5‐34
7.1 Centering the beam 5‐34
Mounting the protective cover 5‐36
Installing the setting device 5‐37
Dismantling the setting device 5‐38
Centering nozzle to beam 5‐38
7.2 Determining and setting the focal position 5‐41
Start focus search 5‐42
7.3 Calibrate the B and C axes 5‐46
7.4 Determining the joint offset 5‐50
Determining the Z-axis joint offset 5‐51
Determining X axis and Y axis joint offset 5‐53
8 Calibrating the measuring equipment 5‐57

8.1 Mounting and activating the sensor 5‐59
8.2 Calibrating the sensor 5‐60
9 Setting up the clamping fixture 5‐63

9.1 Starting the utility program 5‐66
9.2 Checking the measuring sequence (option) 5‐68
9.3 Entering the required position 5‐69
9.4 Measuring the required position 5‐71
9.5 Measuring the actual position 5‐72
9.6 Determining the correction frame 5‐74
Chapter 6 Machine maintenance
1 General guidelines 6‐5
2 Maintenance Overview 6‐6
3 Safety device 6‐10

3.1 Overview 6‐10
3.2 Maintenance Instructions 6‐12
Light grid 6‐12
Laser scanner 6‐13

4 Laser protection device 6‐16
4.1 Overview 6‐16
Safety cabin 6‐18
5 Lubrication 6‐24
5.1 Overview 6‐24
X axis drive 6‐25
Y axis drive 6‐31
Z axis drive 6‐37
Device panel: Low-viscosity grease reser- 6‐44
voir central lubrication
6 Mechanical elements 6‐46

6.1 Overview 6‐46
Machine and workspace 6‐47
Magnetic coupling 6‐56
Smart Optics Setup station 6‐58
Z barrel 6‐60
7 Pneumatic system 6‐61

7.1 Overview 6‐61
Device panel: Maintenance unit basic 6‐62
machine
Device panel: Maintenance unit cutting gas 6‐64
air (option)
Device panel: service unit for expanded 6‐65
compressed air supply or vacuum ejectors
(option)
Device panel: Condensation collection tank 6‐66
Cutting optics: disposable filter, pneumatic 6‐67
connection
8 Gas 6‐68
Cutting optics: disposable filter, gas connec- 6‐68
tion

9 Water 6‐69
9.1 Overview 6‐69
Cooling circuit of the machine 6‐72
Machine cooler (option), water/air chiller 6‐74
Machine cooler (option), water/water chiller 6‐81
10 Optics 6‐86
10.1 Overview 6‐86
Cutting optics with a focal length of 150 mm 6‐88
Angular gear: FocusLine mirror 6‐114
11 Electrics 6‐118
Switch cabinet: Battery/fan unit, NC CPU 6‐118
Switch cabinet: Industrial PC 6‐119
Switch cabinet: Air conditioning unit 6‐120
12 Compact dust extractor 6‐122

Compact dust extractor: dust container/fine 6‐123
dust bag
Compact dust extractor: spark arrester 6‐127
Compact dust extractor: clean gas space 6‐128
Compact dust extractor: MultiCoater 6‐130
13 Scrap conveyor 6‐133

Scrap conveyor: Sensors 6‐133
Scrap conveyor: pedestal bearing 6‐134
Scrap conveyor: lubricant container 6‐135
Scrap conveyor: conveyor belt 6‐136
Scrap conveyor: housing bottom 6‐137
14 Clamping fixture 6‐140


Clamping fixture for IHU workpieces 6‐141
15 TruDisk 6‐144
TruDisk cooling circuit 6‐145
16 Process cooler for TruDisk (chiller) 6‐146

Process cooler: chiller (water-air) 6‐147
Chapter 7 Noise level test certificate
1 Test report 7‐3
2 Measurement result 7‐4
3 Measuring point arrangement 7‐5
Chapter 8 Index

Chapter 1
Safety
Delivery variants 1‐4
1 For your safety 1‐5
2 Terms 1‐7
3 Operational safety 1‐8

3.1 Intended use 1‐8
3.2 Authorized personnel 1‐9
4 Hazards 1‐10
4.1 Overview of laser classes 1‐10
Laser classes of the machine 1‐11
Laser classes of laser device and compo- 1‐11
nents
4.2 Hazards due to laser radiation 1‐11
4.3 Fire hazard 1‐13
B836en 2017-11-17 Safety 1‐1

extractor (Herding) with the CO2 fire extin-
guisher
extractor (Herding) with the argon fire extin-
guisher
Machining highly reactive materials 1‐17
Machining heavily oiled workpieces 1‐18
4.4 Dangers from magnetic fields 1‐19
Magnetic coupling of the processing optics 1‐19
4.5 Dangers due to the open electrical cabinet 1‐20
4.6 Dangers due to live parts 1‐21
4.7 Danger from handling hot components 1‐22
4.8 Dangers due to configured movement sequen- 1‐22
ces
4.9 Dangers when handling clamping fixtures 1‐23
4.10 Dangers due to quickly-rotating rotational 1‐24
changer
4.11 Dangers due to quickly turning rotary indexing 1‐25
table (option)
4.12 Hazard risks due to the scrap conveyor 1‐26
4.13 Dangers due to a suspended axis 1‐26
4.14 Danger while teaching 1‐27
4.15 Dangers in the work area due to a bright 1‐27
source of light.
4.16 Dangers of slipping, tripping or falling 1‐27
4.17 Dangers handling workpieces 1‐28
Sharp-edged workpieces 1‐28
Hot workpieces 1‐28
Suspended loads when setting up workpie- 1‐28
ces
4.18 Hazards due to collisions in the work area 1‐29
4.19 Dangers when working with the 1‐29
4.20 Hazards due to escaping coolant or cooling 1‐30
water
4.21 The risks of no switch cabinet cooling 1‐30
4.22 Dangers due to Teleservice 1‐31
4.23 Dangers when using the MobilelControl app 1‐31
4.24 Hazardous materials 1‐32
Dusts, exhaust air 1‐32
Hazardous materials due to cutting oils 1‐33
Hazardous substances derived from poly- 1‐33
ethylene films
1‐2 Safety 2017-11-17 B836en

5 Measures to be taken by the manufacturer 1‐34
5.1 Danger zones and safeguarding device 1‐34
5.2 Warning signs at the machine 1‐44
6 Organizational measures to be taken by the 1‐48

user
6.1 Observe warnings and warning signs 1‐48
6.2 Training and instructing operators 1‐48
Measures applicable worldwide 1‐48
Protection against radiation: information for 1‐49
Germany
Protection against radiation: additional 1‐50
6.3 Duty of care when handling the machine 1‐50
6.4 Pay attention to water protection 1‐52
6.5 Observe the fire safety rules 1‐53
6.6 Using spare parts, accessories, software and 1‐53
operating materials
6.7 Safety data sheet on hazardous materials 1‐54
7 Overview of residual risks 1‐55
8 Machines without complete safety equip- 1‐59

ment
8.1 Operating safety 1‐59
8.3 Laser safety 1‐61
8.4 Secondary radiation 1‐61
8.5 Overview of residual risks 1‐62
9 Disassembly and disposal 1‐67
B836en 2017-11-17 Safety 1‐3

Delivery variants
The TruLaser Cell 8030 is a laser processing machine for laser
cutting. It corresponds to the current state of technology and is –
when supplied as a complete machine – operationally safe.
The machine can be supplied with different kinds of safety equip-

ment:
■ As fully secured complete machine in compliance with all
requirements contained in the EC Machinery Directive. These
machines are supplied with both CE marking and EU Decla-
ration of Conformity. Sections 1 to 7 of this chapter apply to
such machines in their entirety.
or
■ As basic machine without complete safety equipment. These
machines do not comply with all requirements contained in
the EC Machinery Directive and are delivered with the EU
declaration of incorporation. Section 8 of this chapter also
applies to these machines. Sections 1 to 7 apply condition-
ally depending on the safety equipment which is absent in
each case.
If the machine is delivered without complete safety equipment,

the user must implement measures for the operational safety of
the system in accordance with the legal regulations of the coun-
try of operation. Without complete safety equipment means:
■ Without safety cabin.
■ Without compact dust extractor (filtering installation).
■ Without safeguarding device for the danger zone inside or
outside of the machine.
1‐4 Safety 2017-11-17 B836en

1. For your safety
Regulations and guidelines With the CE marking and the EU Declaration of Conformity,
TRUMPF confirms that the machine meets the basic health and
safety requirements of the EC Machinery Directive.
This TRUMPF machine was registered and certified for North
America by the US Food and Drug Administration (FDA), Center
for Devices and Radiological Health (CDRH), as per the Federal
Performance Standard Title 21 Chapter 1 Section 1040.
The CE marking is located on the nameplate of the machine.
The EU Declaration of Conformity is delivered along with the
machine.
Chapter Safety This chapter describes the safety concept. The chapter describes
how potential dangers can be avoided. The overview of residual
risks contains measures to be taken by the operator in order to
reduce the residual risks.
Note
The operator must adhere to the valid safety and accident pre-
vention regulations of the respective country and the safety laws
of the state and of the region!
Warnings and warning signs Certain operations can be a source of danger during operation.
The documentation contains warnings before the instructions for
these activities. There are warning plates on the machine.
A warning contains signaling words that have been explained in

the following table:
Signaling word Description

DANGER ... refers to great dangers. If not avoided, it can result
in death and serious injuries.
WARNING ... refers to a dangerous situation. It could lead to seri-
ous injuries, if it is not avoided.
CAUTION ... indicates a potentially dangerous situation. It could
lead to injuries, if it is not avoided.
NOTICE If such a situation is not observed, it can lead to dam-
age to property.
Tab. 1-1
B836en 2017-11-17 For your safety 1‐5

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.
1‐6 For your safety 2017-11-17 B836en

2. Terms
Term Meaning
Laser Device for generating laser radiation. Lasers consist of a resonator that comprises a
laser active medium and a partially reflective and translucent mirror.
Laser device Laser plus components for operating the laser such as control technology, energy sup-
ply, cooling system, gas system etc.
Laser system Machine, to which a laser device is connected or should be connected later. The
terms machine and laser system are used as synonyms in this document.
Laser network A laser network is comprised of several processing systems which are connected to a
laser device via laser light cable. The processing systems can use the laser radiation
in alteration.
Processing optics Processing optics is a generic term. It can mean either a laser cutting head, a laser
welding head or a combination head depending on the machine.
Terms Tab. 1-2
B836en 2017-11-17 Terms 1‐7

3. Operational safety
The machine can become a source of danger if it is used inap-

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

■ Notice: Use of controls or adjustments or performance of pro-
cedures other than those specified herein may result in haz-
ardous radiation exposure.
3.1 Intended use
Machine The user may use the machine only in the industrial sector.
The installation, operating and transport conditions prescribed by
TRUMPF must be adhered to and the maintenance work must
be performed. The installation and operation must comply with
the relevant national regulations that are valid in the country of
operation. The user must adhere to the national regulations.
The laser device may be operated, only if all protective and
safety devices are in place and working.
In case of malfunctions, the laser device must be switched off
immediately and prevented from being switched on again.
The user may laser cut three-dimensional workpieces with the
machine. Only metallic materials may be processed with the
machine.
The following is not allowed:

■ Unauthorized alteration or conversion of the machine by the
user or personnel.
■ Operating the machine with a laser device that TRUMPF has
not supplied with this machine, without consulting TRUMPF.
■ Any working procedure that impairs the safety.
− For example, processing with laser beam on but no work-
piece.
− For example, the safety cabin or other laser protection
devices being permanently exposed to laser energy.
■ Laser cutting
− of plastics.
− of wood.
1‐8 Operational safety 2017-11-17 B836en

− of sheets layered with PVC foil.
− of magnesium.
Laser protection device The machine's laser protection devices, for example the window
of the safety cabin, are designed for the wavelength and the
power of the laser device delivered with the machine.
If a laser device is connected with a different wavelength or
power, of if the machine was supplied without a laser, then the
user is obliged to check the effectiveness and suitability of the
existing laser protection devices. The user is responsible for safe
operation.
Laser network If a product from a different manufacturer is connected to a

TRUMPF laser device or if a TRUMPF product is connected to
the laser device of a different manufacturer, then the user is
responsible for the safe operation of the laser network.
A machine without its own chiller (optional machine cooling unit)
may not be connected to a laser network. The integration in a
laser network is only allowed if the machine is retrofitted with a
machine cooling unit in consultation with TRUMPF.
When the machine and the laser device are powered by a
shared electrical connection (optional central power supply instal-
lation possibility), the machine must not be connected to a laser
network.
Exemption from liability Any other form of use is considered unauthorized use. TRUMPF
is not liable for any damage, especially personnel injuries and
production failures resulting from this. The risk is borne solely by
the operator. The warranty will be voided.
3.2 Authorized personnel
■ Operation, setting and maintenance work may only be

carried out by authorized, trained and instructed personnel.
■ Qualified personnel may:
− Transporting the machine to the installation site.
− Carry out work at the laser-specific, pneumatic and elec-
trical modules.
− Carry out setting work and work in teach mode.
− Disassembling the machine.
B836en 2017-11-17 Operational safety 1‐9

4. Hazards
4.1 Overview of laser classes
Laser systems are classified into laser classes as per the Euro-
pean Standard EN 60825-1 (USA: ANSI Z136.1, ANSI B11.21).
The laser class corresponds to the hazard level of the laser light
emitted.
class Description
1 The accessible laser radiation is not dangerous under sensibly predictable
conditions.
2M The accessible laser radiation lies in the visible spectral range of 400 nm
to 700 nm. It is not dangerous for eyes in the case of short exposure time
(up to 0.25 s) as long as the beam is not observed through optical instru-
ments (magnifying glass, lens, telescope). Additional radiation parts
outside the wavelength spectrum of 400-700 nm fulfill the conditions of
class 1M.
2 The accessible laser radiation lies in the visible spectral range (400 nm to
700 nm). It is not dangerous for the eyes when the exposure time is lim-
ited (up to 0.25 s). Additional radiation parts outside the wavelength spec-
trum of 400-700 nm fulfill the conditions of class 1.
Eyes are normally protected from the laser light by turning away and clos-
ing the eyelids.
3R The accessible laser radiation is in the wavelength spectrum of 302.5 nm
to 106 nm and is hazardous to the eye. The power or the energy is maxi-
mum 5x the limit value of the permissible radiation of class 2 in the wave-
length range of 400 nm to 700 nm.
4 The accessible laser radiation is very dangerous to the eyes and danger-
ous to the skin. Diffused radiation can also be dangerous. The laser radia-
tion can lead to a risk of fire and explosion.
Safety precautions must be implemented for laser devices of class 4; ade-
quate eye protection is primarily important.
Laser systems of class 4 are usually sufficiently powerful to burn the skin,
ignite fires and ionize the atmosphere during focussing. Thus, a series of
additional safety measures is required.
Overview of laser classes Tab. 1-3
1‐10 Hazards 2017-11-17 B836en

Laser classes of the machine
Operation Description class

mode
Normal mode Normal mode is the mode of Characteristics: 1
the machine in the entire ■ The machine is controlled by a program or
scope of function including the
by hand.
maintenance work that has
been described in the opera- ■ The protective devices are activated.
tor's manual. ■ The processing optics is in working position
above the workpiece when the laser beam
is switched on.
■ The personnel is located outside the danger
zone.
Teach mode Teach mode is the mode of Characteristics: 1
the machine when teaching/ ■ The machine is operated via a separate
generating NC programs.
teach panel.
■ Teach mode is activated via a key switch.
■ The laser cannot be ignited in teach mode.
Laser classes of the machine Tab. 1-4
Laser classes of laser device and

components
Laser device, component class

■ Laser device with open hood. 4
■ Pilot laser at the emission opening of the laser 3R
device.
■ Pilot laser upon leaving the focusing lens. 2
■ Laser device with closed hood. 1
■ Laser light cable.
Laser classes of laser device and components Tab. 1-5
4.2 Hazards due to laser radiation
TruDisk The TruDisk is a class 4 solid-state laser.

Solid-state lasers generate intensive light in the invisible near-
infrared spectral range with a wavelength of 1030 nm.
Biological tissue absorbs light in different ways. It is usually con-
verted into heat and causes thermal damage (e.g. burns,
destruction of protein) and permanent retina damage.
Eyes and skin are especially at risk due to direct and reflective
laser radiation.
B836en 2017-11-17 Hazards 1‐11

Invisible, high-energy laser radiation!
DANGER
Severe skin burns and eye injuries may occur. Effect on the
sight and blindness!
Ø Operate machines only with active safety devices.
Incorrect laser safety glasses!

DANGER
Serious eye injuries. Impairment to sight and blindness!
Ø Do not mix up laser safety glasses for lasers with differing
wavelengths.
Ø Before using laser safety glasses, check whether they are
approved for the wavelength of the laser radiation.
Invisible, high-energy laser radiation! Monitors and LED

WARNING indicators are integrated into the front side of the safety
cabin. If these devices and display elements are removed
from the safety cabin, laser radiation could escape from the
safety cabin.
Risk of severe skin burns and damage to the eyes. There is
a risk to your sight and a risk of blinding!
Ø The machine may only be operated if both monitors and all
LED indicators or alternatively their cover sheets are fitted to
the safety cabin.
Pilot laser TruDisk The laser device can contain class 3R laser diodes. The red
light of the laser diodes is used for adjustment work on the
machine.
Eye injury due to laser radiation!

WARNING
Laser radiation damages the eyes permanently.
Ø Do not look directly into the beam.
Wavelength 630 nm to 680 nm

Max. power output ≤5 mW
class 3R
Pilot laser technical data Tab. 1-6
1‐12 Hazards 2017-11-17 B836en

4.3 Fire hazard
The following fire extinguishers should be kept ready at the

machine for fire protection:
■ CO2 fire extinguisher (fire classification B) for fires in the
compact dust extractor if the compact dust extractor is equip-
ped with a CO2 extinguisher.
■ Powder extinguisher (fire classification D) for fires in the
compact dust extractor if the compact dust extractor is equip-
ped with an argon extinguisher.
■ Metal bucket (min. 20 l) with dry sand or fire extinguisher
(fire classification D) for metal fires.
Combustible objects in the manchine's work area increase

WARNING the risk of fire.
Fire in the work area or in the compact dust extractor.
Ø Do not bring combustible objects, such as cigarettes, paper
or cardboard, into the work area of the machine.
Ø Service the compact dust extractor (filtering installation),
especially the spark arrester, thoroughly and on a regular
basis.
Ø Replace fine dust bag or dust container when the level is
25%.
Ø Be sure that the clamped dust container at the dust dis-
charge is air tight.
Ø Only use genuine fine filter bags from TRUMPF.
Ø In the event of a fire in the compact dust extractor, inform
the manufacturers (TRUMPF and Herding) without delay.
Ø After a fire, only the manufacturer is permitted to repair the
compact dust extractor.
Formation of foil lint when cutting film-coated aluminum.

WARNING
Health hazard and fire in the compact dust extractor.
Ø During cutting of film-coated aluminum: observe the cutting
procedure. If film lint develops, abort the cutting process and
change the cutting parameters in consultation with TRUMPF.
Ø Service the compact dust extractor (filtering installation) thor-
oughly and on a regular basis; in particular, the spark
arrester.
Ø In the event of a fire in the compact dust extractor, inform
the manufacturers (TRUMPF and Herding) without delay.
Ø After a fire, only the manufacturer is permitted to repair the
B836en 2017-11-17 Hazards 1‐13

Extinguishing the fire in the compact dust
A fire can start in the filter elements or in the dust container. An

acoustic alarm is triggered in the event of a fire.
Means, Tools, Materials

■ CO2 fire extinguisher (fire classification B) for fires in the
compact dust extractor and smaller fires at the machine.
■ Fire extinguisher for metal fires (fire classification D) for
extinguishing again.
Notes
■ The extinguishing openings at the compact dust extractor are
marked with a label and closed by a lid.
■ Caution when opening the extinguisher opening – flames can
emerge.
Risk of burns due to fires and hot components!

WARNING
Ø Only open the compact dust extractor door under cover.
Ø Only touch hot components with protective gloves.
1. If a fire occurs in the compact dust extractor (fumes come

out of the clean gas outlet) immediately:
− Press the EMERGENCY STOP push-button.
− Switch off the MAIN SWITCH Machine.
2. Put on protective gloves.
3. Remove the sealing cap on the side and back.
4. Push the foam tube of the CO2 fire extinguisher all the way
into the extinguisher opening.
5. Insert the extinguishing agent intermittently into the compact
dust extractor.
6. Wait about 5 to 10 minutes for the extinguishing agent to
take effect.
7. Open the door to the clean gas space with someone else
standing by to cover you.
8. If the fire flares up again, extinguish it again by bursts with a
fire extinguisher for metal fires (fire classification D).
1‐14 Hazards 2017-11-17 B836en

extractor (Herding) with the CO2 fire
extinguisher

acoustic alarm is triggered in the event of a fire. The CO2 extin-
guisher system is automatically triggered if a fire is detected.
Conditions
■ The extinguisher system is switched on.
■ Extinguishing gas cylinder is open.

■ Fire extinguisher for metal fires (fire classification D) for
extinguishing again.
Note
Keep a fire extinguisher to hand at all times. A fire can re-ignite
if oxygen is added.
At compact dust extractors equipped with an extinguisher sys-

tem, there may be a temporary increase in the concentration of
the extinguishing gas in the environment of the compact dust
extractor after triggering the extinguisher.
Lack of oxygen due to extinguishing gas after triggering of

DANGER the extinguisher system.
Ø Do not enter a pit in the area of the compact dust extractor.
Ø Ensure good ventilation around the compact dust extractor.

WARNING

take effect.
B836en 2017-11-17 Hazards 1‐15

5. If the fire flares up again, extinguish it again by bursts with a
fire extinguisher for metal fires (fire classification D).

extractor (Herding) with the argon fire
extinguisher

acoustic alarm is triggered in the event of a fire. The argon
extinguishing system is automatically triggered.
Conditions
■ Extinguishing gas cylinder is open.

■ Powder hand-held fire extinguisher, fire classification D.
Note
Keep a fire extinguisher to hand at all times. A fire can re-ignite
if oxygen is added.
At compact dust extractors equipped with an extinguisher sys-

tem, there may be a temporary increase in the concentration of
the extinguishing gas in the environment of the compact dust
extractor after triggering the extinguisher.
Lack of oxygen due to extinguishing gas after triggering of

DANGER the extinguisher system.
Ø Do not enter a pit in the area of the compact dust extractor.
Ø Ensure good ventilation around the compact dust extractor.

WARNING

1‐16 Hazards 2017-11-17 B836en

take effect.
5. If the fire flares up again, extinguish it again intermittently
with a powder hand-held fire extinguisher (fire classification
D).
Machining highly reactive materials
Titanium Titanium is a highly reactive material. In the event of a fire, met-

allic titanium reacts with conventional extinguishing agents, such
as water, N2, CO2, which is why they are not permitted as extin-
guishing agents.
Titanium reacts violently with other substances!

WARNING
Risk of injury and damage to property due to fire.
Ø Do not extinguish fires with water, N2 or CO2.
Ø Only use extinguisher systems of fire class D to extinguish
fires.
Using the MultiCoater The MultiCoater is an option for the compact dust extractor (fil-
tering installation). The MultiCoaters works cyclically or in contin-
uous operation to apply calcium carbonate or trass powder (dis-
pensing material) to the filter elements of the compact dust
extractor.
If the MultiCoater is used for preventive fire protection ("inertiza-
tion"), dispensing material is added continuously to the sepa-
rated, highly reactive dust to minimize the risk of fires.
Notice! Even the use of a MultiCoater does not provide a
100% protection against fire.
The effectiveness of the preventive fire protection depends on
the metering of the dispensing material added. The dispensed
quantity and the metering interval are controlled by parameters
and depend on the material to be processed.
During start-up, the MultiCoater will be configured for a particular
operating mode: "Inertization" or "Precoating".
If the conditions for the "Inertization" mode change, the user may
only change the configuration of the MultiCoaters in consultation
with the manufacturer.
B836en 2017-11-17 Hazards 1‐17

Fire hazard in the compact dust extractor if the MultiCoater
WARNING is not operated correctly!
Ø If highly reactive materials are processed, the MultiCoater
may be operated in "Inertization" operating mode only.
Ø Only use the specified dispensing material.
Ø Make sure there is sufficient dispensing material in the stor-
age container.
Notes
■ If the MultiCoater is configured for "Precoating" operating
mode during start-up, there is no sufficient preventive fire
protection compared to the "Inertization" operating mode due
to the reduced addition of dispensing material to the sepa-
rated dust.
■ If the user deviates from the parameters defined during
start-up without consulting the manufacturer, then the
user is solely responsible for the effectiveness of the
resulting preventive fire protection.
Machining heavily oiled workpieces
Oil residue on workpieces Oil residue on workpieces, especially oil spills on, for example,
rolled or deep-drawn workpieces will vaporize during laser proc-
essing. The oil vapor becomes incrusted onto tube walls and fil-
ter elements.
If there is a high concentration of oil vapor and deposits, then
there is a risk of fires and explosions due to sparks.
Risk of fires and explosions due to oil vapor and oil

WARNING deposits in pipelines, in the machine's work area as well as
in the compact dust extractor.
Ø Clean workpieces prior to set up.
Ø Remove oil residues from fixtures, work tables and the fac-
tory floor at regular intervals.
Ø Extinguish fires using a metal fire extinguisher (fire classifi-
cation D).
Required safety device If it is usually oiled workpieces that are machined in the laser
processing machine, then the compact dust extractor has be
equipped with a MultiCoater to protect the filter elements in the
compact dust extractor (filtering installation) and to minimize the
fire risk.
Using the MultiCoater The MultiCoater is an option for the compact dust extractor (fil-
tering installation). The MultiCoaters works cyclically or in contin-
1‐18 Hazards 2017-11-17 B836en

uous operation to apply calcium carbonate or trass powder (dis-
pensing material) to the filter elements of the compact dust
extractor.
If the MultiCoater is used for preventive fire protection ("inertiza-
tion"), dispensing material is added continuously to the sepa-
rated, highly reactive dust to minimize the risk of fires.
Notice! Even the use of a MultiCoater does not provide a
100% protection against fire.
The effectiveness of the preventive fire protection depends on
the metering of the dispensing material added. The dispensed
quantity and the metering interval are controlled by parameters
and depend on the material to be processed.
During start-up, the MultiCoater will be configured for a particular
operating mode: "Inertization" or "Precoating".
If the conditions for the "Inertization" mode change, the user may
only change the configuration of the MultiCoaters in consultation
with the manufacturer.
Fire hazard in the compact dust extractor if the MultiCoater

WARNING is not operated correctly!
Ø If highly reactive materials are processed, the MultiCoater
may be operated in "Inertization" operating mode only.
Ø Only use the specified dispensing material.
Ø Make sure there is sufficient dispensing material in the stor-
age container.
Notes
■ If the MultiCoater is configured for "Precoating" operating
mode during start-up, there is no sufficient preventive fire
protection compared to the "Inertization" operating mode due
to the reduced addition of dispensing material to the sepa-
rated dust.
■ If the user deviates from the parameters defined during
start-up without consulting the manufacturer, then the
user is solely responsible for the effectiveness of the
resulting preventive fire protection.
4.4 Dangers from magnetic fields
Magnetic coupling of the processing optics
The processing optics are held by a magnetic coupling. The

magnetic coupling consists of an overload flange, mounted on
the barrel, and an overload plate at the processing optics. The
holding force is generated by permanent magnets. The overload
B836en 2017-11-17 Hazards 1‐19

flange is the primary part (permanent magnet). The overload
plate is the anchor part.
In case of a collision of the processing optics with workpieces or
objects in the work area, the electrical monitoring circuit between
the primary part and the anchor part is interrupted; the process-
ing optics are released from the flange.
Magnetic flux density The magnetic flux density is maximum on the surface of the per-
manent magnets in the primary part. If the distance is 30 cm, the
measured value is less than 100 μT (micro tesla).
According to modern medical standards, values up to 100 μT
with a permanent load and a frequency of 50 Hz, are medically
harmless for persons in good health (DIN VDE 0848, Part 4).
Strong magnetic field of the magnetic coupling!

DANGER
Risk of fatal injury for persons with pacemakers.
Ø Persons with a pacemaker must, regardless of whether the
machine is switched on, keep a minimum distance of 30 cm
from the overload flange on the barrel.
Ø Persons with a pacemaker may not perform any service,
maintenance or setting work on the Z axis or on the proc-
essing optics (if installed).
Ø Advise personnel, visitors or visiting personnel of the dan-
gers for persons with a pacemaker.
Ferromagnetic attractive The permanent magnets create a magnetic field. The ferromag-
force netic attractive force is 1000 N.
The attractive force will act suddenly, and depends on the sur-
face and on the mass of the object concerned.
The magnetic attractive force will act suddenly within the

CAUTION immediate vicinity.
Ø Do not bring heavy or large-surface objects made of steel or
iron near to the primary part.
4.5 Dangers due to the open electrical

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

cian.
1‐20 Hazards 2017-11-17 B836en

Electrical voltage!
DANGER
Electric shock!
Ø Keep switch cabinet closed.
Ø Before opening the switch cabinet: switch off the main
switch and secure against switching back on. Wait for the
discharging time (at least 5 minutes).
Hot components!
CAUTION
Burns!
Ø Keep switch cabinet closed.
Ø Before opening the switch cabinet: switch off the main
switch and secure against being switched back on. Wait for
the correct cooling phase (at least 5 minutes).
4.6 Dangers due to live parts
The power supply for the extinguisher cannot be switched

DANGER off via the main machine switch!
Electric shock!
Ø Only a qualified electrician may do work on electrical parts.
Ø Before opening the compact dust extractor, switch off the
extinguisher.
Ø Before touching, ensure that there is no live voltage present.
Live parts of TruDisk laser devices!

DANGER
Risk of electric shock!
Ø Only an electrician may work on electrical devices.
Ø Before repair work: Switch off the laser device and secure it
against being switched on again.
Ø Before touching: check whether the parts are de-energized.
Machine versions complying For machine versions complying with NEC, the switch cabinet
with NEC doors as well as all other electrical switchboxes may not be
secured with safety switches.
These switch cabinet doors and switchboxes are labelled with
two warning signs (see "Warning signs at the machine",
pg. 1‐44).
B836en 2017-11-17 Hazards 1‐21

Note
For warning signs, see the section "Warning signs on the
machine".
Risk of fatal injury due to electric shock! If the main switch

DANGER is turned on, when opening the switch cabinet doors or a
switchbox, the mains disconnector will not switch the
power off.
Ø Observe the warning signs.
Ø Before opening the switch cabinet or a switchbox, set the
main switch to off and lock it to prevent its being switched
back on again. Wait for the discharging time (at least 5
minutes).
4.7 Danger from handling hot

components
There is a rink of burns from touching hot nozzles immediately

after machine operation.
Risk of burns due to hot components!

WARNING
4.8 Dangers due to configured movement

sequences
Configurable control The configurable control interface (referred to as KSS in the fol-
interface lowing) is an option for the laser processing machine.
The user can configure automatic movement sequences themself
with this KSS, without having to add or replace hardware or soft-
ware components in the machine control system.
With the KSS, both fixtures supplied and configured by TRUMPF
can be actuated on the machine, as well as those supplied and
configured by the user.
User responsibility The configured sequences of motion and components must be

safe.
The user is required to produce a hazard assessment for fixtures
and configured sequences of motion.
1‐22 Hazards 2017-11-17 B836en

Danger due to configured movement sequences of the
WARNING components!
Injury to personnel in the danger zone.
Ø No danger may be posed by the configured movement
sequences or components.
Ø The operator must be familiar with the configured sequen-
ces.
Ø Manual operation via manual functions is only permitted
when there is no one in the danger zone and if there is no
hazard.
4.9 Dangers when handling clamping

fixtures
Dangers during transport Clamping fixtures can weigh up to 450 kg, depending on the
and assembly design.
Clamping fixtures for IHU workpieces usually have swivel axes,
which have to be secured during transport or assembly.
Dangers due to improper transport or assembly of the

WARNING clamping fixture on the workpiece changer!
Ø Do not step under suspended loads.
Ø When transporting on a pallet: Secure the fixture against tilt-
ing and falling off the pallet.
Ø In the case of fixtures for IHU workpieces: Lock in place
with the transport securing device before mounting to the
workpiece changer, as well as before transporting the swivel
unit.
Ø Set up or dismount fixture from the workpiece changer out-
side of the enclosed protective housing.
Ø Only remove the tackle once the fixture is securely mounted
on the workpiece changer.
Ø If available, observe the project-specific transport regulation.
Danger while teaching During the teaching process, the operator is in the machine's
work area.
A danger is posed to the operator by pneumatically moving fix-
ture parts when a program is being run in test mode.
B836en 2017-11-17 Hazards 1‐23

Swivel axes as well as actuators actuated via the KSS, such
WARNING as clamping devices or pneumatic cylinders, execute
immediate and unbraked movements in TEACHIN operating
mode!
Health hazard, particularly danger of sustaining a head
injury.
Ø If an NC program is run in TEACHIN mode, step back from
the fixture and maintain a sufficient distance from the clamp-
ing device movement.
Ø In the case of clamping fixtures with swivel axes in
TEACHIN mode, leave the work area before swiveling the
axis and close the safety door from the outside.
Ø In the event of emergency triggering of the a clamping
device: Keep your head and upper body away from the dan-
ger zone of the clamping device movement.
Ø It is not permissible to stand in the danger zone inside the
enclosed protective housing with the access door closed.
4.10 Dangers due to quickly-rotating

rotational changer
Danger zone inside the If the doors of the safety cabin are closed, the safety circuit will
safety cabin be closed and the rotational changer can turn, provided the load-
ing and unloading area is enabled by the safety circuit.
Risk of fatal injury from rapidly rotating rotational changer!

DANGER
Ø Only press the ACKNOWLEDGE DANGER ZONE button
when leaving the danger zone.
and close the door, if there is no one in the safety cabin.
Ø Do not block the access doors from outside.
Ø In an emergency, exit the safety cabin by the shortest possi-
ble route.
Ø Before doing maintenance work in the work area or on the
rotational changer, press the EMERGENCY STOP push-but-
ton.
Danger zone outside the The loading area in front of the rotational changer is monitored
safety cabin by a light grid and a scanner.
1‐24 Hazards 2017-11-17 B836en

Risk of fatal injury due to quickly rotating rotational
DANGER changer in the loading area!
Ø Do not step into the danger zone if the rotational changer is
not in its end position.
Ø Before doing any maintenance work on the rotational
changer, press the EMERGENCY STOP push-button.
Ø Do not step on the rotational changer and do not put any-
thing down on it.
4.11 Dangers due to quickly turning rotary

indexing table (option)
Danger zone inside the If the door of the safety cabin is closed, the safety circuit will be
safety cabin closed and the rotary indexing table can turn, provided the load-
ing and unloading area is enabled by the safety circuit.
In an emergency, the danger zone within the safety cabin can be
left on both sides of the working area. The access door on the
one side and the escape door on the other side can be opened
from inside. The laser unit has an EMERGENCY STOP button
next to the escape door.
Risk of fatal injury from rapidly turning rotary indexing

DANGER table.
Ø Do not block the access and escape doors from outside.
ble route.
rotary indexing table, press the EMERGENCY STOP push-
button.
Danger zone outside the The loading & unloading areas for the rotary indexing table are
safety cabin each monitored with a light grid and a scanner.
B836en 2017-11-17 Hazards 1‐25

DANGER table in the loading and unloading area.
Ø Do not step into the danger zone if the rotary indexing table
is not in its end position.
Ø Do not hold any objects through the protective screen.
Ø Do not remove the protective cover between the protective
screen walls.
Ø Before performing maintenance work on the rotary indexing
table, press the EMERGENCY STOP push-button.
Ø Do not climb on to the rotary indexing table and do not
place any objects on it.
4.12 Hazard risks due to the scrap

conveyor
Waste parts or scrap skeleton parts can get jammed in the con-
veyor belt or between the conveyor belt and the housing, thus
causing malfunctions.
Risk of injury due to jammed waste parts or scrap skeleton!

WARNING
Ø Disconnect the drive motor of the scrap conveyor from the
power supply: turn key switch to the neutral position.
Ø Removed jammed waste parts using a suitable tool.
4.13 Dangers due to a suspended axis
The barrel on the motion unit with a Z axis drive is a suspended

axis.
A suspended axis can pose a fundamental risk of injury to per-
sonnel, for example during teaching, during installation or setup
work as well as maintenance work in the machine's work area.
Risk of injury from a suspended axis.

WARNING
Ø Do not step under the barrel when in the machine's work
area.
1‐26 Hazards 2017-11-17 B836en

4.14 Danger while teaching
During the teaching process, the operator is in the machine's

work area.
A health hazard is posed by pneumatically moving fixture parts
when a program is being run in test mode.
Risk of injury during the teaching process!

WARNING
Ø While an NC program is being run in test mode, maintain a
sufficient distance to the fixture.
Ø In the case of clamping fixtures with swivel axes, leave the
work area before swiveling the axis and close the safety
door from the outside.
Ø Do not step between the machine frame and the barrel.
Ø Do not step under the barrel.
Ø Do not reach with your fingers between the workpiece sur-
face and the nozzle tip.
4.15 Dangers in the work area due to a

bright source of light.
The work area within the safety cabin is lit with 4 LED tube
lamps, which produce a very bright light.
There is a danger of being dazzled by looking directly into

CAUTION the light source.
Looking directly into the light source can temporarily impair
your ability to see and can leave an image in your eyes.
This can lead to irritation, impairments or accidents.
Ø Do not look straight into a light source.
4.16 Dangers of slipping, tripping or

falling
The scrap conveyor in the work area as well as the platform

inside the safety cabin are sources of danger.
Slipping, tripping or falling!

CAUTION
Ø For machines with a rotary indexing table: when in the work
area, fold up the guide plate on the machine frame.
B836en 2017-11-17 Hazards 1‐27

Cutting dust causes a risk of slipping. Very fine, oily cutting
CAUTION dust can be deposited within the safety cabin.
Ø Regularly clean the work area and the machine's compo-
nents.
4.17 Dangers handling workpieces
Processing workpieces can be dangerous. These dangers and

measures are different for every workpiece.
Sharp-edged workpieces
Workpieces have sharp edges!

WARNING
Risk of injury!
Ø Wear personal safety equipment.
Hot workpieces
Hot workpieces after machining!

WARNING
Burns!
Ø Wear protective gloves.
Ø Use auxiliary equipment for workpiece removal.
Ø Avoid direct contact with hot surfaces.
Suspended loads when setting up

workpieces
Large and/or heavy workpieces can be set up on a fixture using

lifting tackle. Loads are suspended during loading and unloading.
Risk of fatal injury due to suspended loads when loading

DANGER and unloading workpieces!
Ø Observe the safety regulations for handling heavy loads.
Ø Do not access areas under suspended loads.
Ø Fasten workpieces securely with a suitable tackle.
1‐28 Hazards 2017-11-17 B836en

4.18 Hazards due to collisions in the work
area
Pay attention to the risk of There is always a risk of collisions between the Z barrel, proc-
collision in the work area essing optics and fixtures, table sets, or workpieces in the 3-D
working range of the machine.
There is a particular risk of collision:

■ When starting the axes.
■ When starting a machining program.
■ When resuming work with an interrupted machining program.
Risk of collision between Z barrel and fixture or workpieces

NOTICE in the working range of the machine!
Considerable property damage to the barrel can result.
Ø Each time before the axes or the NC program is started, the
operator must make sure that the barrel cannot collide with
objects in the workspace.
In the case of a collision of the processing optics with workpie-

ces or components in the work area, the magnetic coupling trig-
gers and the processing optics immediately separates from the
magnetic coupling. The machine stops with FEED HOLD. This
will greatly reduce the consequences of the collision.
4.19 Dangers when working with the

The Smart Optics Setup station (option) is a swivelable setting

device, which can be used to perform setting work for the proc-
essing optics as well as for the machine.
The setting device is manually swiveled out of the parking posi-
tion into the working range of the machine (setup position)
before beginning with setting work.
Test sheets, sacrificial plates and the test sheet holder get
WARNING hot during laser processing!
B836en 2017-11-17 Hazards 1‐29

Risk of crushing or hitting when swiveling the
CAUTION Smart Optics Setup station!
Ø When swiveling, make sure that no parts of the body get
caught.
Ø Touch the swivel arm at the handle to swivel it.
Ø Lock the swivel arm in the set-up position and in the parking
position.
4.20 Hazards due to escaping coolant or

cooling water
Escaping coolant or cooling water!

NOTICE
Ø Switch off the process cooler immediately.
Ø Put the machine or system into service only once the mal-
function has been eliminated.
Switching off the process In the case of a severe malfunction at the process cooler (e.g. a
cooler in case of emergency leak in the cooling water circuit or coolant circuit), the process
cooler must be switched off immediately.
■ If the process cooler is switched on and off via the machine's
power supply: switch off the MAIN SWITCH of the machine
or
■ If the process cooler has its own power supply: switch off the
MAIN SWITCH on the process cooler.
4.21 The risks of no switch cabinet

cooling
The machine's cooling circuit can be arranged as follows:

■ The machine has a separate cooling unit (optional machine
cooler).
■ The machine's cooling circuit is cooled via the laser cooler
(the standard case).
The machine cooler variant: The switch cabinets in the body of
the machine will be cooled via its cooler unit. If the machine's
MAIN SWITCH is on, but the machine's drives are off (DRIVES
ON button is not lit), then the machine's cooling and thus the
switch cabinet's cooling will not be active.
1‐30 Hazards 2017-11-17 B836en

The switch cabinets in the body of the machine will not be
NOTICE cooled if the machine's drives are switched off.
If the temperature rises, components in the switch cabinet
can prematurely age or fail.
Ø If the machine is at a standstill for a longer period e.g. over
the week end, set the machine's MAIN SWITCH to off.
Ø Only switch off the machine's drives when required and then
only for a short period.
The laser cooler variant: If the machine is not equipped with its
own cooler, then the switch cabinets in the body of the machine
will be cooled via the laser cooler.
The switch cabinets in the body of the machine will not be

NOTICE cooled if the laser device is switched off.
If the temperature rises, components in the switch cabinet
can prematurely age or fail.
Ø If the laser is switched off for a longer period, then you
should also set the machine's MAIN SWITCH to off.
4.22 Dangers due to Teleservice
Teleservice is used to establish a connection between the

machine and Technical Service.
The service engineer can access the user interface to analyze
problems and in some cases to eliminate them directly.
Teleservice activated!
WARNING
Injury and damage to property.
Ø Only persons trained by TRUMPF may take part in a Tele-
service session.
Ø If doubts arise regarding the qualifications of the persons
involved or if comprehension issues arise, TRUMPF can
refuse Teleservice or terminate the Teleservice session.
4.23 Dangers when using the

MobilelControl app
The MobileControl app (option) allows the user to remotely con-

trol the machine via a mobile terminal.
B836en 2017-11-17 Hazards 1‐31

Remote control of the machine with one mobile terminal!
WARNING
Ø While the remote control is in use, do not enter the
machine's danger zone.
Ø The remote control may only be activated if the machine is
ready for operation.
Ø The remote control is forbidden for maintenance work at the
machine.
4.24 Hazardous materials
In the case of hazardous materials, TRUMPF indicates the sour-

ces of danger only as an example. The user must estimate the
danger caused by a processed material. The user must check
and initiate the required measures.
Insufficient exhaust system for the work area!

WARNING
Hazardous gasses and particles enter the respiratory tract
during laser processing.
Ø Do not operate without the required exhaust system for the
work area.
Dusts, exhaust air
Exhaust air compact dust The user must comply with the national regulations for handling
extractor, regulation outside the exhaust air of the compact dust extractor and the dusts it
of Germany contains.
Exhaust air compact dust For the laser processing of stainless steel and materials from
extractor, regulation which harmful substances can arise as suspended dust, the
Germany exhaust air of the compact dust extractor must be conducted to
the outdoors.
In Germany, the limits for the return of cleaned air into the room
air are defined in "Technical Rules for Hazardous Materials
TRGS 560".
Note
For the laser processing of mild steel or aluminum, for example,
the cleaned air of the compact dust extractor may be fed back
into the room air.
Cleaning the machine The machine may only be cleaned with an industrial vacuum
cleaner which meets at least the standards for "dust-class M"
according to IEC/EN 60335-2-69.
1‐32 Hazards 2017-11-17 B836en

In Germany, when materials are processed that are listed in the
technical rules for hazardous materials TRGS 560, then an
industrial vacuum cleaner for "dust class H" must for used for
cleaning.
Further Information The databases from GESTIS contain limit values for dust con-
centrations and notes about danger (hazardous substance infor-
mation system of the German Social Accident Insurance). The
databases are available via the Internet in German and English.
Hazardous materials due to cutting oils
If metallic materials are processed with cutting oils, this might

lead to organic compounds (liquid or gaseous) during laser cut-
ting or welding.
Note
If there is a danger of dangerous emissions, the user must carry
out measurements and implement safety measures.
Hazardous substances derived from

polyethylene films
Certain materials are covered with a polyethylene film in order to

protect the surface.
Polyethylene film is vaporized during laser cutting. The resulting
organic compounds (e.g. alcane) do not exceed the exhaust air
limit values.
However some of the resulting organic compounds lead to smell
load in very small concentrations (ppb area) in the exhaust air.
B836en 2017-11-17 Hazards 1‐33

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
The service doors with electrical locking devices (option) have

their own control panel.
Depending on the configuration of the machine, the following

additional EMERGENCY STOP impact buttons are installed:
■ Inside the safety cabin next to the escape door.
■ On the laser device, on the operating panel as well as on
the control panel of the laser device.
1‐34 Measures to be taken by the manufacturer 2017-11-17 B836en

1 Escape door 4 Safety fencing 7 Control panel
2 Light grid 5 Laser scanner 8 Service door
3 Rotary indexing table control 6 Safety strip 9 Main switch of the machine
panel
Rotary indexing table: Danger zone safeguarding device Fig. 71419
B836en 2017-11-17 Measures to be taken by the manufacturer 1‐35

1 Protective wall 4 Laser scanner 6 Service door
2 Rotational changer control panel 5 Main switch of the machine 7 Control panel
3 Light grid
Rotational changer: Safeguarding the danger zone with Basic Loading Fig. 73836
1 Rotational changer control panel 3 Laser scanner 5 Service door

2 Light grid 4 Control panel 6 Main switch of the machine
Rotational changer: Safeguarding the danger zone with Comfort Loading Fig. 74464

Light grid and laser scanner There are two possible variants to safeguard the danger zone
for the rotational changer around the rotational changer outside of the safety cabin:
■ The Basic Loading variant: The loading & unloading area is
safeguarded with side protective walls, a laser scanner and a
light grid (see fig. 73836).
■ The Comfort Loading variant: The loading & unloading area
is safeguarded with a laser scanner and a light grid around
three sides.
The danger zone is secured in all operating modes of the con-

trol.
■ The rotational movement of the rotational changer is only
enabled if the laser scanner does not register any objects
within the protected field.
■ The interruption of the light grid will trigger a feed hold while
the rotational changer is moving.
■ If the laser scanner detects an object in the danger zone, a
feed hold will be triggered.
Rotary indexing table, light By default, the loading & unloading area for the rotary indexing
grid and laser scanner table (option) is safeguarded by a vertical light grid, by a laser
scanner as well as with protective walls. The safeguarding of the
danger zone is effective in all of the control system's operating
modes.
■ The rotation of the rotary indexing table will only be enabled
if neither laser scanner registers any object within the pro-
tected field.
■ Interrupting a light grid will trigger a feed hold while the
rotary indexing table is moving.
■ If the laser scanner detects an object in the danger zone, a
feed hold will be triggered.
ACKNOWLEDGE DANGER
ZONE button
1 ACKNOWLEDGE THE DANGER ZONE button

Fig. 73839
As soon as an access door is opened, the movement of the

rotational changer or of the rotary indexing table (option) will be
disabled in all operation modes.

The movement of the rotational changer or of the rotary indexing
table and the starting of a machining program will only be ena-
bled again if the acknowledgement button inside the safety
cabin, next to the access door, is pressed and the corresponding
access door is closed within the valid time window of 3 seconds.
Escape door for machines In an emergency, the danger zone within the safety cabin can be
with a rotary indexing table exited via the service door or via the escape door on the oppo-
site side.
The working range inside the safety cabin is entered and exited
via the service door. The escape door is only to be opened in an
emergency, from inside. It is not an access door to the working
area.
Depending upon the version installed, the escape door may be

on the left or the right.
1 Service door 2 Escape door

Fig. 73832

The escape door is labelled inside the safety cabin with an
"Emergency exit" sign and is secured by a safety switch. There
is also an EMERGENCY STOP push-button next to the escape
door.
1 EMERGENCY STOP push-but- 2 Escape door

ton
Fig. 73838
Safety cabin For machines with a rotational changer: The machine is sup-
plied with a completely enclosed safety cabin with a roof and
access doors on the left and right. One of the doors is fitted with
a laser protection window. The safety cabin is designed for a
maximum laser power of 4000 W.
For machines with a rotary indexing table: The machine is
supplied with a completely enclosed safety cabin with a roof as
well as one access door and an escape door. The access door
is fitted with a laser protection window. The safety cabin is
designed for a maximum laser power of 4000 W.
The doors are electrically secured and monitored by the control
system. The laser beam is only ignited if the doors are closed. If
a door is opened during machining, then a feed hold will be trig-
gered.
Both opening a door as well as pressing the EMERGENCY
STOP push-button will immediately stop the movement of the
workpiece changer.
Do not access the roof of the safety cabin.
The access doors as well as the escape doors from the safety
cabin must be freely accessible from both sides and must not be
obstructed.

Main switch The machine is switched on and off via the main switch. The
main switch can be secured against being switched on again
using a padlock.
The main switch has two positions:
Switch setting 0 The machine is switched off and the voltage

supply of the machine is interrupted.
Switch setting 1 The machine is switched on.
Tab. 1-7
EMERGENCY STOP push- Pressing an EMERGENCY STOP push-button results in the fol-
button lowing:
■ The shutter switch of the installed light path (LLK) is disabled
in the laser device.
■ The gas supply is interrupted.
■ All axis motions stop. All drives are shut down safely.
■ The central compressed air supply is switched off.
■ Stop workpiece changer and scrap conveyor.
■ Fixtures (option), which are actuated via the KSS:
− The power supply for the outputs of the I/O bus modules
is switched off.
− Valves remain in spring-loaded neutral position and retain
their respective status.
− Vacuum ejectors are not switched off; the vacuum is
maintained.
TruDisk emergency stop Note

push-button
If the laser device is located directly next to the machine or up
to a maximum of 10 m away from the machine, the EMER-
GENCY STOP push-button is enclosed and cannot be operated.
If the laser device is installed further away from the machine, the
EMERGENCY STOP push-button is not enclosed.
If the EMERGENCY STOP push-button is not encapsulated, the

following applies:
■ The EMERGENCY STOP push-button on the laser device
causes an EMERGENCY STOP exclusively on the laser
device.
■ All potentially dangerous components of the laser device are
switched off.

■ The shutter switches of the installed laser light cable are dis-
abled.
■ If the laser is assigned to the machine:
− Laser processing is discontinued.
− An error message is displayed in the PRODUCTION
main operation.
− All manual functions can continue to be used in the SET
UP main operation.
Note
The EMERGENCY STOP section on the laser device can only
be acknowledged on the laser device.
STOP push-button on teach Pressing the STOP push-button on the teach panel results in the
panel following:
■ The laser beam is switched off.
■ The shutter switch of the installed light path (LLK) is disabled
in the laser device.
■ All axis motions stop. The drives are shut down safely.
■ The central compressed air supply is switched off.
■ Stop workpiece changer and scrap conveyor.
is switched off.
− Valves remain in spring-loaded neutral position and retain
their respective status.
maintained.
FEED HOLD A FEED HOLD leads to the following:

■ All axis motions are stopped.
■ No beam enable for the installed light path.
■ The rotational movement of the rotational changer stops.
■ The rotational movement of the rotary indexing table stops.
■ The waste conveyor belt stops.
is maintained.
− The voltage supply for the fixture in the loading position
is interrupted.
maintained.
Key switch on the laser The key switch on the laser device can be turned into the posi-
device. tions 0 and 1.

Switch setting 0 The key can be removed in this setting. The
unauthorized activation of the laser is pre-
vented.
Switch setting 1 The laser is in the operating state.
Tab. 1-8
Key-operated switch In TEACHIN operating mode, the separate teach panel can be
TEACHIN used to manually program 3D workpieces and move NC axes.
The TEACHIN operating mode is activated or deactivated on the
control panel with the TEACHIN key switch.
In TEACHIN operating mode, the machine axes move at
reduced speed and only if the operator keeps at least one ena-
ble key constantly pressed. If no enable key is pressed then a
FEED HOLD will be applied.
Switch setting 0 ■ TEACHIN mode is deactivated.

Switch setting 1 TEACHIN operating mode is activated. The fol-
lowing functions are activated automatically in
teach mode:
■ LASER TEST is activated: the shutter switch
of the installed light path (LLK) is disabled.
■ Axes can only be moved with the teach
panel.
■ The axes move at a safely reduced speed.
− X axis: 10000 mm/min.
− Y axis: 10000 mm/min.
− Z axis: 5000 mm/min.
− B axis: 12 rpm (3600°/min).
− C axis: 4 rpm (1800°/min).
■ The drive of the rotational changer or of the
rotary indexing table is shut down safely.
Tab. 1-9
Safety Integrated The machine is equipped with the control software Safety Inte-
grated by Siemens. The functions of this safety concept are
effective with open or closed safety devices (safety cabin, light
barrier, light grid, laser scanner, etc.) and during teaching. Safety
Integrated is effective in all control operating modes.
The safety functions of Safety Integrated include:

■ Safe operating stop (SBH) when a safety device is open.
The drives are regulated and monitored for safe standstill.
The software issues a FEED HOLD.
■ Safely reduced speed (SG):
− Monitoring of the limit values for the speed of all axes
when the safety device is open and during teaching.
− Monitoring of the limit values for the speed of all axes
when the safety device is closed.

The following must be ensured for the Safety Integrated safety
function to be able to function correctly and reliably:
■ All NC axes must be referenced safely.
■ A safety test has to be performed every 8 operating hours.
The safety test is used to check if the drives of the NC axes
are switched off electrically in the event of an error.
MobileControl App If the remote control of the machine is activated by the Mobile-
Control app (option), the following safety measures become
effective:
■ Operation by the control panel is disabled. A red/yellow
warning frame is shown on the control panel.
■ The Internet connection is limited to the local WLAN of the
machine.
■ The remote control is activated by a WPA key created
dynamically at the machine.
■ The mobile terminal cannot access the Internet while the
remote control is active.
■ The WLAN connection is terminated as soon as the remote
is disabled via the MobileControl app.
Magnetic coupling barrel To reduce the consequences of a collision of the processing

optics e.g. with the workpiece, there is a magnetic coupling
(overload coupling) between the processing optics and the flange
on the barrel.
If there is a collision, the processing optics is separated from the
flange. The processing optics is held by a catch strap. FEED
HOLD is triggered.
The magnetic coupling's holding power is 1000 N.
Suction system in the work The work area of the machine is vacuum-cleaned through the
area open surface of the scrap conveyor. The air which is suctioned
off is guided to the compact dust extractor through the 2 connec-
tion sockets and a piping system.
The extraction and filtration system (compact dust extractors)
provided by TRUMPF in combination with the machine is
designed in such a way that the aerosols and dust emitted are
efficiently separated if the machine is used as intended (refer to
the "Hazardous substances" section.
Laser status lamp The laser status lamp (orange) indicates that the laser device is
assigned to the machine or that laser radiation is escaping at the
processing optics.
Laser status lamps are part of the machine's safety equipment
and are monitored by the control. A faulty laser status lamp will
block the beam path to the machine, resulting in a FEED HOLD.
It will have to be replaced.

Laser warning lamp, laser Laser warning lamps on the laser device indicate that the laser
device light is being emitted at the processing point and that the laser is
ready to emit laser light even when laser light is no longer being
emitted (in the "Laser is on" status).
5.2 Warning signs at the machine
Location of signs, machine with rotational changer Fig. 71414

Location of signes for a machine with rotary indexing table Fig. 71415
Warning signs draw attention to dangers when operating the

machine.
Sign no. Warning signs on the basic machine Meaning

1 Laser Product Class 1
2, 3 Caution, there will be invisible

laser radiation when the cover
is opened and the safety lock is
bypassed.
Avoid eye or skin exposure to
direct or scattered radiation.

2, 4 Caution, there will be invisible
laser radiation when the cover
is opened.
Avoid eye or skin exposure to
direct or scattered radiation.
2, 5 Laser radiation – do not look

into the beam.
P ≤ 1mW: λ=630-660 nm
Laser class 2
- Machine versions complying

with NEC:
CAUTION: To be opened only
by qualified personnel.
- Machine versions complying

with NEC:
DANGER: Hazadous Voltage
Contact will cause electric
shock.
Disconnect and lock out power
before servicing.
- For machines with a rotary

indexing table: "Emergency exit"
escape door.
- Warning of laser beam.
- Warning of electrical voltage.
- Warning of hot surface.
- Warning of suspended axis.

- Warning of the risk of crushing.
- No access for persons with a

pacemaker or with an implanted
defibrillator.
- Entering the area prohibited.
- Climbing on prohibited.
Warning signs at the machine Tab. 1-10

6. Organizational measures to be taken
by the user
6.1 Observe warnings and warning signs
Certain operations can be a source of danger during operation.

The documentation contains warnings before the instructions for
these activities and warning signs are provided on the machine.
6.2 Training and instructing operators
Measures applicable worldwide
The user must take the following measures before the personnel
start working on the machine:
■ 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.
■ Require that personnel read the technical documentation of
the machine. Recommendation: obtain written confirmation
from the personnel.
■ Inform the personnel about the measures for protection
against radiation:
− Instruct the personnel in operating processes of the laser.
− Use protection against radiation correctly, e.g. wear laser
safety glasses.
− Instruct the personnel about the accident prevention pro-
cedures.
− Explain the biological effects of laser radiation on eyes
and skin.
■ For fault diagnosis and error correction, a connection will be
made via Teleservice by TRUMPF between the machine and
Technical Service. When the machine is commissioned the
user will be informed about the sequence and possible risks
of the Teleservice. The user must provide safety instruction
to operators who are involved in the Teleservice.
Protection against radiation Only personnel trained and instructed in laser radiation and
in service mode appropriately equipped may carry out adjustment and setup work
1‐48 Organizational measures to be taken by the user 2017-11-17 B836en

in service mode. In service mode, the machine's laser corre-
sponds to class 4.
■ The personnel must wear laser safety glasses that conform
to the requirements of the following standards IEC/
EN 60825-1 or EN 207, for the USA: ANSI Z87.1.
■ If necessary, the danger zone must also be secured by the
customer (e.g. with portable barriers made of sheet steel
and/or laser safety glass).
Appointing a laser safety When the user operates the machine during service mode, or
officer carries out adjustment and setup work in service mode, he or
she must designate a laser safety officer in writing.
The user has to observe national laws and regulations.
The standard IEC/EN 60825 as well as ANSI-Norm Z136.1,
which is for the USA, describe the area of responsibility of the
laser safety officer.
Protection against radiation: information

for Germany
Observe the accident In Germany, the employer's liability insurance association regula-
prevention regulations tion on laser radiation (DGUV regulation 11, formerly numbered
BGV B2).
Training a laser safety The following organizations in Germany train laser safety
officer officers, for example:
■ Berufsgenossenschaft für Feinmechanik und Elektrotechnik
(German Employer's Liability Insurance Association for Preci-
sion Mechanics and Electrical Engineering), Postfach
510580, Gustav Heinemann Ufer, D-50968 Cologne, Ger-
many.
■ Physikalisch-Technische Bundesanstalt (Physical-technical
Federal Agency), Bundesallee 100, D-38116 Braunschweig.
■ TÜV Akademie Bayern/Hessen GmbH (Technical Inspection
Academy of Bavaria/Hesse Ltd), Postfach 210420, Westend-
straße 199, D-80686 München, Germany.
■ Technische Akademie Esslingen, Postfach 1265, In den Anla-
gen 5, 73760 Esslingen, Germany.
B836en 2017-11-17 Organizational measures to be taken by the user 1‐49

Protection against radiation: additional
Appointing a laser safety The following instances, the user must appoint a laser safety offi-
officer cer:
■ For class 3B or 4 laser systems.
■ The user operates the machine in service mode.
■ The user carries out adjustment and setup work in service
mode.
The area of responsibility of the laser safety officer is defined in
the ANSI standard Z136.1. The standard can be obtained from
the American Laser Institute.
Laser Institute of America (LIA)
13501 Ingenuity Drive, Suite 128
Orlando, FL 32826
www.laserinstitute.org
LIA also offers training courses for laser safety officers.
6.3 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 repair work. The oper-
ator must replace and put the safety devices into operation after
completing work.
Once per shift, preferably before starting the production:

■ Check the light grids and laser scanner for proper function.
■ Check the safety cabin, viewing window, partition wall and
sealing strips on the rotational changer or rotary indexing
table and on the scrap conveyor to make sure there is no
damage: do not put the machine into operation if the safety
equipment is damaged (deep scorching, holes, cracks, defor-
mations, etc.).
After all work on safety light barriers and light grids, particularly
when the layout has changed:
■ Check the safety light barriers and the light grids for proper
function.

Ensuring the perfect User:
working order ■ The user must ensure that the machine is installed as per
the installation plan and installation conditions.
■ The user must ensure that only authorized personnel works
at the machine.
■ The user must ensure that damaged or missing warning
signs on the machine are replaced.
■ The user or the persons appointed by him/her must operate
the machine when it is in perfect working order.
■ The user must ensure that the work station is kept clean and
tidy by issuing appropriate instructions and conducting
inspections.
■ The user must ensure that the working areas are supplied
with sufficient fresh air.
Operator:
■ The operator must immediately report changes (including the
operating performance) occurring in the machine to the user.
The machine must be checked for externally visible defects
and damage at least once per shift.
■ The operator must immediately press the EMERGENCY
STOP push-button if a viewing window is damaged during
laser operation. Processing may only continue once the win-
dow has been properly replaced.
Teach panel: Ensuring its The gray STOP push-button on the teach panel is a safety-rele-
perfect working order vant component. It has the same functionality as an EMER-
GENCY STOP push-button.
The teach panel can be disconnected. The electrical interface
can then by bypassed using a plug in the scope of delivery.
The following should be observed when using the teach panel:

■ The STOP push-button is only active if the teach panel is
connected.
■ A disconnected teach panel must be stored in such a way as
to prevent any operating error. It must be stored e.g. in a
drawer.
■ When the teach panel is not used, store it in the mounting
device provided on the enclosed protective housing.
■ The STOP push-button must be tested in cycles. Recommen-
dation: every 6 months.
■ After any severe impact to the teach panel, e.g. due to it fall-
ing down, the function of the STOP push-button must be
checked.
Observing the shutdown The prescribed shutdown procedures must be adhered to during
procedure all operations (e.g. setting and maintenance work).

Switching off the process In the case of a severe malfunction at the process cooler (e.g.
cooler in case of emergency leakage in the cooling water circuit), the process cooler must be
switched off immediately.
■ If the process cooler is switched on and off via the machine's
power supply: switch off the MAIN SWITCH of the machine
or
■ If the process cooler has its own power supply:
Switch off the MAIN SWITCH at the process cooler.
Pay attention to the user The process cooler is subject to the EU directive 2014/68/EU
responsibilities for the about the provision of pressure devices on the market.
process cooler
The user has to observe regulations and laws.
According to the European standard EN 378 for cooling systems,

the following is to be observed:
■ The operator must maintain a system log for the process
cooler.
■ The user must have the process cooler inspected regularly
by a qualified person and the result must be document the
test in the system log.
■ The user must install a quick guide in clear view and in dura-
ble form on the process cooler or the machine.
Note
The operator's manual for the cooling unit always includes one
sample for the quick guide and the information required by
EN 378 for the system log.
6.4 Pay attention to water protection
Water-pollutant substances (e.g. oil) should not enter the ground

or into water bodies.
Cooling water may be disposed off together with waste water
only in agreement with the local waste disposal authority.
The Federal Republic of The principle of precaution is applicable for machines in the Fed-
Germany eral Republic of Germany: water should not become contami-
nated when using water-pollutant substances (Federal Water Act
WHG).
The plant decree and the administrative regulations of the Fed-
eral states explain how this principle of precaution should be
adhered to.
Water-pollutant materials Lubricants

Water Hazard Class 1 or 2

Volume of water-pollutant materials ≤1000 l (≤264 gal)
Hazard level of the machine A
Water protection specifications Tab. 1-11
Outside the Federal Outside the Federal Republic of Germany, the respective
Republic of Germany national regulations as regards water protection must be adhered
to.
6.5 Observe the fire safety rules
Extinguisher system If the compact dust extractor is equipped with an extinguisher

system, the user must have the extinguisher system serviced
and checked once a year. The test must be recorded.
Maintenance work on the extinguisher system may only be car-
ried out by service engineers from the manufacturer or other
authorized and accordingly trained personnel.
6.6 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.
Note
Safety data sheets can be obtained from the manufacturers of
the respective operating materials.
6.7 Safety data sheet on hazardous

materials
The safety data sheets e.g. for lubricants, cleaners or gases can
be downloaded from the TRUMPF web page: http://
www.trumpf.com/s/msds.

7. Overview of residual risks
The machine has residual risks in spite of its safety devices and
construction type.
The following overview of residual risks is a summary of the
main potential threats to life and limb posed by the machine.
Any additional precautions that can be taken by the machine
owner to reduce residual risks are specified in the overview of
residual risks.
For detailed descriptions of the measures: (see "Hazards",
pg. 1‐10).
Residual risk Dangerous point Type of danger Measure to be taken by

the operator
Mechanical elements
Crushing While teaching Risk of injury ■ If there is a danger
risk, immediately press
Shearing
the STOP push-button
Impacts on the teach panel.
■ Do not step between
the machine body and
the barrel.
■ Do not reach between
the workpiece surface
and nozzle tip.
Z barrel: Suspended axis Risk of injury ■ Do not go under the Z
within the safety cabin barrel.
■ Lower the barrel before
doing maintenance
work.
Integration of fixtures by Risk of injury ■ Create a risk assess-
the user ment for integration of
the fixture.
■ Observe the notes in
the operating manual.
Fixtures with swivel axes Risk of injury ■ For clamping fixtures
and/or pneumatically actu- for hot-formed workpie-
ated clamping elements: ces: Maintain a suffi-
fast clamp movement or ciently large distance
swivel movement of axes from the fixture while
during teaching the NC program is run
in test mode.
■ For clamping fixtures
for IHU workpieces:
Before the NC program
is run in test mode,
leave the work area
and close the door
from the outside.
B836en 2017-11-17 Overview of residual risks 1‐55

the operator
Crushing Danger zone inside the Risk of fatal injury ■ Exit the safety cabin
safety cabin immediately by the
Shearing
nearest door in the
Impacts event of danger.
■ For all maintenance
and cleaning work,
press the EMER-
GENCY STOP push-
button and leave the
service door open.
■ Only acknowledge the
danger zone when
leaving the safety
cabin.
■ The doors to the safety
cabin must be freely
accessible from both
sides and must not be
obstructed.
When setting up large Risk of fatal injury ■ Observe safety regula-
and/or heavy workpieces tions for the handling
or fixtures of heavy loads.
■ Never walk under a
suspended load.
■ Fasten workpieces or
fixtures firmly using
suitable tackle.
Jammed scrap and scrap Risk of injury ■ Before every fault elim-
skeleton parts in the ination, de-energize the
scrap conveyor or waste drive motor of the
conveyor belt. scrap conveyor: Turn
the scrap conveyor key
switch into the neutral
position.
Swivel arm Risk of injury ■ Observe the notes in
(Smart Optics Setup the operating manual.
option)
Remote control with Mobi- Risk of injury ■ Observe the notes in
leControl (option) the operating manual.
Heat
Touching Hot workpieces Risk of injury ■ Wear protective cloth-
ing and gloves.
Hot slag
■ Use gloves and tools
to remove workpieces.
Hot nozzle Risk of injury ■ Wear protective gloves.
Hot sacrificial plates and Risk of injury ■ Wear protective gloves.
hot test sheet holder ■ Observe the notes in
(option, the operating manual.
Smart Optics Setup sta-
tion)
Radiation
1‐56 Overview of residual risks 2017-11-17 B836en

the operator
Laser Alignment laser (Pilot Risk of injury ■ Observe the notes in
laser TruDisk) the operating manual.
■ Do not gaze into the
laser beam.
Impermissible openings in Risk of injury ■ Observe the notes in
the safety cabin with no the operating manual.
monitor or no LED display
Optical radiation Lighting within the safety Risk of injury ■ Do not look direct into
cabin the light source.
Materials
Through contact with or Cutting gas, dust, aero- Health hazard. ■ Ventilate the workplace
by inhaling toxic fluids, sols, cutting oils, PE- sufficiently.
gases, mist, vapors, and coated profiles ■ Observe the notes in
dust. the operating manual.
Thermally decomposed Health hazard. ■ Observe prescribed
lenses or mirrors measures in the event
of an accident.
■ Dispose of corrupted
lenses properly.
Extinguishing gasses CO2 Health hazard. ■ After triggering the
or argon extinguisher, ensure
proper ventilation of
the area.
Fire and explosion
Fire hazard Reflection of laser radia- Risk of injury ■ Keep a powder hand-
tion held fire extinguisher
ready (fire classification
D).
■ Smoking is prohibited
Compact dust extractor Risk of injury ■ Keep a CO2 hand-held
fire extinguisher ready
(fire classification B).
■ Keep a powder hand-
held fire extinguisher
D).
If available: extinguisher Risk of injury ■ Do not turn off extin-
deactivated guishing gas cylinder.
■ Do not switch off the
extinguisher.
■ Reactivate the extin-
guisher following main-
tenance work on the
Machining oily sheets or Risk of injury ■ Replace the dust con-
highly reactive materials tainer on a daily basis.
Malfunction or incorrect function
Malfunction / error rota- The workpiece changer Risk of injury ■ Do not enter the dan-
tional changer stops at an undefined ger zone.
position and does not
reach an end position
Magnetic fields
B836en 2017-11-17 Overview of residual risks 1‐57

the operator
Magnetic field of the per- On the surface of the Danger to life of persons ■ Persons with pacemak-
manent magnet, regard- magnetic coupling on the with pacemakers ers must keep a mini-
less of whether the B/C gearbox of the Z bar- mum distance of 30
machine is switched on or rel cm to the magnetic
off coupling on the Z bar-
rel.
Ferromagnetic attractive On the surface of the Attractive force of the per- ■ Do not hold metallic
force when no voltage is magnetic coupling (without manent magnet (300 N) objects, watches, etc.,
present processing optics) takes effect suddenly up against the mag-
netic coupling.
On the surface of the Attractive force of the pri- ■ Do not hold metallic
magnetic coupling (without mary part (1000 N) takes objects, watches, etc.,
processing optics) effect suddenly up against the mag-
netic coupling.
Electrics
Electric shock Components with residual Risk of fatal injury ■ The residual voltage is
voltage >60 V. Note a dis-
charge time of more
than 5 s (see warning
sign).
The mains disconnector Risk of fatal injury ■ Observe warning stick-
does not switch off when ers.
opening the electrical cab- ■ Work on electrical
inet doors facilities may only be
carried out by a trained
electrician or a person
with electrical engineer-
ing training.
Teleservice
Crushing, cutting, separat- Movements of the Risk of injury ■ Have Teleservice per-
ing, impacting machine formed only by persons
who have been trained
by TRUMPF.
■ If the danger zone has
to be accessed: assign
a second person with
safeguarding.
■ Reduce the speed of
dangerous movements
as far as possible.
Residual risks Tab. 1-12
1‐58 Overview of residual risks 2017-11-17 B836en

8. Machines without complete safety
equipment
8.1 Operating safety
If the machine is supplied and operated without the complete

array of safety equipment, then there will be certain hazards con-
nected with the operation of the machine, e.g.:
■ Unsecured danger zone.
■ Danger due to laser radiation.
■ Danger due to secondary radiation.
■ Danger from dusts and gases.
The operator is obligated to implement suitable measures for the

operational safety of the machine:
■ The operator needs to be informed of the dangers originating
in the machine.
■ The danger zone around the machine, including project-
related handling components need to be secured with appro-
priate measures.
■ The user must mark the danger zone and place suitable
warning signs in view.
■ For machines without compact dust extractors (filter system),
the working area needs to be vacuum-cleaned effectively.
Dust which accumulates needs to be disposed of properly.
■ Machines without safety cabins must provide the operator
and other personnel in the danger zone of the machine with
protection against laser radiation and secondary radiation.
■ In the case of machines with a depression in the work area,
adequate measures must be applied to secure the danger
zone.
When partly completed machinery is operated in the EC region,
the owner must take suitable measures for operational safety to
meet the requirements of the EC Machinery Directive
2006/42/EC.
B836en 2017-11-17 Machines without complete safety equipment 1‐59

8.2 Suction system in the work area
For machines supplied without compact dust extractor and/or

without scrap conveyor, the user must extract dust from the
machine's work area effectively. If the exhaust system is insuffi-
cient then neither the continued operation of the machine nor
compliance with the permissible emission values can be guaran-
teed.
Health hazard due to insufficient or no dust extraction at

WARNING the work area!
Ø The machine must not be put into operation if dust extrac-
tion is insufficient in the work area.
Insufficient or no dust extraction at the work area.

NOTICE
Damage to the guide rails and drive by laser dust accumu-
lating in the work area.
Ø The following specification for a filtering installation to be
provided by the customer must be ensured.
Ø The following specification for waste disposal by the cus-
tomer must be ensured.
If a customer's filter system/filtering device is integrated, the user

is obliged to comply with the following specification:
■ The required suction power (volume rate of flow) at the
extraction inlets is in all at least 4500 m3/h (per extraction
inlet 2250 m3/h).
■ The flow speed in the suction channel of the customer's pip-
ing has to be at least 15 m/s at all points along the entire
length of the piping.
■ The underpressure inside the safety cabin must be at least
11.5 Pa (test pressure).
If a scrap conveyor to be provided by the customer is integrated,

the user is obliged to comply with the following specification for
the design of the exhaust piping in the work area:
■ There are at least 2 exhaust inlets in the safety cabin.
■ The total suction power at the exhaust inlets is a minimum of
4500 m3/h (2250 m3/h per extraction point).
■ The distance of the exhaust inlets from the machining posi-
tion is no more than 500 mm.
1‐60 Machines without complete safety equipment 2017-11-17 B836en

8.3 Laser safety
Laser class Laser machines without safety cabins are categorized as Class 4
laser systems in accordance with EN 60825-1.
Invisible, high-energy laser radiation

DANGER
Serious burns of the skin and injury to the eyes may occur.
Impairment of vision or even complete blindness can be the
consequence.
Ø No personnel are permitted to be present in the machine's
danger zone during machining.
Ø The areas where the operator is to be found during machin-
ing operations need to be marked and properly secured.
Ø The operator must be protected against hazardous laser
radiation during processing operations: personal protective
gear is necessary, and laser safety glasses are to be worn.
Ø The machining may not be started until all other personnel
have been cleared from the danger zone of the machine.
Identification of the laser Class 4 laser product

system
Tab. 1-13
8.4 Secondary radiation
For machines without a safety cabin, the operator will be

exposed to hazardous secondary radiation during the laser proc-
essing. The secondary radiation It is composed of ultraviolet (<
400 nm), harsh, visible and infrared radiation (> 780 nm).
Danger due to secondary radiation during laser processing

DANGER
Intense visible and invisible radiation can irreversibly
damage the retina in your eyes as well as your skin.
Ø The operator must be protected from secondary radiation.

8.5 Overview of residual risks
The following overview of residual risks is a summary of the

main potential threats to life and limb posed by the machine.
Any additional precautions that can be taken by the machine
owner to reduce residual risks are specified in the overview of
residual risks.
The residual risks differ depending on the delivery version of the
machine.

the operator
Mechanical elements
Crushing Motion of the X, Y, Z, B Risk of injury ■ Secure danger zone.
and C axis
Shearing
Movement of project-spe- Risk of injury ■ Secure danger zone.
Impacts cific workstations or
clamping stations
Movement of project-spe- Risk of injury ■ Secure danger zone.
cific material supply and
removal equipment
While teaching Risk of injury ■ If there is a danger
risk, immediately press
the STOP push-button
on the teach panel.
■ Do not step between
the machine body and
the barrel.
■ Do not reach between
the workpiece surface
and nozzle tip.
Z barrel: Suspended axis Risk of injury ■ Do not go under the Z
within the safety cabin barrel.
Fixtures with swivel axes Risk of injury ■ For clamping fixtures
and/or pneumatically actu- for hot-formed workpie-
ated clamping elements: ces: Maintain a suffi-
fast clamp movement or ciently large distance
swivel movement of axes from the fixture while
during teaching the NC program is run
in test mode.
■ For clamping fixtures
for IHU workpieces:
Before the NC program
is run in test mode,
leave the work area
and close the door
from the outside.

the operator
Crushing Danger zone inside the Risk of fatal injury ■ Check the danger zone
safety cabin in the safety cabin
Shearing
before each restart or
Impacts following an interrup-
tion.
■ In case of danger,
leave the danger zone
immediately.
■ For all maintenance
and cleaning work,
press the EMER-
GENCY STOP push-
button and leave the
service door open.
For machines with a pit in Risk of injury ■ Secure danger zone.
the work area, e. g. for
disposing of scrap mate-
rial.
Getting caught or due to Jammed scrap and scrap Risk of injury ■ Before every fault elim-
winding skeleton parts in the ination, de-energize the
scrap conveyor or waste drive motor of the
conveyor belt. scrap conveyor: Turn
the scrap conveyor key
switch into the neutral
position.
Swivel arm Risk of injury ■ Observe the notes in
(Smart Optics Setup the operating manual.
option)
Remote control with Mobi- Risk of injury ■ Observe the notes in
leControl (option) the operating manual.
Movement of rotating Risk of injury ■ Secure danger zone.
work or clamping stations
(project-specific)
Due to fluids and gases Cutting gas Risk of injury ■ Secure danger zone.
being expelled under high
Compressed air reservoir Risk of injury ■ Secure danger zone.
pressure
Heat
Thermal radiation or spurt- Ejected slag spatters Risk of injury ■ Secure danger zone.
ing melted parts
Touching Hot workpieces Risk of injury ■ Wear protective cloth-
ing.
■ Use gloves and tools
to remove workpieces.
Hot nozzle Risk of injury ■ Wear protective gloves.
Hot sacrificial plates and Risk of injury ■ Wear protective gloves.
hot test sheet holder ■ Observe the notes in
(option, the operating manual.
Smart Optics Setup sta-
tion)
Radiation

the operator
Laser In machines without a Health hazard, blindness ■ Secure danger zone.
safety cabin: radiation dur- ■ Determine and mark
ing machining the position of the
operator during
machining
■ Wear protective cloth-
ing and laser safety
glasses.
Pilot laser TruDisk Risk of injury ■ Do not gaze into the
laser beam.
Impermissible openings in Risk of injury ■ Observe the notes in
the safety cabin with no the operating manual.
monitor or no LED display
For machines without a Permanent damage to the ■ Observe the notes in
safety cabin: Secondary retina in your eyes and to the operating manual.
radiation during process- your skin
ing
Light source Lighting within the safety Risk of injury ■ Do not look direct into
cabin the light source.
Materials
Through contact with or Cutting gas, dust, aero- Health hazard. ■ Vacuum clean the
by inhaling toxic fluids, sols, cutting oils, PE- working range.
gases, mist, vapors, and coated profiles ■ Ventilate the workplace
dust. sufficiently.
■ Dispose of dust prop-
erly.
Thermally decomposed Health hazard. ■ Observe prescribed
lenses or mirrors measures in the event
of an accident.
■ Dispose of corrupted
lenses properly.
Extinguishing gasses CO2 Health hazard. ■ After triggering the
or argon extinguisher, ensure
proper ventilation of
the area.
Fire and explosion

the operator
Fire hazard Reflection of laser radia- Risk of injury ■ Keep a powder hand-
tion held fire extinguisher
D).
Compact dust extractor Risk of injury ■ Keep a CO2 hand-held
fire extinguisher ready
(fire classification B).
■ Keep a powder hand-
held fire extinguisher
D).
Concentration of dust in Risk of injury ■ Vacuum clean the
the working area working range.
■ Ventilate the workplace
sufficiently.
If available: extinguisher Risk of injury ■ Do not turn off extin-
deactivated guishing gas cylinder.
■ Do not switch off the
extinguisher.
■ Reactivate the extin-
guisher following main-
tenance work on the
Machining oily sheets or Risk of injury ■ Replace the dust con-
highly reactive materials tainer on a daily basis.
Malfunction or incorrect function
Malfunction/error case in The workpiece changer Risk of fatal injury ■ Do not enter the dan-
the workpiece changer stops at an undefined ger zone.
position and does not
reach an end position
Magnetic fields
Magnetic field of the per- On the surface of the Danger to life of persons ■ Persons with pacemak-
manent magnet, regard- magnetic coupling on the with pacemakers ers must keep a mini-
less of whether the B/C gearbox of the Z bar- mum distance of 30
machine is switched on or rel cm to the magnetic
off coupling on the Z bar-
rel.
Ferromagnetic attractive On the surface of the Attractive force of the per- ■ Do not hold metallic
force when no voltage is magnetic coupling (without manent magnet (300 N) objects, watches, etc.,
present processing optics) takes effect suddenly up against the mag-
netic coupling.
On the surface of the Ferromagnetic attractive ■ Do not hold metallic
magnetic coupling (without force when live objects, watches, etc.,
processing optics) up against the mag-
netic coupling.
Electrics

the operator
Electric shock Components with residual Risk of fatal injury ■ The residual voltage is
voltage >60 V. Note a dis-
charge time of more
than 5 s (see warning
sign).
The mains disconnector Risk of fatal injury ■ Observe warning stick-
does not switch off when ers.
opening the switch ■ Work on electrical
cabinet doors facilities may only be
carried out by a trained
electrician or a person
with electrical engineer-
ing training.
Teleservice
Crushing, cutting, separat- Movements of the Risk of injury ■ Have Teleservice per-
ing, impacting machine formed only by persons
who have been trained
by TRUMPF.
■ If the danger zone has
to be accessed: assign
a second person with
safeguarding.
■ Reduce the speed of
dangerous movements
as far as possible.
Residual hazards connected with machines lacking complete safety equipment Tab. 1-14

9. Disassembly and disposal
TRUMPF recommends that TRUMPF machine tools be disas-

sembled and disposed of by Technical Customer Support or a
specialist disposal company. The following notes are to be
passed on to the specialist disposal company performing the dis-
posal work, to guarantee fast, environmentally sound 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 power supply by a
trained electrician.
■ If available: close off the compressed air and gas supply and
disconnect from the machine.
■ Wait at least an hour to allow any residual voltage in the
machine to dissipate and hot components to cool down. All
assemblies/components can then be touched.
Overview of hazardous The following hazardous substances are to be disposed of

materials according to applicable legislation prior to disassembly:
Hazardous substance Installed in assembly

Arsenic Diodes (Solid-state laser)
Refrigerant
Lubricant container (e.g. central Basic machine
lubrication)
Cooling water with biocides Process cooler
Filter plates Compact dust extractor
Metal dust Compact dust extractor
Batteries Electrical cabinet, APC, control sys-
tem, ...
Possible hazardous substances Tab. 1-15
Declaration of substances in The declaration of substances is only necessary for the area of
acc. with GB/T 26572‑2011 application in China.
(China RoHS 2)
B836en 2017-11-17 Disassembly and disposal 1‐67

Conformity label at the nameplate Fig. 82463
Part desig- Hazardous substances

nation
Lead Mercury Cadmium Hexavalent Polybromi- Polybromi-
chromium nated nated
biphenyls diphenyl
ethers
(Pb) (Hg) (Cd) (Cr+6) (PBB) (PBDE)
Basic X O O O O O
machine
Laser X O O O O O
Dust extractor X O O O O O
Process X O O O O O
cooler
Automation X O O O O O
components
(option)
O:
Indicates that this hazardous substance is present in all homogeneous materials for the parts listed. In terms of
EIP-A, EIP-B and EIP‑C, the value is below the limit stipulated in GB/T 26572‑2011.
X:
Indicates that this hazardous substance in all homogeneous materials in terms of EIP-A, EIP-B and EIP-C is
above the limit value stipulated in GB/T 26572‑2011.
Comments: -
Tab. 1-16
Dismantling ■ Poisonous vapors can result when thermally cutting painted

components or components made out of composite materials!
− Select a suitable cutting process.
or
− Wear a suitable protective mask and ensure there is a
sufficient supply of fresh air.
■ Secure top-heavy assemblies to prevent them from tipping
over and carefully put them in a good transport position (cen-
ter of gravity down).
■ Moving assemblies may be unbraked after being discon-
nected from the power supply!
− Fix movable assemblies prior to disassembly/transport, so
that the center of gravity cannot move in an 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.
1‐68 Disassembly and disposal 2017-11-17 B836en

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.
B836en 2017-11-17 Disassembly and disposal 1‐69

1‐70 Disassembly and disposal 2017-11-17 B836en
Chapter 2
Installation conditions
To what does this apply? 2‐4
1 Planning aid 2‐5
2 Installation site 2‐9

2.1 Space requirements 2‐9
2.2 Floor requirements 2‐9
2.3 Weight load 2‐11
2.4 Ambient conditions 2‐12
2.5 Installation of compact dust extractor 2‐15
2.7 Installation of the process cooler 2‐17
External cooling circuit 2‐18
2.8 Cable racks for laser light cables 2‐24
2.9 Customer screen options 2‐25
Installing the monitor 2‐27
B836en Installation conditions TruLaser Cell 8030 (L60) - 2‐1

Version 4
3 Gas supply 2‐28
3.1 Cutting gases 2‐29
Purity 2‐29
Cutting gas consumption 2‐29
Supply lines for cutting gas supply 2‐30
Requirements on the connection point of 2‐31
the machine
Cutting gas supply with cylinders or bundles 2‐31
Cutting gas supply with gas tank 2‐32
4 Electric power supply 2‐34

4.1 Electrical connection 2‐34
4.2 Power supply 2‐36
4.3 Connected load and fuse protection 2‐37
Central power supply 2‐37
Decentralized power supply 2‐38
4.4 Teleservice 2‐42
4.5 Network connection 2‐42
5 Compressed air supply 2‐43
6 Operating materials 2‐46

6.1 Gases 2‐46
6.2 Cooling water 2‐46
6.3 Dispensing material for MultiCoater 2‐49
7 Transport 2‐50
7.1 Dimensions and weights of the transport units 2‐52
7.2 Transporting machine and machine compo- 2‐56
nents
Transporting basic machine with truck 2‐57
Loading and unloading container 2‐59
Transporting the basic machine to the 2‐60
installation site
Transport TruDisk laser device 2‐61
Transport rotational changer with a crane or 2‐62
forklift
Transporting rotary indexing table with 2‐63
Transportation of scrap conveyor 2‐65
2‐2 Installation conditions TruLaser Cell 8030 (L60) - B836en

Version 4
Transporting the compact dust extractor 2‐65
(Herding)
Transporting process cooler 2‐66
7.3 Installing the system 2‐66
Preparing the factory floor 2‐66
B836en Installation conditions TruLaser Cell 8030 (L60) - 2‐3

Version 4
To what does this apply?
The installation conditions contain all information for the installa-
tion of the machine including the following lasers:
TruDisk 2000, TruDisk 3001 and TruDisk 4001.
The TruLaser Cell 8030 is a system for laser cutting metallic
materials.
Machining of plastic materials is not permitted!
Who does what? Customer: All the conditions described in this chapter must be
fulfilled before the machine is delivered. If this is not the case,
the TRUMPF service engineers will not be able to start up the
machine.
Pass along the respective subsections in accordance with the
following planning aid to the specialist companies/plants (e.g.
electrical installer, specialist plant for industrial gases...) in a
timely manner.
Note
During start-up, the main switch on the machine may only
be switched on by TRUMPF service engineers.
Technical Service: Start-up of the machine is performed by the

service engineer. It includes the following activities.
■ Installing, aligning, leveling and securing the machine.
■ Laying laser light cable.
■ Filling up the process cooler.
■ Connecting the machine to the supplies (with the exception
of the electrical power supply).
■ Performing a functional test.
■ Instructing personnel.
2‐4 Installation conditions TruLaser Cell 8030 (L60) - B836en

Version 4
1. Planning aid
The planning aid checklist below provides an overview of the

measures and preparations to be undertaken by the customer.
Detailed information can be found in the respective sections of
the installation conditions.
Time before Planning crite- Measures Measure

the delivery of rion imple-
the machine mented
14 weeks Personnel and - Appoint a member of staff to be
training responsible for the handover of the
machine.
Appoint operating and service
personnel and programmers.
Arrange training schedules for specialist

personnel.
Check whether a laser safety officer is

needed. Observe national laws and reg-
ulations (Germany: DGUV regula-
tion 11). Further information in the
standards: IEC/EN 60825 and
ANSI Z136.1 (for the USA)
14 weeks Installation site See Section 2, Check space requirements as specified
Installation site in the installation plan.
(see "Installation
site", pg. 2‐9)
Check the floor requirements (floor
quality, how level it is, oil-proof floor
without expansion joints). Keep the
weight and dimensions of the machine
in mind.
Check that the requirements for the
ambient conditions are met (ambient
temperature, insolation, purity of ambi-
ent air.)
Contact the responsible government
agency to determine whether the puri-
fied exhaust air of the compact dust
extractor must be channeled outdoors.
Check the transport route (gateway
dimensions, header heights, cable rack
heights, space to maneuver around cor-
ners etc.).
12 weeks Gas supply See Section 3, Arrange for the installation of supply
Gas supply (see lines for welding gas and cutting gas
"Gas supply", supply to the installation site.
pg. 2‐28)
Decide about the gas supply method
(gas cylinders, cylinder bundles or gas
tank).
B836en Planning aid - Version 4 2‐5

the machine mented
12 weeks Electrical supply See Section 4, Install electrical connections on the
Electrical power installation site. The conductor cross-
supply (see section and fuse protection should be
"Electric power installed in accordance with legal
supply", requirements.
pg. 2‐34)
Note: There can be a different number

of connections depending on the config-
uration.
■ In default: The basic machine, the
laser device and the process cooler
for the laser device each require a
separate electrical connection.
■ Central power supply option: A
shared electrical connection is instal-
led for the basic machine, the laser
device and the process cooler
(chiller). If a user's process cooler is
to be connected, a connection cable
for the process cooler is required.
4 weeks Operating mate- see Section 6, Stock up on operating material: cutting
rials Operating mate- gases and cooling water.
rials (see "Oper-
Dispensing material if a MultiCoater is
ating materials",
used (option).
pg. 2‐46)
Please note:
■ Cooling water in the required quan-
tity and quality is to be provided for
the commissioning.
■ "High purity ethylene glycol" must be
provided for the commissioning of
the process cooler if it is to be
installed in areas vulnerable to frost.
4 weeks Teleservice See Section 4, Provide access to the internet.
Electrical power
supply (see
"Electric power
supply",
pg. 2‐34)
4 weeks Network connec- See Section 4, The network connection requires a sep-
tion Electrical power arate power supply.
supply (see
"Electric power
supply",
pg. 2‐34)
2‐6 Planning aid - Version 4 B836en

the machine mented
4 weeks Fire protection - Keep the following fire extinguisher
ready at the machine for reasons of fire
protection:
■ If the compact dust extractor is
equipped with a CO2-extinguisher:
CO2 fire extinguisher (fire classifica-
tion B)
■ If the compact dust extractor is
equipped with an argon extinguisher:
powder extinguisher (fire classifica-
tion D).
■ Hand-held fire extinguisher for metal
fires (fire classification D).
4 weeks Transport See Section 7, If you are transporting the machine to
Transport (see the installation site yourself, ensure the
"Transport", required means of transportation and
pg. 2‐50) transport aids are available.
4 weeks Laser safety - Observe the regulations applicable in
the country of operation.
Valid for Germany:
Register the laser machining system
with the employer's liability insurance
association and with the trade board.
Make laser safety glasses available for
service work, safety glasses for laser
light with a wavelength of 1030 nm.
4 weeks Planning aid - Check whether all necessary measures
preparation for preparing installation and commis-
installation and sioning of the machine have been
start-up taken.
Send the "Installation and start-up plan-
ning aid" to Technical Service in the
respective country or to the respective
representative.
4 weeks Foundation See Section 7.2, Prepare the foundation of the basic
Installing the machine according to the foundation
system (see plan. Apply bore holes and cut-outs.
"Installing the
system",
pg. 2‐66)
4 weeks Cable rack for See Section 7.2, Please note: If no "standard cable
laser light cable Installing the rack" is installed, the user must install
system (see the cable racks himself in which the
"Installing the laser light cable is routed from the laser
system", installation site to the machine.
pg. 2‐66)
4 weeks Accessories -
option
Access Con-
trol Key
B836en Planning aid - Version 4 2‐7

the machine mented
During the deliv- Transport See Section 7, If the customer transports the machine
ery of the Transport (see to the installation site himself:
machine "Transport", ■ Make the required means of trans-
pg. 2‐50)
portation available.
■ Have qualified transport personnel
available.
Note: TRUMPF Technical Service pro-
vides the required means of transporta-
tion and auxiliary transport equipment
when assigned with conveying the
machine to the customer's site.
During installa- Qualified electri- - Have qualified electricians available to
tion and start-up cians connect the system.
of the machine
Check list for planning aid Tab. 2-1
2‐8 Planning aid - Version 4 B836en

2. Installation site
What does the customer Please consult a structural analyst for professional support, par-
need to do? ticularly in connection with the topic of floor requirements, and
give him a copy of the pertinent section.
Platform installation If supply units of the machine, such as process coolers, compact
dust extractors or electrical cabinets, are put up on a platform,
note the following:
■ The platform does not belong to the machine's scope of
delivery.
■ The platform must meet applicable standards and national
regulations concerning safety of being stepped on.
■ Leaking water, oil or other operating materials have to be
captured.
2.1 Space requirements
An installation plan is created for each machine. The required

space for opening the doors of the control cabinet, suction sys-
tem and the laser device is illustrated there.
Any subsequent supplementations to the machine by the cus-
tomer, for example automation components, are not included in
the installation plan and must be taken into account by the oper-
ator.
2.2 Floor requirements
Flatness ■ The floor on which the machine is installed should be as

even as possible. Minor unevenness can be compensated for
using adjustable legs or wedge mounts.
■ In the range of the machine's installation surface, the height
variation may not exceed 12 mm per 10 m. In the range of
the safety doors at the front and the side, for laser safety
reasons the floor's height variation must not exceed 5 mm .
Installation surface ■ The installation surface for the basic machine must consist of
a continuous base plate in the area of the load-bearing
points.
■ There may not be any expansion joints between the load-
bearing points.
B836en Installation site - Version 4 2‐9

■ In the area around the wedge mounts plastic or asphalt
coatings are not permissible
■ In the case of newly laid floor/ceiling plates, it is imperative
e.g. during the drying process, to avoid settling effects which
would exceed the maximum values indicated above.
External influences due to changing loads in the immediate vicin-

ity of the machine can affect the quality of the workpieces.
These are e.g.:
■ Fork lifts, industrial trucks, etc.
■ The installation or removal of other machines in the immedi-
ate vicinity of the machine.
■ Machines which excite vibrations during operation, such as
punch presses etc.
Note
Exact inspections must be conducted in individual cases.
Flexible base plate ■ Load capacity 20 kN/m2.

■ Minimum thickness 250 mm.
■ Concrete quality (corresponding to a strength class of
C 25/30):
− Cylinder compressive strength fck, cyl ≥ 25 N/mm2.
− Cube compressive strength fck, cube ≥ 30 N/mm2.
■ Concrete steel reinforcement with:
− characteristic rated value fy ≥ 435 N/mm2.
− an elasticity module for which Es ≥ 200000 N/mm2.
− a reinforcement at the top, crosswise for each 3.7 cm2/m.
− a reinforcement at the bottom, crosswise for each
3.7 cm2/m.
■ Elastic cushioning of the base plate on foundation with a
minimum ballast number of C ≥ 5000 kN/m3 (loess loam).
■ No joint of any kind, nor any dummy joint (separated shield-
ing panel) may be located in the area of the machine or
within at least 1.0 m of it.
Ceiling plate/free span base ■ Load capacity 20 kN/m2.

plate ■ Minimum thickness 250 mm (for load capacity 20 kN/m2).
As a fundamental principle, the statics of the ceiling or floor plate
on hand must be checked by a structural analyst.
Maximum stress due to Acceleration of vibration 0.01 g (100 mm/s2)

vibration for TruDisk laser Maximum stress due to vibration in vertical direction Tab. 2-2
If the vibration at the installation site is higher, then shock-

absorbing pads must be used. To correctly dimension the shock-
2‐10 Installation site - Version 4 B836en

absorbing pads, the vibration at the installation site must be
measured.
2.3 Weight load
Structural stress analysis The load capacity of the floor surface must be subjected to a
structural stress analysis prior to installation. The weights of the
relevant components and the loads on the support points can be
taken from the following overview.
Foundation load Component Weight Distribution of

in kg weight
Basic machine TruLaser Cell 9100 Weight is distributed
8030, including switch cabinet over 10 wedge
mounts (surface 120
mm x 175 mm). The
wedge mounts on the
extension arm side
carry approx. 2/3 of
the total load.
Compact dust extractor - The edges support the
DELTA Comp 1500-14/9 SB main load.
- without soundproofing cover 1250
- with soundproofing cover 1350
MultiCoater type 55/1 (option) 170 -
Workpiece changer: - -
- Rotational changer 2500 Weight is evenly dis-
tributed over 8 surfa-
- Rotary indexing table (option) 4500
ces.
Scrap conveyor: - -
- For rotational changer 1270 Weight is evenly dis-
tributed over 12 surfa-
- For rotary indexing table 1500
ces.
(option)
Basic machine system components Tab. 2-3
Laser device filled with cooling Weight Distribution of

water in kg weight
TruDisk 2000 470 Weight is evenly dis-
tributed over 4 adjust-
TruDisk 3001 470
able legs.
TruDisk 4001 470
Laser device TruDisk Tab. 2-4

The following table is valid for water/air process coolers manu-
factured by Riedel, product group type RLxx/0 SR (TR):
Machine without machine cooler Machine with machine cooler Distribution of

weight
Laser device Process cooler Weight in kg Process cooler Weight in kg Weight is evenly
filled filled distributed over
4 adjustable
TruDisk 2000 RL13/0 300 RL10/0 300
legs.
TruDisk 3001 RL17/0 410 RL17/0 410
TruDisk 4001 RL20/0 440 RL17/0 410
Process cooler, chiller for TruDisk Tab. 2-5
The following table is valid for water/water process coolers

manufactured by Riedel, product group type RWxx/0 SR (TR):
Machine without machine cooler Machine with machine cooler Distribution of

weight
Laser device Process cooler Weight in kg Process cooler Weight in kg Weight is evenly
filled filled distributed over
4 adjustable
TruDisk 2000 RW13/0 300 RW13/0 300
legs.
TruDisk 3001 RW17/0 400 RW13/0 300
TruDisk 4001 RW20/0 400 RW17/0 400
2.4 Ambient conditions
Ambient temperature Notes

■ Avoid one-sided, direct exposure to sunlight or drafts coming
from one side.
■ Keep the ambient temperature constant while operating the
machine. Ensure sufficient circulation of air in the factory hall.
Temperature
Operation between +10 °C and +43 °C
Storage between +5 °C and +43 °C
Permissible machine ambient temperature Tab. 2-7
Temperature
Operation between +10 °C and +50 °C
Storage
Relative air humidity maximum 100% at 28°C
(see dew point dia-
Tropical version: maximum of 100 % at 32 °C
gram)

Temperature
Protection class IP 54 with closed doors and covers
Note: If the environment is exposed to large
quantities of dust or aerosol, TRUMPF recom-
mends a housing for the laser device.
Permissible ambient temperature TruDisk Tab. 2-8
Dew point Dew point diagram TruDisk 2000:
U Ambient temperature RL Relative humidity

Dew point diagram Fig. 88327
Dew point diagram TruDisk 3001, TruDisk 4001:
t Ambient temperature RL Relative humidity

Dew point diagram Fig. 87523
When operating the laser device, the values must be within the
gray area of the dew point diagram.

The closer the ambient conditions are to the limit values shown
in the diagram, the longer the advance time of the air cleaner
can become. In some cases, it is advisable to leave the laser
control system, and thus the air treatment, switched on.
If the required ambient conditions cannot be maintained, appro-
priate conditions must be created artificially for the laser device
(e.g. cabin, air-conditioning).
Tropical version When the ambient temperature is between +35°C and +43°C the
machine is delivered in tropical version.
Switch cabinet cooling The air conditioning unit sucks the warm air from the switch cab-
inet and blows cold air back into the switch cabinet. Cooling is
switched off while the switch cabinet doors are open.
Note
Damp rooms are not suitable for the operation of the control sys-
tems, mainly because contact corrosion can develop on contac-
tors and relay contacts, resulting in control system errors.

2.5 Installation of compact dust extractor
The machine is standard equipped with a Herding compact dust

extractor. The air in the machine's work area is extracted and is
conducted via a pipeline system to the compact dust extractor,
where it is cleaned.
Note
The compact dust extractor may only be installed in the interior
space.
International/national Regulation outside of Germany:

regulation ■ The user must comply with the national regulations for han-
dling the exhaust air of the compact dust extractor and the
dusts it contains.
Regulation in Germany:
■ For the laser processing of stainless steel and materials from
which harmful substances can arise as suspended dust, the
exhaust air of the compact dust extractor must be conducted
to the outdoors.
− In Germany, the limits for the return of cleaned air into
the room air are defined in "Technical Rules for Hazard-
ous Materials TRGS 560".
■ For the laser processing of mild steel or aluminum, for exam-
ple, the cleaned air of the compact dust extractor may be fed
back into the room air.
Exhaust air system The exhaust air system beginning at the clear gas duct port of
the compact dust extractor must be installed by the customer.
The pipeline must be installed as follows:
■ Max. of two 90° tube bends (radius = diameter x 1.5).
■ Max. length: 10 m.
■ Tube diameter: at least 300 mm.

A without soundproofing B with soundproofing
Clear gas duct connection according to DIN 24154-R2 Fig. 73826
MultiCoater (option) The compact dust extractor may be optionally equipped with a
MultiCoater.
The MultiCoater may only be installed in the interior space.

2.6 Suction system in the work area
If a waste conveyor provided by the customer and/or a filtering

installation provided by the customer are/is to be integrated, a
sufficient and effective exhaust system must be provided in the
work area. Continued operation of the machine cannot be guar-
anteed if the exhaust system is insufficient.
Exhaust system If a scrap conveyor to be provided by the customer is integrated,

requirements if a customer's the user is required to comply with the specification recom-
waste conveyor is integrated mended by TRUMPF for the design of the exhaust piping in the
work area.
All on-site measures should be implemented in accordance with
the specification "Interface for Integration of the Scrap Conveyor
to be Provided by the Customer", drawing no. 93964-425-A50.
In this case, this interface description belongs to the project lay-
out.
Exhaust system If a customer's filtering installation is integrated, the user is obli-

requirements if a customer's gated to comply with the following specification:
filtering installation is ■ The total suction power at the exhaust inlets is a minimum of
integrated
4500 m3/h (2250 m3/h per extraction point).
■ The flow speed in the suction channel of the customer's pip-
ing has to be at least 15 m/s at all points along the entire
length of the piping.
It must be ensured that no dust is deposited in the pipeline.
Note
The filtering installation belongs to the safety equipment of the
laser machine. The filtering installation is a significant feature for
the issue of the EU declaration of conformity. In order to issue
an EU declaration of conformity for the laser machine, the filter-
ing installation provided by the customer must meet the safety
requirements defined by TRUMPF.
2.7 Installation of the process cooler
Note
The standard-process cooler is not suitable for outdoor installa-
tion.

Outdoor installation If the process cooler is installed outdoors, the following must be
observed:
■ Process coolers for outdoor installation have their own main
switch and require a separate power supply.
■ Process coolers for outdoor installation have tank heating.
■ At an ambient temperature under 0 °, the MAIN SWITCH of
the process cooler may not be switched off.
■ At an ambient temperature of < 6 ° ethylene glycol must be
added to the cooling water.
■ The installation surface for the process cooler must be
designed in such a way that no escaping water or oil passes
into the ground.
■ A weather protection cover, or weather protection hood is
required for the process cooler. In order to allow access for
maintenance and repair work, comply with the minimum dis-
tances as shown in the drawing.
Example: Minimum distances for the weather protection Fig. 39478

cover
Process cooler laser device The laser device is delivered with an external process cooler
(chiller). The chiller is connected to the internal cooling circuit of
the laser device.
External cooling circuit
Note
This section is only relevant if the user connects the laser device
TruDisk to an on-site in-house water system or to a process
cooler provided by the user.

What does the customer The user sets out the external cooling circuit according to the
need to do? performance data which follows and connects the in-house water
connections or the process cooler to the laser device.

Requirements on an external The laser device may be connected to an on-site in-house water
cooling circuit system or to a process cooler provided by the user.
Supply and return connec- Hose fitting with 1" outside diameter or union nut with 1 1/4" internal thread
tions on the laser device
Permitted connection materi- V2A, V4A, brass/red brass, PVC-U, EPDM, red brass, nitrile rubber (NBR), cop-
als per
Line pressure on the con- ≤ 6 bar
nection point
Permitted differential pres- TruDisk 2000 1 bar ≤ Δp ≤ 6 bar
sure between supply and
TruDisk 3001 0.2 bar ≤ Δp ≤ 6 bar
return lines at the connec-
TruDisk 4001
tion point
Permitted supply tempera- TruDisk 2000 +5 °C up to +25 °C
ture
TruDisk 3001 +5 °C up to +28 °C
TruDisk 4001
Water quality Cooling water tower according to VDI 3803, appendix B, table B3.
A prefilter ≤ 135 μm must be installed for heavily contaminated water.
Overflow valve An overflow valve is required for process coolers (chillers).
External laser device cooling circuit Tab. 2-9
Notes
■ If the machine does not have a machine cooler, the optical
components of the machine are cooled by means of the
process cooler for the laser device (chiller). This means that
the process cooler provided by the user or the in-house
water system must have a 4 KW higher cooling capacity than
a machine with a machine cooler.
■ For the required cooling capacity for process coolers with a
water-air cooling circuit, see: Required cooling capacity for
water-air cooling circuit.
Cooling water requirement The cooling water requirement for an external process cooler or
characteristic curve an in-house water system is dependent on the laser power and
the maximum supply temperature of the external cooling unit.
The characteristic curves indicate the minimum cooling water
requirement at maximum power input (service case), dependent
on the maximum supply temperature.
Note
The following characteristic curves are only valid for the laser
device TruDisk. This does not takes account of the 4 KW higher
cooling capacity for cooling the optical components of the
machine.

A Minimum water requirement [l/h] t Supply temperature [°C]
Cooling water requirement characteristic curve Fig. 88325

Differential pressure The minimum differential pressure (with internal valves open) at
characteristic curve the connection point on the laser device is obtained from the
flow rate calculated.
B Flow rate [l/h] ΔP Differential pressure [bar]

Differential pressure characteristic curve Fig. 88326
Calculating the minimum The required minimum differential pressure between the supply
differential pressure and return at the connection point is obtained from the supply
temperature and the flow rate calculated.

In this example, the required minimum differential pressure is
1 bar between the supply and return.
A Minimum water requirement [l/h] B Flow rate [l/h]

t Supply temperature [°C] ΔP Differential pressure [bar]
Calculating the minimum differential pressure Fig. 79721
Notes
■ If the cooling capacity of the external cooling circuit is set too
low, the cooling unit's regulation reserve reduces. This could
result in frequent operational malfunctions of the laser device
due to excess temperature.
■ TRUMPF recommends incorporating a safety margin of
0.5 bar in the calculated minimum differential pressure for the
design of the hose cross sections and hose lengths.
Required cooling capacity The following cooling capacities are required for process coolers
for water-air cooling circuit with a water-air cooling circuit1:
Laser Machine with Machine without

machine cooler machine cooler
TruDisk 2000 ≥ 9.4 KW ≥ 13.4 KW
TruDisk 3001 ≥ 14.5 KW ≥ 18.5 KW
TruDisk 4001 ≥ 17 KW ≥ 21 KW
Required cooling capacity Tab. 2-10
Note
The required pump pressure at the connection point is calculated
from the total pressure loss: pressure loss at the connection
point as per the characteristic curve "Pressure difference" + pres-
sure loss from supply line = total pressure loss.
1 Rated power following degradation.

2.8 Cable racks for laser light cables
Note
The laser light cable is installed by Technical Service.
The laser light cable (LLK) is guided in a cable rack from the
installation site of the laser to the machine. If a standard cable
rack is installed, this belongs to the machine's scope of delivery.
If no standard cable rack is installed, the following applies:

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

2.9 Customer screen options
Screens are integrated in the front side of the safety cabin for
the functions "Residual run time display" and "Work area moni-
toring". The monitors can be delivered as an option.
Alternatively, the user has the option to insert their own screens
in the recesses provided for this purpose. The screen for observ-
ing the work area is mounted and connected on the left and the
screen for displaying the residual run time on the right.
What does the customer If a customer's screen is to be installed, the user must mount
need to do? the screen in the safety cabin wall and connect it electrically
themselves.
Screen specification TRUMPF recommends installing screens with the following spec-
ification:
Monitor 32" TFT screen

Resolution: 1920 x 1080
Voltage supply 24 V DC.
Power typically 80 Watt, maximum
90 Watt
Plug socket 3 individual connections for plug
type Cinch
Tab. 2-11
Mechanical interface The following mechanical interface is available for the screen in
the front side of the safety cabin:
Mechanical interface for the screen Fig. 78929
Screen holder To fasten the screens in place, a screen holder, type VESA MIS-
F (600 mm x 200 mm) can, for example, be installed.

Electrical interface To connect the screen (transfer the video signal) an Cinch con-
nection cable with 3 individual plugs is mounted in the recess for
the screen.
Cover for screen recess For the customer screen option, the recess for the screen in the
safety cabin is provided with a cover on delivery of the machine.
Cover for screen recess (rear view) Fig. 78931

Installing the monitor
1. Unscrew the four marked fastening screws on the inner wall

of the safety cabin to be able to remove the cover in the
front side.
1 Fixing screws
Cover attachment from inside Fig. 79719
2. Remove the cover for the screen recess at the front side of
the safety cabin.
1 Screen recess cover

Cover Fig. 78928
3. To install the screen:

− Insert the screen into the recess in the safety cabin.
− Screw the screen from the inside onto the safety cabin
wall either directly or by means of the screen holder.
− Connect the screen electrically.

3. Gas supply
What does the customer Professional gas installation is a basic prerequisite for smooth
need to do? commissioning and trouble-free operation of the installation. The
following chapter must therefore be passed along to the special-
ist company for industrial gases you have contracted with in a
timely manner in accordance with the planning aid.
Notes
■ Recommendation from TRUMPF: Contact your gas supplier
regarding the gas supply.
■ Installation must be performed by a qualified industrial gas
company. A specialized company certified by the DVGW
(German Technical and Scientific Association for Gas and
Water) or a gas and water fitter is not suitable.
■ The gas installation at the customer site must be laid up to
the connection points on the machine.
■ Observe applicable standards
■ Separate gas connections are required for the gas supply of
fixtures. It is not permitted to used the gas supply from the
machine.
Short circuit or fire hazard when gas lines and electrical

WARNING cables are laid together.
Ø Do not lay gas lines together with electrical cables in a sin-
gle cable duct.
Ø Keep gas lines separate up to the connection point on the
machine.
2‐28 Gas supply - Version 4 B836en

3.1 Cutting gases
Note
Compressed air cutting gas: see "Compressed air supply" sec-
tion.
Purity
Cutting gas Purity

Oxygen (O2) 3.5 99.95 % by vol.
Nitrogen (N2) 5.0 99,999% by vol.2
Argon (Ar) 4.6 99.996 % by vol.
compressed air See Section “compressed air supply“
Cutting gas purity Tab. 2-12
In exceptional cases, nitrogen of purity 4.6 (99.996) or other puri-

ties can be used as long as the following limit values are not
exceeded:
■ O2 ≤ 100 ppm
■ H2O ≤ 5 ppm
■ CnHm ≤ 1 ppm
■ ≤100 particles (for particles ≤0.3 µm; based on 2.83 l ≙ 0.1
ft3)
Cutting gas consumption
Typical consumption during The cutting gas consumption depends on the nozzle diameter
high-pressure cutting and on the cutting gas pressure:
N2 high pressure
Minimum input pressure (required flow 27 bar
pressure at the connection point of the
machine)
Cutting gas pressure 20 bar
Nozzle diameter 2.3 mm
2 When using nitrogen with low purity, oxygen impurities of 100 ppm and
above can cause discoloration of the cutting edges during high-pres-
sure cutting. This can only be avoided by using nitrogen with a purity
of 5.0 or by a cutting gas supply from a gas tank (the nitrogen purity
in the gas tank is usually 5.0).
B836en Gas supply - Version 4 2‐29

N2 high pressure
Cutting gas consumption (under stand- 55 m3/h
ard conditions)
High-pressure cutting with nitrogen Tab. 2-13
Supply lines for cutting gas supply
This symbol indicates the connection point for the cutting gas in
the installation plan.
The customer must provide the cutting gas supply lines up to the
connection point on the machine:
■ The supply lines must be installed up to the connection point
on the installation plan indicated by the symbol on the left.
■ Pipes should be used for the entire gas installation from the
gas cylinder or central gas tank to the connection point of
the machine.
■ The vaporizer must be designed to accommodate the maxi-
mum consumption of all connected machines. The line from
the vaporizer to the connection point must be kept as short
as possible.
■ Set up the external gas installation in such a way that the
supply lines to the connection point of the machine and the
connection point itself are unable to ice up.
■ As a general principle, a stopcock must be mounted before
each branch in a ring pipeline in order to make it possible to
shut down the each ring pipeline segment separately.
Note
The gas temperature must not exceed 50 °C. This is of
particular importance if the required gas pressure is generated
by means of pressure booster systems!
Pipes ■ Oil and grease-free lines made of special quality copper pip-
ing ("refrigerator quality", inert-soldered with simple forming
gas) are sufficient for the cutting gases.
■ Use Swagelok clamping ring screw fittings.
■ Secure sealing points with flat gaskets.
Notes
■ Teflon tape, liquid Teflon, sealing sprays, lubricants and lubri-
cating pastes must not be used.
■ Stainless steel pipes are not necessary.
■ Protect pipes against contamination during transport and stor-
age.

Pipeline section Pipe dimen- Nominal
sions width [mm]
For tank installation: from the vaporizer to ¾" or 22 x 19
the ring pipeline 1.5
Ring pipeline for supplying more than two 1" or 28 x 25
laser systems 1.5
From the ring pipeline/main supply strand 5/8" or 18 x 16
to the tapping point (N2) 1.5
From the tapping point to the connection ½" or 15 x 1 13
point on the machine (O2)
Supply line for the cutting gas supply Tab. 2-14
Requirements on the connection point of

the machine
O2 Stand- N2 High
ard pres- pressure
sure
Min. input pressure flow pressure in bar 8 27
Max. static input pressure 3 in bar 21 33
Max. cutting gas pressure in bar 6 20
Volume rate of flow4 in m3/h (under 10 55
standard conditions)
Tube connection, outside diameter ∅ 8 ∅ 10
in mm
Cutting gas supply: Machine connection point Tab. 2-15
Cutting gas supply with cylinders or

bundles
Note
Cylinders or bundles are not suitable for high-pressure cutting
with N2.
Cylinders or bundles ■ The supply of cutting gas with pressure reducers for cylin-
ders or bundles require increased handling, however, due to
3 The machine is equipped with blow-off valves that respond at high

input pressure, making a whistling sound in the process.
4 The volume rate of flow depends on the maximum cutting gas pres-
sure selected and the nozzle diameter specified

the high level of consumption. One bundle consists of twelve
cylinders = approx. 120 m3 gas.
■ The gas flow is interrupted when changing the cylinder or
bundle.
Cylinder banks or cylinder ■ Switchover devices are required for uninterrupted operation
bundle banks with bottle or cylinder banks.
■ The switchover is performed manually or automatically.5
■ Cylinder banks or cylinder bundles are frequently installed at
some distance from the laser machine. For this reason, the
use of a tapping point pressure reducer close to the laser
system is recommended.
Pressure control O2 Standard N2 High pres-

specifications pressure sure
Admission pressure in bar 0 - 200 0 - 200
Maximum permissible back pres- 25 40
sure in bar
Minimum flow rate in m3/h 30 90
(under standard conditions)
Other requirements Suitable for oxy- Oil and grease-
gen; free of oil free
and grease
Cutting gas supply: pressure control specifications Tab. 2-16
Note
The pressure must be monitored by installing the specified pres-
sure regulators on the supply unit. The pressure regulators must
be secured against the maximum input pressure (intrinsically
safe).
Cutting gas supply with gas tank
Gas tank ■ A tank system is appropriate for safe gas supply at a gas
consumption of at least about 200-400 m3/week.
■ The optimum tank size depends on the tapping quantity and
on the local conditions.
■ The customer should consult the gas supplier.
5 We recommend using a signaling unit for automatic switchover, since

otherwise both sides of the cylinder or bundle bank could be drained
without being noticed.

The following are requirements for high-pressure cutting with
nitrogen:
■ Do not use a tapping point pressure regulator between the
gas tank and the machine behind the pressure regulating
station.
■ Between the gas tank and the machine, a stop valve must
be installed at the end of the pipeline, i.e. at the machine
entrance.
O2 Standard N2 high pres-

pressure sure
Required pressure in bar 18 36
Maximum tapping pressure 14 30
in bar
Cutting gas supply – tank system Tab. 2-17
Pressure control O2 Standard N2 High pres-

specifications pressure sure
First pressure stage (tank)
Safety pressure regulation sys- Optional Recommended
tem6
Second pressure stage (tapping
point)
Tapping point pressure regulator Recommended Not recom-
mended
Back pressure in bar 0-16 -
Other requirements Suitable for oxy- Oil and grease-
gen, free
oil and grease-
free
Cutting gas supply: pressure control specifications Tab. 2-18
6 The safety pressure regulation system is installed close to the tank. It

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

4. Electric power supply
What does the customer Professional electrical installation is a basic prerequisite for
needs 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 con-
tracted with in a timely manner in accordance with the planning
aid.
Area of application IEC-/NEC ■ IEC is valid worldwide.

■ NEC applies only to Canada and the USA.
Decentralized power supply In a standard case, the user has to install 3 individual electrical
connections for the laser processing machine:
■ For the basic machine.
■ For the laser device.
■ For the external laser process cooler.
Central power supply Optionally, the laser processing machine can be equipped with
a central power supply. All machine components, including the
the laser device and the external process cooler are then pow-
ered via a common electrical connection.
A central power supply is also possible in the following condi-

tions:
■ If the customer connects the laser device to a process cooler
provided by the user. In this case, the process cooler can
also be powered from the central feed.
■ If the user integrates an on-site scrap conveyor. In this
case, the user must install a separate electrical connec-
tion for the scrap conveyor. The scrap conveyor is not
powered from the central feed.
A central power supply is not possible in the following cases:

■ If the laser device or the process cooler are set up in a dif-
ferent room, e.g. in the basement.
■ If the laser device or the process cooler are set up on a plat-
form.
4.1 Electrical connection
Area of application Rated voltage Frequency

IEC 400 V ±10 % 50 Hz ±1 %
460 V +10%/ -5% 60 Hz ±1 %
2‐34 Electric power supply - Version 4 B836en

Area of application Rated voltage Frequency
NEC 460 V +10%/ -5% 60 Hz ±1 %
Rated voltage and frequency Tab. 2-19
Notes
■ The tolerance range applies to the short-term supply fluctua-
tions. Impermissible voltage fluctuations endanger the fault-
less operation of the machine and reduce performance.
■ In the event of continuous impermissible fluctuations, e.g. a
network stabilizer or an undervoltage supply is recom-
mended.
■ The line tolerance must be determined if the nominal voltage
is 380 V or 415 V at 50 Hz.
■ No isolating transformer is required if the tolerance is
between 360 V and 440 V.
■ NEC: the specification complies with the standards of the
American National Standard (ANSI) C84.1-1989 Table 1,
"Voltage range A".
The symbol indicates the connection points in the installation

plan.
The following table applies to the connection of the basic
machine and to the connection of the external process cooler
for the laser device.
IEC NEC
Electrical supply Version according to -
DIN EN 60204-1/4.3.1
Leadership Four-core copper cable Four-core copper cable (L1, L2, L3,
(L1, L2, L3, PE) PE):
■ THHN copper or equivalent is
recommended (2000 V test volt-
age) designed for a maximum
temperature of 90 °C/194 °F.
■ No aluminum cables may be
used for the connection.
Conductor cross-section Version according to ■ The conductor cross-section
IEC 60364-4-43 must comply with NEC 670-4
(VDE 0100, part 430) (a). The conductor cross-section
must be designed for at least
125 % of the nominal current.
The nominal current is specified
on the nameplate.
■ To ensure voltage stability and
rating, the line dimension should
be larger than specified in the
NEC table 310-16.
Ground wire Version according to -
IEC 60364-5-54
(VDE 0100, part 540)
Fuse type gL/gH RK1/Class J
Electrical connection cable Tab. 2-20
B836en Electric power supply - Version 4 2‐35

4.2 Power supply
Uninterruptable power The following applies if it is necessary to connect the machine to

supply (USV) an uninterruptible power supply (UPS):
■ When working out the dimensions of the UPS, the short-cir-
cuit and overload responses of the UPS system are to be
taken into account, along with the continuous power and the
electrical connected loads (see Section "Connected loads,
fuse protection").
■ As a rule: overload capacity of the UPS ≥200 % for 0.5 s.
Note
The dimensioning of the uninterruptible power supply must be
established by the manufacturer of the UPS plant.
Fault current circuit breaker A fault current circuit breaker provides protection from fault cur-
(RCD) rents due to directly or indirectly touching live parts.
■ If a fault current circuit breaker is used to provide protection
from direct contact, an isolating transformer must be used.
This is because the leackage current resulting from the
design is >30 mA.
■ If a fault current circuit breaker is to be used to provide pro-
tection from indirect contact, this must be selected depend-
ing on the machine's leakage current.
Notes
■ Whether a fault current circuit breaker has to be used
depends upon the local electricity company.
■ The machine must be separated from the power supply by
an isolating transformer if the leakage current of the machine
is higher than the fault current set when using a fault current
circuit breaker (EN 50178, Point 5.2.11.1, VDE 0160).
■ On the line side, only fault current circuit breakers of type B
(sensitive to all types of fault current, EN 50178,
Point 5.2.11.2; VDE 0160) are approved to provide protection
against direct or indirect contact.
Power supply configurations The power supply for the connection is configured as a TN sys-
tem with grounded star point. The connecting cable has four
cores (L1, L2, L3 with clockwise phase rotation and PE).
With IT and TT line structures as well as asymmetrical lines (one
phase grounded - corner-grounded delta network), the machine
must be connected via an isolating transformer.
Note
A surge diverter is required if the machine is connected to an IT
system.

NEC conditions The following conditions apply in the area of application of the
standards UL489 and UL248 (for USA and Canada):
■ Grounding: The machine and power distributor system must
be equipped with a grounding line in accordance with
NEC article 250, "Grounding".
■ Three phase power supply: For a three phase power sup-
ply without a ground, an unregulated isolating transformer
must be installed (NEC item 450-5). Less faults will occur,
excessive voltages will be reduced and the power network
will be protected from voltage shifts.
■ Back-up fuse: the user must equip the machine with a back-
up fuse for its connection which limits the SCCR value to
35 kA, insofar as the power supply has a higher SCCR
value.
Isolating transformer The following requirements apply for the isolating transformer:
■ Construction service: at least 125 % of the maximum con-
nected load.
■ Power-on time: 100 %.
■ Short-circuit voltage: ≤2.4 %.
■ Winding structure (circuit): DYN5.
■ Secondary voltage:
− At 50 Hz: 400 V.
− At 60 Hz: 460 V.
■ Additional connections on the primary side for adjusting the
line voltage: +10 V, +20 V, –20 V, –10 V.
■ Recommendation: insert transformer with copper coil. Alumi-
num wound transformers are not recommended because of
their inherently higher impedance.
■ Registration for the corresponding country, e.g. CE marking
for Europe or UL for USA.
Note
The isolating transformer does not belong to the machine's
scope of delivery. It must be provided by the user.
4.3 Connected load and fuse protection
Central power supply
Central power supply is an option. All machine components,

including the laser device and the external laser process cooler
are powered via a shared electrical connection.

Machine including TruDisk and TruDisk TruDisk TruDisk TruDisk TruDisk TruDiks
laser cooler, machine with:7 2000 3001 4001 2000 3001 4001
Valid for water-air process cooler Valid for water-water process cooler
Typical rated power [kVA] 35.5 40 45.7 36 38.5 44.2
Connected load [kVA] 38 46 51 38.5 44.5 49.5
at 400 V and 460 V
Nominal current [A] at 400 V 51 57 67 52 55 65
Nominal current [A] 460 V 45 53 61 45 51 59
Maximum fuse protection [A] 100 100 100 100 100 100
at 400 V and 460 V
Connection cable cross-section 35 35 35 35 35 35
[mm2] [Cu]
Maximum acceptable interruption See EN 60204, Part 1, Sect. 4.3.2, Alternating current supply
of nominal voltage [ms]
Standard values, connected load and fuse protection, central power supply Tab. 2-21
Variant if process cooler The process cooler provided by the user is connected in the
provided machine switch cabinet. The interface is a motor circuit-breaker
with the following fuse protection:
Laser device Motor circuit- For a machine For a machine

breaker inter- with a machine without a
face cooler machine cooler
TruDisk 2000 =EP.EL+CB1- 16 - 25 A 16 - 25 A
A1.F2
TruDisk 3001 16 - 25 A 25 - 32 A
TruDisk 4001 25 - 32 A 32 - 40 A
Motor circuit-breaker fuse protection Tab. 2-22
Note
The process cooler is connected by the user. The required con-
nection cable for the process cooler is provided by the user.
Decentralized power supply
The electrical power supply of the laser processing machine

each requires 3 separate electrical connections as standard:
■ A connection for the electrical supply of the basic machine,
including rotational changer or rotary indexing table, scrap
conveyor and compact dust extractor.
■ A connection for the electrical power supply of the laser
device.
■ A connection for the electrical power supply of the external
process cooler (chiller) for the laser device.
7 The values are valid for the central power supply option regardless of
whether the machine has a machine cooler or whether a process
cooler provided by the user is connected.

Single connection, basic Typical rated power [kVA] 18.5
machine Connected load for basic machine [kVA] 24
Maximum fuse protection of the basic machine 100
and 400 V and 460 V [A]
Cross-section of the connection cable for the 35
basic machine [mm2] [Cu]
Maximum acceptable interruption of nominal volt- See EN 60204,
age [ms] Part 1,
Sect. 4.3.2,
Alternating cur-
rent supply
Recommended values, connected load and fuse protection, Tab. 2-23
basic machine
Single connection, laser Electrical supply Version according to

device DIN EN 60204-1 TN network
according to 60364-1, clockwise
phase rotation
cos φ (DPF) with rated output 0.96
λ with rated power (total power 0.96
factor)
Insulation resistance TruDisk 2000 210 kΩ
TruDisk 3001 260 kΩ
TruDisk 4001
Maximum permitted external TruDisk 2000 ≤700 mΩ
impedance Zv at the mains con-
TruDisk 3001 ≤180 mΩ
nection point8 TruDisk 4001
Back-up fuse, line configuration TruDisk 2000 25 A
operating class gl/gG line protec-
TruDisk 3001 32 A
tion
TruDisk 4001
Electrical connection cable and fuse protectionTruDisk Tab. 2-24
Laser device Typical rated Maximum Typical con- Maximum Current [A] - Current [A] -
power [kW] power input nected load connected typical maximum
[kW] [kVA] load [kVA] at 400 V at 400 V
TruDisk 2000 9.4 11.8 10 12.4 14.2 18
TruDisk 3001 11.2 17.4 12 18.4 17 26
TruDisk 4001 14.2 21 15.2 22.2 22 32
Connected loadTruDisk Tab. 2-25
8 If the external impedance is exceeded, the safety measures for protec-

tion against electrical shocks must be re-assessed.

Single connection, external The following table is valid for water/air process coolers manu-
process cooler factured by Riedel, product group type RLxx/0 SR (TR) for the
variant Machine without machine cooler:
Process Maximum Connected Typical rated Maximum Connected Maximum

cooler for power input load [kVA] power [kW] power input load [kVA] fuse protec-
laser device [kW] at 50 Hz at 60 Hz [kW] at 60 Hz tion [A]
at 50 Hz at 60 Hz
Process 7.5 9.0 14.1 10.3 11.2 20
cooler
RL13/0 for
TruDisk 2000
Process 9.5 11.5 20.6 11.7 14 25
cooler
RL17/0 for
TruDisk 3001
Process 12 14.2 21.3 16 18.3 35
cooler
RL20/0 for
TruDisk 4001
Connected load for process cooler, chiller for TruDisk Tab. 2-26

factured by Riedel, product group type RLxx/0 SR (TR) for the
variant Machine with machine cooler:

at 50 Hz at 60 Hz
Process 6.4 8 11.2 8 9.8 16
cooler
RL10/0 for
TruDisk 2000
Process 9.5 11.5 20.6 11.7 14 25
cooler
RL17/0 Tru-
Disk 3001
TruDisk 4001

manufactured by Riedel, product group type RWxx/0 SR (TR) for
the variant Machine without machine cooler:

at 50 Hz at 60 Hz
Process 6 7.3 17.4 7.5 8.8 16
cooler
RW13/0 for
TruDisk 2000
Process 9 10.5 24.7 11 13 25
cooler
RW17/0 for
TruDisk 3001
Process 9.8 11.2 23.3 12.4 14.3 25
cooler
RW20/0 for
TruDisk 4001

manufactured by Riedel, product group type RWxx/0 SR (TR) for
the variant Machine with machine cooler:

at 50 Hz at 60 Hz
Process 6 7.3 17.4 7.5 8.8 16
cooler
RW13/0 for
TruDisk 2000
TruDisk 3001
Process 9 10.5 24.7 11 13 25
cooler
RW17/0 for
TruDisk 4001

4.4 Teleservice
The following interface for the network connection is available in

the machine electrical cabinet: RJ45 plug.
Net work requirements for For Teleservice via Internet the following configuration is required
Teleservice via Internet in the user's LAN:
UDP Port 500 and UDP Port 4500, enabled for Internet access
via the LAN.
Note
Access to the user's LAN from the Internet is not required: com-
munication takes place via the two enabled UDP ports.
4.5 Network connection
An RJ45 plug is installed in the machine's switch cabinet to

allow the machine control system to be integrated in a network
(e. g. connection to a programming system).
A personal hub (netwrk distributor) is required if several
machines are to be connected to the network. It is located in the
switch cabinet of the machine and must be supplied with AC cur-
rent by the customer, as the distributor must als work if the
machine is switched off. The power supply must be provided in
the same way as for the following production control technology
projects.
For production control projects connected to a CELL SERVER,

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

IEC 400 V ±10 % 50 Hz ±1 %
460 V +10%/ -5% 60 Hz ±1 %
NEC 460 V +10%/ -5% 60 Hz ±1 %
Rated voltage and frequency Tab. 2-30

5. Compressed air supply
What does the customer For professional use with respect to the subject of compressed
needs to do? air supply, please consult a suitable specialist company and pass
along the following subchapter to the appropriate officials there.
The symbol indicates the connection points in the installation

plan.
The following should be observed during installation at the site:

■ The supply line for the compressed air supply must be instal-
led by the user up to the connection points marked in the
installation plan.
■ The compressed air connection may be flexible or may con-
sist of a fixed pipeline to the machine.
■ Each compressed air connection must be equipped with a
manual shut-off valve.
■ Recommendation: In case of an unstable compressed air
network or low system pressure, connect compact dust
extractor independently of the machine.
Note
The requirements for the purity of the compressed air and for
the installation of the supply lines are identical for all com-
pressed air supply ports required at the machine.
Additional compressed air A separate compressed air supply is required in addition to the
connection basic machine compressed air supply:
■ For laser cutting with compressed air.
■ For the vacuum ejectors (option) or for the additional com-
pressed air supply (option) on the rotational changer or the
rotary indexing table.
Note: The additional compressed air supply is only possible
as an alternative to the vacuum ejectors.
■ For project-specific components requiring compressed air.
Basic machine consumption A (shared) compressed air connection is required for the com-
pressed air supply of the basic machine, including the supply to
existing valve arrays on the rotational changer or rotary indexing
table.
B836en Compressed air supply - Version 4 2‐43

Average consumption (required volume flow rate according to
ISO 1217 or DIN 1945):
Required flow pressure in bar min. 6 - max.12

Typical consumption of basic machine in m3/h approx. 30
Temporary maximum consumption over a period approx. 40
of two to five minutes, no more than once an hour
in m3/h/ (under standard conditions)
Maximum permissible consumption for valve termi- approx. 30
nals in m3/h (under standard conditions)
maximum: 78
Compressed air consumption Tab. 2-31
Compressed-air cutting A separate compressed air supply is necessary for compressed-

air cutting. The compressed air consumption depends on the
nozzle diameter and on the cutting gas pressure.
Typical application Mild steel 1 mm Mild steel 2 mm

Maximum permissible line pres- 18 18
sure in bar
Minimum input pressure in bar 12 14
(flow pressure required at the
connection point)
Cutting gas pressure in bar 9 12
Nozzle diameter in mm 1.7 2.3
Cutting gas consumption in m3/h 15 35
Compressed-air cutting Tab. 2-32
Supply lines The following specification applies to all compressed air supply
ports:
Min. nominal diameter of the ½" (DN13)

supply line
Ring circuit length in m max. 50 (due to formation of water
condensation)
Ring circuit diameter at least 1" (26 mm)
Length of the connection line max. 5
from the ring circuit to the con-
nection point on the machine
in m
Hose range for the sleeve at the Nominal width DN 13
connection point
Connection point (without grom- Thread ½"
met)
Specification for supply lines Tab. 2-33
2‐44 Compressed air supply - Version 4 B836en

Purity The compressed air must have the following properties at its tap-
ping point:
Property Requirement Quality class Measure (rec-

ISO°8573-1 ommendation)
Edition 2001
Dust-free Maximum parti- 7 Air filter on the
cle size: 40 μm compressor
Maximum parti-
cle density:
10 mg/m3
Condensate-free cooled to +3°C / 4 Cold dryer
37°F (pressure
dew point)
Oil-free Maximum oil 4 Oil-free com-
content: pressing screw-
5 mg/m3 type compressor
Requirements Tab. 2-34
B836en Compressed air supply - Version 4 2‐45

6. Operating materials
What does the customer Operating materials must be provided by the user for starting up
need to do? the machine.
Notes
■ Provide cooling water (deionized water) in sufficient quantity
and in suitable containers.
■ If the laser device is to be connected a local water system or
to a process cooler provided by the user, the cooling circuit
provided at the site must be ready for use and available at
the time of starting up.
6.1 Gases
Gas types, their purity and connections, hoses, etc. are specified
in section 2, "Gas supply."
6.2 Cooling water
Cooling water is required to cool the laser unit and for cooling
the optical components on the machine. There are the following
cooling circuits:
■ Internal cooling circuit, laser device.
■ External cooling circuit, laser device chiller (external process
cooler or in-house water system).
■ Machine cooling circuit for cooling the optical components on
the machine. This cooling circuit only occurs when the
chiller is integrated into the machine body.
For cooling the optical components of the machine, there are the
following variants:
■ Standard: The optical components of the machine are cooled
via the external cooling circuit of the laser device (chiller).
■ Option: The optical components of the machine are cooled
via the internal chiller in the machine body.
■ The internal chiller in the machine body is absolutely neces-
sary in the following variants:
− Connection of the laser device to a facility water installa-
tion at the customer site
− Connection of the laser device to a process cooler pro-
vided by the user
− Pedestal or cellar installation of the laser device or the
external process cooler (chiller).
2‐46 Operating materials - Version 4 B836en

Damage is caused to the machine and to the laser device if
NOTICE tap water or contaminated water is used!
Ø Cooling water should be stored only for short periods.
Ø Transport and store water in clean plastic containers (without
deposits).
Ø Avoid contact with the water. Foreign substances (excluding
algae inhibitors and anticorrosive agents) impair the quality
of the water.
Ø Use additional equipment for filling water, such as pumps,
hoses or stop valves, exclusively for handling the cooling
water.
Required cooling water All of cooling circuits will be flushed repeatedly and then filled
with cooling water at the time the machine is commissioned.
This table is valid in connection with a chiller, water/air

type RLxx/0 SR/TR:
Internal cooling circuit External cooling cir- Machine cooling circuit Total
of the laser device cuit, laser device9 require-
ments10
Cooling water Require- Volumetric Require- Volumetric Require- Volumetric
quantity in l ment capacity of ment capacity of ment capacity of
cooling cir- cooling cir- cooling cir-
cuit cuit cuit
Variant: Machine with machine cooler
Process cooler approx. approx. 30 approx. approx. 80 approx. 48 approx.
RL10/0 for Tru- 120 320 160 600
Disk 2000
Process cooler approx. approx. 55 approx. approx. approx. 48 approx.
RL17/0 for Tru- 220 600 150 160 980
Disk 3001
TruDisk 4001
Process cooler approx. approx. 30 approx. approx. 80 - - approx.
RL13/0 for Tru- 120 320 440
Disk 2000
Process cooler approx. approx. 55 approx. approx. - - approx.
RL17/0 for Tru- 220 600 150 820
Disk 3001
RL20/0 for Tru- 220 600 150 820
Disk 4001
Required cooling water at time of commissioning Tab. 2-35
9 They are valid for Riedel process coolers: type RLxx/0 SR(TR).
10 Total requirement for starting up the laser processing machine
B836en Operating materials - Version 4 2‐47

This table is valid in connection with a chiller, water/water
type RWxx/0 SR/TR:
Internal cooling circuit External cooling cir- Machine cooling circuit Total
of the laser device cuit, laser device11 require-
ments10
Cooling water Require- Volumetric Require- Volumetric Require- Volumetric
quantity in l ment capacity of ment capacity of ment capacity of
cooling cir- cooling cir- cooling cir-
cuit cuit cuit
RW13/0 for Tru- 120 320 160 600
Disk 2000
RW13/0 for Tru- 220 320 160 700
Disk 3001
Process cooler approx. approx. 55 approx. approx. approx. 48 approx.
RW17/0 for Tru- 220 600 150 160 980
Disk 4001
Process cooler approx. approx. 30 approx. approx. 80 - - approx.
RW13/0 for Tru- 120 320 440
Disk 2000
RW17/0 for Tru- 220 600 150 820
Disk 3001
RW20/0 for Tru- 220 600 150 820
Disk 4001
Required cooling water at time of commissioning Tab. 2-36
Requirements The cooling water must be de-ionized.
Cooling water. Properties

Conductivity of freshly filled water max. 10 μS/cm
Conductivity for newly replaced water Max. 20 μS/cm
after 10 minutes of circulation
Conductivity limit of the cooling water Cu cooling circuit:
after addition of the anti-corrosive agent max. 200 μS/cm
Max. permissible carbonate content less than 100 mg/l
Color Colorless
Cloudiness None
Odor odorless
Requirements Tab. 2-37
Notes
■ The specified chemical/physical characteristics must be
observed.
11 Valid for standard Riedel process coolers: type RLxx/0 SR(TR).
2‐48 Operating materials - Version 4 B836en

■ Do not use distilled water! The quality of distilled water can
fluctuate considerably.
■ For a local water system provided at the site as the external
cooling system for the TruDisk laser device, tap water
according to VDI Norm 3803 can be used.
■ Odor is an indication for a biological contamination of the
water.
■ Any type of cloudiness (e.g. from suspended matter, threads,
flakes, particles) marks an impurity in the water.
Installing process cooler in If the process cooler is installed in an area with a risk of frost,
an area with a risk of frost then the "high purity ethylene glycol" antifreeze agent must be
added to the cooling water.
The antifreeze agent is to be provided by the customer at
machine start-up.
The mixing ratio is dependent on the temperature at the installa-

tion site.
Temperature up to -15 C (5°F) up to -24 C (11.2°F)

Percent by weight in 30 40
%
Percent by volume in 27 35
%
Mixing ratio Tab. 2-38
6.3 Dispensing material for MultiCoater
Note
Calcium carbonate or trass powder are required exclusively as
the dispensing material for the MultiCoater (optional compact
dust extractor).
Name Calcium carbonate Trass powder

(CaCo3)
Grain size range ≥0 µm and ≤90 µm ≥0 µm and ≤150 µm
Average grain size ≥5 µm and ≤15 µm ≥20 µm and ≤40 µm
Purity level 99.1 % -
Filling volume of stor- 55 liters 55 liters
age container
Specification of dispensing material for MultiCoater Tab. 2-39
B836en Operating materials - Version 4 2‐49

7. Transport
What does the customer All components are to be examined upon receipt for any damage
need to do? caused during transit. Any visible damage caused during transit
must be recorded on the consignment note and countersigned
by the truck driver. Hidden damage caused during transport must
be reported to the insurance company and to TRUMPF within six
days at the latest.
The customer must (unless other agreements have been
made) make the necessary arrangements and convey the
machine and components from the truck to its final installation
site.
The transport route to the machine's installation site must be
clarified in due time prior to the machine's delivery. In particular,
gates, header heights, cable rack heights, ground conditions for
armored rollers etc. must be checked by the customer. The
transport route must take the dimensions of the machine into
account according to the installation plan!
Transport regulation Transport of the machine and machine components: see trans-
port regulation drawing no. 93964-5-800, material no. 1848703
(drawing in folder for TRUMPF service engineer).
The transport regulation documents the loading process, trans-

port and the unloading process of the machine and its compo-
nents in different ways:
■ Transport via trucks: see Sheet A.
■ Transport via container: see Sheet A and Sheet B.
2‐50 Transport - Version 4 B836en

Transport equipment and The following means of transport and additional equipment must
additional equipment be provided by the user at the time of delivery and for position-
ing the machine.
■ With container transport: Double ladder or telescopic boom
lift for opening the container lid.
■ For the transport and construction of the safety cabin:
− Two double ladders, each 4 m high or telescopic boom
lift.
− Forklift truck with min. stroke height of 4.5 m and mini-
mum fork length of 3.5 m.
■ For transport by crane:
− Indoor crane or mobile crane with a carrying capacity of
at least 10 MP.
− VIP sling chain ND16, two-stranded, 2500 mm long with
locking hooks VIP Copra. Minimum carrying capacity
10 MP at an angle of twist of 45° to 60°. The sling chain
(TRUMPF mat. no. 1850719) is not part of the machine's
scope of delivery. It can be purchased from the Carl
Stahl Co. under order number 6201.VO.16.
− Alternative to the sling chain: Spreader bar (carrying
capacity of at least 15 MP) with two chain strands and
load hooks for swivel bearer WBG8 M36.
− Chains and transport straps.
− 4 eyebolts M12.
− Transport beam and steel rods for transporting the laser
device.
■ For corridor transport of the basic machine:
− Armored rollers (1 x steerable, 2 x rigid).
− 4 hydraulic hoisting jacks with a min. carrying capacity of
8 MP (adjustable height ≤ 50 mm).
− Hoisting iron (1 m) and extension.
■ For transport with a forklift truck or pallet jack:
− Pallet jack or forklift truck with minimum carrying capacity
of 4 MP or 8 MP.
− For the rotational changer on the pallet: Pallet jack or
forklift truck with carrying capacity of at least 4 MP. If the
rotational changer is to be grabbed longitudinally, a mini-
mum fork length of 2.8 m is required.
− For the rotary indexing table (optional) on pallet: Pallet
jack or forklift truck with carrying capacity of at least
8 MP and minimum fork length of 2.8 m.
− For the compact dust extractor on the pallet: Forklift truck
with carrying capacity of at least 4 MP. If the pallet is to
be grabbed longitudinally, a minimum fork length of 2.8 m
is required.
B836en Transport - Version 4 2‐51

Container transport If the machine and the components are delivered in the con-
tainer, an indoor crane or mobile crane must be available.
If an indoor crane is not available or if the clearance height
below the indoor crane is less than 5 m, the container will
have to be unloaded outside.
The container can be unloaded either on the face side through

the open door or through the open roof. The required crane
hook clearance above the factory floor for unloading the basic
machine is:
■ Greater than 6 m when unloading the basic machine from
the container from the face side.
■ Greater than 9 m when unloading the basic machine through
the open roof of the container.
The basic machine and the workpiece changer are transported

High Cubein one container. All other system components are
transported in 3 or 4 standard containers.
Length Width Height

in mm in mm in mm
Basic machine with 12190 2440 2800
workpiece changer and
point of the jib.
High Cube container Tab. 2-40
7.1 Dimensions and weights of the

transport units
Dimensions and weights of The machine body and motion unit, the switch cabinets installed
the basic machine in the machine body and the chiller (optionally on the console)
for the basic machine all belong to the transport unit of the basic
machine.
Basic machine Length Width Height Weight

in mm in mm in mm in kg
TruLaser Cell 8030 approx. approx. approx. approx.
with console12 5900 3017 3030 9100
TruLaser Cell 8030 approx. approx. approx. approx.
without console 5320 3017 3030 9100
Basic machine including transport equipment Tab. 2-41
12 Console for machine chiller (optional).

Dimensions and weights of Component Length Width Height Weight
system components in mm in mm in mm in kg
Workpiece changer
without fixtures on
pallet:
- Rotational changer 4100 1500 1500 approx.
2700
- Rotary indexing 2700 2300 1500 approx.
table 4500
Compact dust extrac- DELTA Comp 1500-14/9 SB
tor horizontal on pal-
let:
- without sound- approx. 1780 1050 approx.
proofing 3500 1250
- with soundproofing approx. 1780 1050 approx.
3500 1350
Scrap conveyor on Scrap conveyor
pallet:
- for rotational 6500 1200 2130 1270
changer
- for rotary indexing 7200 1200 2130 1500
table
Transport units Tab. 2-42
Dimensions and weights - The modules of the safety cabin are supplied on three wooden
safety cabin pallets and transported.
Pallet Length Width Height Weight

in mm in mm in mm in kg
Pallet 1 5700 1600 1800 approx.
3000
Pallet 2 3300 2300 1700 approx.
2000
Pallet 3 3000 2300 2000 approx.
1500
Safety cabin modules Tab. 2-43
Dimensions and weights - Laser device Length Width Height Weight

TruDisk (without packaging) in mm in mm in mm in kg
TruDisk 2000 1120 730 1375 approx.
470
TruDisk 3001 1175 725 1430 approx.
TruDisk 4001 470
TruDisk laser device Tab. 2-44

Dimensions and weights, The following table is valid for water/air process coolers manu-
chiller for TruDisk factured by Riedel, product group type RLxx/0 SR (TR) and for
the variant Basic machine without chiller:
Process cooler Length Width Height Weight

(empty) in mm in mm in mm in kg
Process cooler 1144 720 1550 220
RL13/0 for TruDisk
2000
RL17/0 for TruDisk
3001
RL20/0 forTruDisk
4001

factured by Riedel, product group type RLxx/0 SR (TR) and for
the variant Basic machine with chiller:

RL10/0 for TruDisk
2000
RL17/0 for TruDisk
3001TruDisk 4001

manufactured by Riedel, product group type RWxx/0 SR (TR)
and for the variant Basic machine without chiller:

RW13/0 for TruDisk
2000
RW17/0 for TruDisk
3001
RW20/0 for TruDisk
4001

manufactured by Riedel, product group type RWxx/0 SR (TR)
and for the variant Basic machine with chiller:

RW13/0 for TruDisk
2000
TruDisk 3001
RW17/0 for TruDisk
4001

7.2 Transporting machine and machine
components
Suspended load!
DANGER
Falling loads could lead to severe bodily injury or even
death.
Ø Observe relevant safety regulations regarding 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 work in accordance with the transport
regulations.
Improper handling can cause the basic machine to tip over

DANGER during transport or during installation.
This could lead to severe bodily injury or even death
Ø The basic machine may only be transported with a crane or
with armored rollers.
Ø During transport, no-one may be in the danger zone.
Ø The basic machine may only be transported with transport
devices (support) fitted.
Ø The transport devices must not be removed until the
machine body is anchored in the foundation.
Ø When transporting the basic machine with armored rollers,
the armored rollers may only be attached at the marked
points pos. C (rotational moving device) and pos. D (fixed
armored rollers) according to fig. 71416.
Ø The machine may not swing.
Ø Observe center of gravity position.
Ø Machine must hang horizontally on the cross beam or from
the sling chains.
Ø If a cross beam is being used, the chains must hang verti-
cally and symmetrically from the cross beam.

1 Sling chains B Sling chain securing point D Position of the armored rollers
2 Transport device support C Rotational moving device posi- E Position of hydraulic hoisting
A Transport locking points tion jack
Transport of the basic machine TruLaser Cell 8030 (L60) Fig. 71416
Transporting basic machine with truck
The machine body with extension arm, including the switch cabi-
nets in the machine body, the process cooler for the machine on
a console (optional) and the rear wall of the safety cabin are all
part of the transport unit of the basic machine.

Conditions
■ Cantilever is located centrally at position X1500.
■ Y slide is at position Y0.
■ Barrel is lowered to Z0.
■ Transport securing devices for switch cabinet doors are
mounted.

■ Sling chain two-stranded (or spreader bar).
■ Indoor crane or mobile crane.
Note
The basic machine and the machine components may only be
transported on a truck withpneumatic suspension.
Preparing the basic machine 1. Screw the transport securing device support tightly in the
for transport middle of the machine body. Tighten the fastening screws to
a max. torque of 100 Nm. Set the screw jack in such a way
that there is some 15 mm of space between the lower edge
and the factory floor.
2. For crane transport: tightly screw in the left swivel bearer into
the lower thread and the right swivel bearer into the upper
thread on the machine body up to the limit stop.
Attach sling chain to the swivel bearers at pos. B in accord-
ance with fig. 71416.
Transporting the basic 3. Lift the basic machine onto the loading area of the truck
machine using the indoor crane or crane truck.
4. Lock the support onto the loading area.
5. Remove sling chains.
6. Securely clamp the machine bodies to all of the locking
points (fig. 71416, pos. A, front and rear side) with transport
belts on the loading area of the truck.
Unloading the basic 7. Loosen transport belts.

machine from truck 8. Attach sling chains to the swivel bearers.
Note
For further transport using armored rollers: The machine
body should not be lowered to the floor without a support
frame as it would otherwise no longer be possible to install
hydraulic hoisting jacks under the machine body. The dis-
tance between the lower edge of the machine body and the
floor must be at least 100 mm.
9. Unload the basic machine from the truck using a crane or
crane truck.

Loading and unloading container
The basic machine and the workpiece changer are transported

together in one container.
Conditions
■ Cantilever is located centrally at position X1500.
■ Y slide is at position Y0.
■ Barrel is lowered to Z0.
■ Transport securing devices for switch cabinet doors are
mounted.
■ The point of the jib is disassembled and the transport protec-
tion is attached.
■ Energy chains of the X and Z axes are lowered and secured
with transport securing devices.
■ Partition walls and supporting sheets of the rotary indexing
table (optional) are disassembled.

■ Double ladder or telescopic boom lift.
■ Pallet jack or forklift truck.
Notes
■ The point of the jib is transported on a pallet.
■ Rotational changer or rotary indexing table (optional) are
transported on a pallet.
Loading container 1. First load the basic machine into the container either from
the top or from the front wall.
2. Securely clamp the machine bodies to all of the locking
points (fig. 71416, pos. A, front and rear side) with transport
belts in the container.
3. Then load and secure the other transport units into the con-
tainer.
Unloading container 4. Open container at the top: Remove cover tarpaulin and
strengthening ribs or cover sheets.
5. Open container door.
6. Either fully remove the door bar or open and swivel to the
side on which the rear wall of the machine body is standing.
7. Loosen transport belts.
8. Attach sling chain or spreader bar to the swivel bearers
(fig. 71416, pos. B).

Note
For further transport using armored rollers: The machine
body should not be lowered to the floor without a support
frame as it would otherwise no longer be possible to install
hydraulic hoisting jacks under the machine body. The dis-
tance between the lower edge of the machine body and the
floor must be at least 100 mm.
9. Unload components one after the other: either by lifting them
out through the container wall or on the face side, horizon-
tally through the open door.
Transporting the basic machine to the

installation site

or
■ Armored rollers and hydraulic jack.
Note
The basic machine and components are first positioned
beside the actual installation site.
1. With crane transport: Attach sling chains or spreader bars to

the swivel bearers securing points pos. B in accordance with
fig. 71416 and transport.
2. If the basic machine is to be transported with armored rollers
and rotational moving device to the installation site:
− Apply a hydraulic hoisting jack in accordance with
fig. 71416, pos. E to the machine body at the front and
rear sides.
− Lift all four hydraulic hoisting jacks slowly and evenly.
− Position armored rollers (pos. D) and rotational moving
device (pos. C) in accordance with fig 71416 underneath
the machine body.
− Lower the hydraulic hoisting jacks slowly and evenly.
− Drive the basic machine slowly to the installation site.
− Leave the basic machine standing on armored rollers
and rotational moving device.

Transport TruDisk laser device
The laser device can be transported by crane truck or forklift

truck. Please note:
■ When transporting with a forklift: The laser device may
not be tilted by more than a maximum of 10°. Use a padded
mat to protect the laser device from damage. Secure the
laser device from falling down using a transport belt on the
mast of the forklift truck.
■ When transporting using a lift truck: insert the lift truck so
that front rollers do not touch the bottom plate of the laser
device.
Conditions
■ Laser device is switched off.
■ Laser light cable (LLK) is disconnected.
■ Supply connections have been removed.
■ At temperatures below 0 °C or for long-distance transport:
The cooling circuit has been drained completely and blasted
using compressed air.

■ Padded mat.
Damage to the laser device!

NOTICE
Ø Carefully raise, transport and set down the laser device.
Ø Transport the laser device standing and horizontally leveled.
Ø Transport the laser device with an air-cushioned truck.
Ø Use plywood crates for long-distance transport.

1 Padded mat
Transporting TruDisk Fig. 81494
1. Cover laser device with a padded mat.

2. Insert the lift truck or forklift in the bottom plate of the laser
device according to Fig. 81494.
3. When transporting using a forklift truck: Secure the laser
device with a transport belt.
4. Lift and transport the device.
Transport rotational changer with a crane

or forklift
The rotational changer is transported completely mounted on a

wooden pallet. It can be transported either by crane or forklift
truck.
The wooden pallet can be grabbed either longitudinally or cross-
wise when transporting using the forklift truck.
If the wooden pallet is to be grabbed longitudinally by the forklift
truck, a fork length of at least 2.8 m is required.
Condition
■ Fixtures and horizontal fixture port are disassembled.

■ Chains or transport belts.

Note
When transported with a forklift truck, the rotational changer is
transported on the wooden pallet.
1 4 securing points, load stand threading M16

Transporting the rotational changer Fig. 73824
1. When the rotational changer is transported with a crane:

− Attach transport belts or chain slings to the four securing
points on the rotary table.
− Raise the rotational changer.
− Remove the wooden pallet.
− Transport the rotational changer to the installation site.
2. When the rotational changer is transported with a forklift
truck:
− Grab wooden pallet crosswise or longitudinally.
− Remove the wooden pallet at the installation site.
Transporting rotary indexing table with

The rotary indexing table is supplied on a wooden pallet. It can

be transported either by crane or forklift truck.
Conditions
■ Fixtures and horizontal fixture port are disassembled.
■ Partition walls have been removed.

■ Chains or transport belts.
■ Pallet jack or forklift truck with minimum carrying capacity of
8 MP.

Note
When transported with a forklift truck, the rotary indexing table is
transported on the wooden pallet.
1 3 securing points, attachment eye threading M20

Transporting rotary indexing table Fig. 73825
1. When the rotary indexing table is transported with a crane:

− Attach transport belts or chains to the three securing
points on the rotary table.
− Raise rotary indexing table.
− Remove the wooden pallet.
− Transport rotary indexing table to the installation site with
crane or crane truck.
2. When the rotary indexing table is transported with the forklift
truck.
− Grab the wooden pallet from the narrow side and trans-
port it to the installation site.
− Remove the wooden pallet at the installation site.
Transporting the safety cabin
The modules of the safety cabin are transported on a total of

three wooden pallets.
When transporting pallet 1 with 5.7 m in length using forklift
truck the following applies: The pallet may only be grabbed lon-
gitudinally by the forklift truck. The required fork length is at least
3.5 m.

■ Transport belts.
Ø Transport the wooden pallets individually to the installation

site using a crane, a crane truck or a forklift truck.
Transportation of scrap conveyor
The rotational changer is transported completely mounted on a

wooden pallet. Ideally it should be transported with a crane.
When the scrap conveyor is transported with a forklift truck, grab
the wooden pallet crosswise if possible.

Ø Lift scrap conveyor with load straps at the 4 marked securing

points (2 bollards in the high-angle piece and 2 eye bolts in
the straight piece) and transport.
Transporting the compact dust extractor

(Herding)
The compact dust extractor has four flanges on the upper collar
/ on the sound proofing cover for attaching chains or transport
belts.
The device is transported horizontally on a wooden pallet and
only set upright once it is at the installation site and lifted off the
pallet afterwards.

■ Forklift truck

Damage due to improper transport!
NOTICE
Ø Transport the compact dust extractor from the pallet to the
installation site.
Ø At the installation site, only set the compact dust extractor
upright using a crane or crane truck.
1. Transport the pallet to the installation site with the forklift

truck.
2. Attach transport belts or chain slings to the securing points
and slowly set the device upright.
3. Only lift the device off the pallet when it is vertical.
Transporting process cooler

Ø Lift process cooler with chains or load straps at the

four marked securing points and transport.
Transporting the safety cabin
The modules of the safety cabin are either supplied on wooden

pallets or in a separate container directly from the supplier.
Ø Transport the wooden pallets to the installation site using a

crane, a crane truck or a forklift truck.
7.3 Installing the system
Preparing the factory floor
The factory floor must be prepared by the user in accordance

with the machine's foundation plan before the machine is deliv-
ered. The machine body is lowered onto the foundation by the
service engineer and secured and leveled.

Conditions
■ The foundations have been prepared. Holes and cut-outs
have been made in the factory floor in accordance with the
foundation plan.
■ The floor requirements at the installation site must comply
with the installation requirements. No expansion joints in the
factory floor are permitted inside the installation surface.
■ Any floor paint or screed which is available in the area of
the cast surfaces of the bore anchors must be removed.
■ The cast surfaces must be free of dust and grease.
■ Gas, air and power connections must be installed at the site
of the machine in accordance with these installation condi-
tions.
Note
When using rotational moving devices, keep the machine body
or platform on the rotational moving device and armored rollers.
Have four hydraulic hoisting jacks readily available.
1. Clean the surface thoroughly. Remove any loose and non-

adhesive coats of paint, laitance or screed from the area of
the cast surfaces.
2. Draw the zero point lines for the X and Y axes on the factory
floor.
3. Mark the bore holes to be used to anchor the machine body
on the factory floor.
4. Drill holes into the factory floor.

Chapter 3
Description
1 Machine concept 3‐3
2 Coordinate system and working range 3‐4

2.1 Coordinate system 3‐4
2.2 Working range 3‐6
3 Machine components 3‐8

3.1 Sub-assemblies of the basic machine 3‐10
Machine body 3‐11
Motion unit 3‐11
Hydroforming package (option) 3‐11
Beam guidance 3‐12
Dynamic cutting optics 3‐13
3.2 Laser protection device 3‐19
3.3 Exhaust system and filtering installation 3‐21
3.4 Workpiece changer 3‐25
3.5 Clamping fixture 3‐29
B836en 2017-11-17 Description 3‐1

Clamping fixture for inner high-pressure 3‐37
3.6 Solid-state lasers 3‐43
4 Technical data 3‐45
3‐2 Description 2017-11-17 B836en

1. Machine concept
Characteristics The laser processing machine TruLaser Cell 8030 is a productive

machine which is ideally suited for the batch production of
formed sheet metal parts. It features standardized components
and compact installation.
The features are:

■ Suitable for laser cutting high-strength components with high
dynamics.
■ Using the solid-state laser TruDisk as a beam source allows
the machine to be integrated into a laser network.
■ Quick rotational changer with matching fixture system, includ-
ing control.
■ Highly productive rotary indexing table (option) with 3 produc-
tion places, including fixture equipment and a control.
■ Optional safeguarding of the danger zone around the work-
piece changer outside of the safety cabin.
■ Scrap conveyor for continuous removal of cut-outs and sheet
skeletons.
Solid-state lasers The machine comes standard-equipped with a solid-state laser of

the TRUMPF TruDisk series, with a laser power of 2000 W,
3000 W or 4000 W.
B836en 2017-11-17 Machine concept 3‐3

2. Coordinate system and working
range
2.1 Coordinate system
The standard equipment for the system includes 5 NC axes. The

integration of additional NC axes is possible.
Coordinate system Fig. 88769
X axis Horizontal movement of the cantilever lengthwise in relation to the machine body
Y-axis Horizontal travel movement of the Y carriage
Z axis Vertical travel movement of the Z barrel
B axis Swivel movement of the processing optics around the Y axis (±135°)
C axis Rotary movement of the processing optics around the Z axis (n*x 360°)
NC axes of the machine Tab. 3-1
3‐4 Coordinate system and working range 2017-11-17 B836en

Kinematic transformation The machine has two coordinate systems:
■ Machine coordinate system (MKS): Kinematic transforma-
tion is activated. The path information for the X, Y and Z
axes refers to the coordinates of the pivot of the B/C axis in
the angular gear.
■ Workpiece coordinate system(WKS): Kinematic transforma-
tion is active. The path information for the X, Y and Z axes
refers to the coordinates of the tool tip (Tool Center Point).
The B and C axes perform compensating movements during
linear axes positioning.
Note
The kinematic transformation is activated with the
TC_TRAFO_ON command and deactivated with the
TC_TRAFO_OFF command.
Joint offset The offset value for the X, Y and Z axes between the beam cen-
ter of the pivot of the B/C angular gear and the beam center of
the focus point (Tool Center Point) is referred to as the joint off-
set.
1 Beam center of B/C gear pivot 2 Beam center (TCP)

Y Joint offset of the Y axis Z Joint offset of the Z axis
Joint offset Fig. 37800
B836en 2017-11-17 Coordinate system and working range 3‐5

2.2 Working range
Working range Fig. 58690
X axis in mm Y axis in mm Z axis in mm

3000 1300 600
Working range Tab. 3-2
X axis in mm Y axis in mm Z axis in mm

3000 1300 600
Working range Tab. 3-3
3‐6 Coordinate system and working range 2017-11-17 B836en

3D working range The 3D working range (core range) depends on the processing
optics used.
The zero point of the Z axis refers to the center of rotation in the
B/C gear (see Fig. 37800, pos. 1).
1 Working height 2 3D core range 3 Processing optics

3D working range Fig. 28857
Core range The core range is the 3D working range that can be used with-
out restrictions, regardless of the position of the B and C axes.
The core range is calculated as follows:

■ X3D = X2D - (2 x Zoffset)
■ Y3D = Y2D - (2 x Zoffset)
■ Z3D = Z2D - Zoffset
B836en 2017-11-17 Coordinate system and working range 3‐7

3. Machine components
1 Cooler (optional) 5 Instrument panel 8 Control panels

2 Basic machine 6 Scrap conveyor 9 Rotational changer
3 Switch cabinets 7 Control panel 10 Safety cabin
4 Compact dust extractor
Standard variant, machine with rotational changer Fig. 71418
Components Function Documentation

Basic machine Machining workpieces Operator's manual
TruLaser Cell 8030
Spare parts catalogue
TruLaser Cell 8030
Control panel Operation of the machine Operator's manual
TruLaser Cell 8030
Creation of NC programs
Programming manual
Data management
TruLaser Cell 8030
TruDisk laser device Generation of laser radiation Operator's manual for TruDisk Laser
Spare parts catalogue for the Tru-
Disk laser
Laser light cable (LLK) Beam guidance from the laser -
device to the basic machine
External process cooler for Tru- Cooling the laser unit and optical Operator's manual for the process
Disk components of the machine cooler
Chiller for basic machine Cooling the optical components of Operator's manual
(optional) the machine TruLaser Cell 8030
3‐8 Machine components 2017-11-17 B836en

Components Function Documentation
Switch cabinet CNC control for machine Electrical circuit diagram
Electrical supply to drives
Logic and performance section
Safety cabin Shield against laser radiation -
Securing the danger zone
Compact dust extractor Extraction of fumes and airborne Operator's manual for the compact
particles in the working room dust extractor (filtering installation),
Herding
Rotational changer Holding and fixing the workpieces Operator's manual
rotary indexing table (option) during processing TruLaser Cell 8030
Scrap conveyor Collection and removal of waste Operator's manual for the Kabels-
parts and sheet skeletons from the chlepp scrap conveyor
work area
Components of the laser processing machine Tab. 3-4
Nameplate The nameplate is located next to the main switch.
Video monitoring (option)
Camera for work area monitoring Fig. 78933
The machine can be optionally equipped with a video camera for

work area monitoring and with a monitor.
Software is protected by The software installed on the machine, including any storage
copyright media and documentation supplied may only be used for this
machine. The software may only be copied to make a backup.
The software may not be sold or passed on without the
machine. If the machine is sold, the buyer must assume a corre-
sponding obligation to this effect.
B836en 2017-11-17 Machine components 3‐9

3.1 Sub-assemblies of the basic machine
1 Z barrel 5 Machine body

2 Y axis drive 6 B- and C-axis drive
3 X-axis drive 7 Extension arm
4 Z-axis drive 8 Processing optics
Basic machine modules Fig. 75192
Assembly Function
Machine body Tool holder of the motion unit and all functional
components.
Motion unit Tool holder X-, Y- and Z- carriage-
Beam guidance components and media feed.
Z barrel Laser beam guidance and media feed.
Drives for B and C axis.
Collimation Coupling of laser light cable in the barrel.
Processing optics Focuses the laser beam on the workpiece.
Basic machine modules Tab. 3-5

Machine body
The machine body is a torsion-resistant welded construction. It

includes all basic functions that are relevant to the machine's
accuracy. These include:
■ Motion unit holder.
■ Fixation of the safety cabin, energy supply, suction system
and all technical functions concerning gases and devices.
The solid anchoring with cast wedge mounts provides optimum
rigidity and the long-term alignment of the machine.
The two switch cabinets are mounted on the rear side in the
machine body; the device panel is on the front side in the
machine body.
Motion unit
The motion unit consists of a cantilever extension arm and the

attached Y slide with integrated Z axis. The extension arm is
connected to the machine body via guide rails (X slide). The
most important modules of the motion unit include:
■ Cantilever with Y slide and X drive.
■ Z axis drive and guide (barrel).
The following are integrated in the barrel:

■ Drives for B and C axis.
■ B/C gear and angular gear.
■ Magnetic coupling and processing optics.
■ Collimation: input coupling of the laser beam in the barrel.
The travel ranges of the X, Y, and Z axes are limited by software
limit switches.
Hydroforming package (option)
The hydroforming package is a machine option. It is normally

used on machines primarily used to process workpieces formed
with high internal pressure (IHU).
The hydroforming package protects the motion unit from dirt and
wear. The following components belong to the hydroforming
package option:
■ Protective hoods for the motors of the X, B and C axes.
■ Metal fins for protecting the Y axis bellows.

■ Cover for protecting the Z axis rack.
■ Various protective plates.
Beam guidance
Optical components The laser beam is directed through the barrel to the deflection
mirror in the B/C gearbox and channeled to the processing
optics. Quartz lenses in the processing optics focus the beam
through the nozzle onto the workpiece.
The laser light is coupled with a laser light cable (LLK), coming
from the beam source, from above via the cable carrier into the
Z barrel in the collimation.
The collimation has a quartz lens. The beam diameter is
adjusted in the factory using this lens.
In addition to the beam source, the LLK, the collimation, as well
as the processing optics are among the optical components of
the machine. The laser light cable, collimation and optics form
an optical unit and depend on the beam quality.
Laser device LLK diameter Focal length Focal length

collimation processing
optics
TruDisk 2000 75 μm f = 100 mm f = 200 mm
TruDisk 3001 100 μm f = 89 mm f = 150 mm
TruDisk 4001
Optical configuration depending on the beam quality Tab. 3-6
Notes
■ The laser light cable and collimation may only be replaced
together. The replacement may only be performed by
TRUMPF service engineers. After replacement, a basic
adjustment of the beam is required.
Improper replacement will lead to the destruction of the
collimation and laser light cable!
■ Notice! The new generation of cutting optics for the TruLaser
Cell 8030 (L60) may not be used on the predecessor
machine TruLaser Cell 8030 (L45) or on a machine of the
TruLaser Cell 7000 series (L31).
The raw beam diameter is too large for the focusing lens
and will lead to the thermal destruction of the optics.
■ On the TruLaser Cell 8030 (L60) machine with a LLK diame-
ter of 100 μm, it is possible and permissible to use dynamic
cutting optics of the predecessor machine TruLaser Cell 8030
(L45) or the TruLaser Cell 7000 series (L31).

Collimation cooling The collimation and the connection of the laser light cable is
cooled via the cooling circuit of the laser device (laser recooling
unit) as standard. Optionally, the machine can be used with a
recooling unit (machine cooler) for cooling the optical compo-
nents.
Deflection mirror in the B/C The deflection mirror in the B/C gearbox directs the laser beam
gearbox to the processing optics. The deflection mirror is air-cooled.
Option FocusLine: The deflection mirror is an adaptive mirror,
which controls the focal position with compressed air.
FocusLine With the FocusLine option, the focal position is automatically

adapted to the type of material and sheet thickness during proc-
essing. The focal position is controlled via the laser technology
table (LTT) and the FocusLine mirror in the B/C gearbox.
FocusLine has the following advantages:

■ A utility program is used to exactly determine the focal posi-
tion.
■ The focal position is automatically adjusted to the respective
sheet thickness and type.
■ The focal position can vary during processing.
The following applies to machines without FocusLine:

■ Before the beginning of processing, the focal position must
be adjusted manually depending on the type of material and
sheet thickness.
■ The focal position is not determined using a utility program.
The required focal position must be determined by means of
tests.
Dynamic cutting optics
Notes
■ Operation of the "dynamic distance regulation": refer to the
"TruLaser Cell series operator's manual", chapter
"Operation", section "Working with dynamic distance regula-
tion".
■ Programming the "dynamic distance regulation": refer to the
"TruLaser Cell programming manual", chapter "Cycles for
laser processing", section "Dynamic distance regulation".

Thermal destruction of the optics if used on a predecessor
NOTICE machine TruLaser Cell 8030 (L45) or on a machine of the
TruLaser Cell 7000 series (L31)!
Ø These cutting optics of the new generation may only be
used on a TruLaser Cell 8030 (L60).
1 Catch strap 5 Additional axis drive

2 Magnetic coupling 6 Cutting insert
3 Housing 7 Sensor body and nozzle
4 LED display
Dynamic cutting optics Fig. 75193
The dynamic cutting optics is equipped with an additional axis

for dynamic distance regulation (ADC).
The cutting optics are marked laterally with the material number,
serial number as well as a product code. The machine control
recognizes the product code automatically.
The optical components are made of silica glass, they are not
cooled.
Technical data Dynamic cutting optics F150 D30 R230 F200 D25 R230
Focal length f =150 mm f = 200 mm
X axis joint offset 0 mm 0 mm
Y-axis joint offset with magnetic -158 mm -158 mm
coupling
Y-axis joint offset without mag- -112 mm -112 mm
netic coupling

Technical data Dynamic cutting optics F150 D30 R230 F200 D25 R230
Z axis joint offset13 230 mm 230 mm
Stroke of ADC additional axis ±10 mm ±10 mm
Weight with yoke plate Approx. 5 kg Approx. 5 kg
Theoretical focal position for col- Nozzle distance Nozzle distance
limated beam 1 mm 3 mm
Permissible focal position adjust- -5.25 mm to -12.5 mm to
ment range +5.25 mm +8.0 mm
Technical Data Tab. 3-7
Sensor system The sensor system of the cutting optics features dedicated soft-
ware which is checked when the optics are set up and automati-
cally updated if required.
The software consists of two components: the bootloader to load
the software and the software program itself. The electronics of
the cutting optics use this software to communicate with the dis-
tance regulation (ControlLine) of the machine.
The current operating status of the sensor system is displayed

using LEDs.
LED display Fig. 51640
Display Normal Update Error Error Error

mode
POWER (green) Illuminated Illuminated Illuminated Illuminated Illuminated
Power supply present
ONLINE (orange) Illuminated Illuminated off off off
Connection to ControlLine active
13 Nominal tool length, corresponds to the swivel radius at 1 mm nozzle

distance in the neutral position of the additional ADC axis.

Display Normal Update Error Error Error
mode
BOOT (red) off Illuminated flashes off Illuminated
Bootloader active
RUN (yellow) Illuminated flashes flashes off off
Software program active
Measures required - - Electronics Electronics Communica-
defective. defective. tion with
Send the Send the ControlLine
cutting cutting interrupted:
optics to optics to contact
TRUMPF for TRUMPF for TRUMPF
repair. repair. Technical
Service.
Sensor operating status display Tab. 3-8
Magnetic coupling The processing optics are held by a magnetic coupling. The
magnetic coupling consists of an overload flange, mounted on
the barrel, and an overload plate at the processing optics. The
holding force is generated by permanent magnets. The overload
flange is the primary part (permanent magnet). The overload
plate is the anchor part.
In case of a collision of the processing optics with workpieces or
objects in the work area, the electrical monitoring circuit between
the primary part and the anchor part is interrupted; the process-
ing optics are released from the flange.
Note
The green LED on the magnetic coupling lights up when the
processing optics are docked correctly on the magnetic coupling.

1 Catch strap 5 Foam rubber
2 Bellows 6 LED magnetic coupling
3 Metal cable ties 7 Knurled screw
4 Sleeve
Magnetic coupling with bellows Fig. 60955
Damage to the processing optics when torn from the

NOTICE magnetic coupling!
Ø Replace the banjo screws whenever the processing optics
are dropped.
Ø Properly mount the catch strap.
Ø Replace damaged catch strap.
Ø Replace damaged bellows.
Ø Set the B and C axes to 0° before switching off the
machine.
The processing optics are secured against uncontrolled ejection

when there is a collision with the following securing elements:
■ With the catch strap, as far as it is mounted.
■ With bellows. The bellows "open" in the event of a collision.
Here, the bellows on the yoke plate of a bushing are held
onto the flange with 3 knurled screws. In the event of a colli-
sion, the bellows protect the optics as well as the beam guid-
ance from dirt.

Securing element, bellows Fig. 60957
Notes
■ Catch-ropes can be used in combination with a bellows.
■ The foam rubber in the yoke plate seals and protects against
dirt. If damaged, the foam rubber must be exchanged.
■ When exchanging the bellows, the two metal cable ties
(inside and out) for fastening the bellows must be
exchanged.

3.2 Laser protection device
In order to protect the operator against laser radiation, the work

area of the system is equipped with an encapsulated safety
cabin with a roof and lateral service doors. The safety cabin is
comprised of sheet elements. The window in the service door is
a special laser protection window.
Doors and laser light-relevant cover plates are monitored with
the use of safety locks. The laser beam is only ignited if the
doors are closed.
The interface between the workpiece changer and the safety
cabin is protected by partition walls and sealing strips. Partition
walls and sealing strips are part of the laser protection device of
the machine.
1 Safety cabin sealing strips 3 Rotational changer partition wall 5 Conveyor/safety cabin interface
(green) 4 Laser protective window
2 Partition wall sealing strips (red)
Overview of the safety cabin with a rotational changer Fig. 71420

1 Conveyor/safety cabin interface 3 Partition wall sealing strips (red) 5 Laser protection window
2 Safety cabin sealing strips 4 Rotary indexing table partition
(green) wall
Overview of the safety cabin with a rotary indexing table Fig. 71421

3.3 Exhaust system and filtering
installation
The aerosols and dust emitted when laser cutting metal are
extracted from the working range of the machine and directed to
a suction and filtering system (compact dust extractor) via a pipe
system, where they are separated efficiently.
The work area of the machine is vacuum-cleaned through the
open surface of the scrap conveyor. The suctioned air is guided
to the compact dust extractor via 2 connection sockets and a
piping system.
When the exhaust system is in operation, there is underpressure
inside the safety cabin.
During machining, a cyclone arises around the workpiece and
the fixture. The airflow must be permitted to flow unimpeded so
that the work area can be vacuum-cleaned effectively. This is to
be observed in the constructive design of the fixtures and fixture
holders.
In order to guarantee the full efficiency of the exhaust system,

pay attention to the following:
■ Fixtures and fixture holders must be permeable for the circu-
lating air.
■ The slottings in the front side of the safety cabin must not be
sealed.
■ The service door is sealed with foam rubber. The door must
be fit closely so that it is air-tight. If there is even a small
amount of damage, the foam rubber must be replaced.
■ The guide plates (see the following figures), which effectively
support air circulation, must not be dismounted. The lateral
guide plates must be closed during processing.
■ The grids in the exhaust piping to the left and right on the
scrap conveyor must be checked daily and cleaned weekly.

1 Guide plate, machine body 3 Guide plates, scrap conveyor
2 Lateral guide plates, front and
rear
Exhaust system, machine with rotational changer Fig. 75194
1 Guide plate on the machine 4 Lateral guide plate, front

body 5 Guide plate, scrap conveyor
2 Lateral guide plate, rear
3 Hinged guide plate
Exhaust system, machine with rotary indexing table Fig. 75195

Arrangement of fixtures During machining, a cyclone arises around the workpiece and
the fixture. The airflow must be permitted to flow unimpeded so
that the work area can be vacuum-cleaned effectively. For this
reason, the following should be observed when arranging the fix-
tures and fixture holders during construction:
■ The fixture or fixture holder must be permeable for the circu-
lating air.
■ The plane between the rotational changer and the fixture or
fixture holder (section B, Fig. 61680), including the work-
piece, must allow air to permeate over the whole cross-sec-
tion in a section of at least 200 mm.
■ The clearance at the cantilevered end of the fixture or fixture
holder must be at least 200 mm over the whole cross-section
(section A, Fig. 61680).
■ The maximum fixture height is 600 mm, starting from
Z = 0 mm.
Note
Recommendation for the design of cutting fixtures: see "Cutting
fixture" section.
1 Fixture/workpiece A Clearance
2 Scrap conveyor B Air-permeable section
3 Rotational changer
Arrangement of fixtures Fig. 61680
Compact dust extractor The machine is equipped as standard with a compact dust
extractor (synonym: filtering installation) with a spark arrester.
The dust container is equipped with a special non-flammable,
replaceable fine dust bag for collecting the extracted dust . The
extracted dust is collected and disposed of in the dust bag.
The compact dust extractor can optionally be equipped with the

following components:
■ Fire extinguisher with argon or CO2 as inert extinguishing
gas for fighting fires in the compact dust extractor.
■ Soundproofing cover for reducing the sound pressure level
by 3 dB at the workplace (see the "Noise level test certifi-
cate" chapter.

■ MultiCoater for preventive fire protection ("inertization") or for
protecting the filter elements ("Precoating").
■ The fill level sensor signals when the maximum permissible
fill level has been reached. In this case, the control issues a
message.
The suction power inside the safety cabin is 4000 m3/h. The air
suctioned in the work area is separated and cleaned in the com-
pact dust extractor. The cycles for purging the filter elements are
controlled according to the jet-pulse principle (depending on the
differential pressure).
Extinguisher system If the compact dust extractor is equipped with an automatic

(optional) extinguisher system, an acoustic alarm is triggered if a fire is
detected. The gate valves of the air supply and exhaust air sys-
tem are immediately closed. The complete interior space of the
compact dust extractor is flooded (gaseous) CO2 or argon.
MultiCoater The (optional) MultiCoater is an autonomous device that is con-

nected to the control and supply ports of the compact dust
extractor. The compact dust extractor must be prepared for the
use of an MultiCoater.
The MultiCoater blows dispensing material (calcium carbonate or
trass powder) onto the filter elements of the compact dust
extractor in the clean gas space.
During start-up of the laser processing machine, the MultiCoater

is normally parameterized for a use case or operating mode. A
distinction is made between the following operating modes:
■ "Inertization": means minimizing the risk of fire. A large
amount of dispensing material is continuously blown into the
clean gas space of the compact dust extractor and thus
added to the discharged dust.
■ "Precoating": After the cyclic purging of the filter elements,
dispensing material is applied to the filter elements for pro-
tection. Pre-coating can be used for processing oily sheets.
The filling level of the storage container is monitored. If the per-
missible minimal filling level has been reached, a message will
be issued.
The MultiCoater's cover is monitored by a proximity switch. If the

cover is opened while the red lamp is lit, the pre-coating proce-
dure is interrupted. After the cover is closed, the pre-coating pro-
cedure will continue after 5 seconds. While the pre-coating pro-
cedure is active, the red signal light next to the cover is lit.
Signal light is lit Pre-coating procedure is active. Do not open the cover from the
storage container.
Signal light flashes Compressed air supply is insuffi- Check why either no or too little
cient. compressed air has been provided.
Red signal light Tab. 3-9

3.4 Workpiece changer
The workpiece changer is the work station at which the workpie-

ces are clamped in a fixture during machining.
The components are set up outside of the safety cabin. After-
wards, the workpiece changer rotates the clamped component
into the machining position. After the end of machining, the work-
piece changer rotates into the unloading position. Afterwards, the
finished machined workpiece can be removed and a new unpro-
cessed part set up.
1 Device box fixture 3 Slot number 5 Workpiece

2 Production place number 4 Fixture interface 6 Fixture
Workpiece changer with fixture and workpiece Fig. 74470
Components Each workpiece changer consists of standard modules and fix-

tures (optional). The changer consists of the following assem-
blies:
■ Drive with rotary plate and partition wall(s).
■ Fixture interface:
− Rotary plate for mounting a maximum of 2 fixtures per
production place.
− Media connections for electrics, pneumatics and vacuum
(optional) for the connection of the fixtures.
■ Horizontal fixture carrier (option): 2 carriers for each produc-
tion place for accommodating the fixtures.
■ Project-specific TRUMPF fixtures or customer-provided fix-
tures.

Loading and unloading the Operating production places as well as workpiece changer: (see
workpieces "Operating the workpiece changer", pg. 4‐57)
Workpieces can be loaded and unloaded in different ways.
Machine with rotational changer and Basic Loading safeguarding

device (standard):
Fig. 71178
The loading and unloading area is located at the front in front of

the safeguarded danger zone.

Machine with rotational changer and Comfort Loading safeguard-
ing device (option):
Fig. 71179
All 4 sides around the safeguarded danger zone can be used for
loading and unloading.

Machine with rotary indexing table (option) and safeguarding
device:
Fig. 75196
The rotary indexing table has 3 production places, which can be

used for either loading or unloading. The user can configure the
loading and unloading area himself. The rotary indexing table
moves by 120° for each step.
Scrap conveyor Waste parts or scrap skeletons are collected on a scrap con-
veyor and transported out of the work area with a conveyor belt.
The lag time of the scrap conveyor is 90 seconds.
Property damage caused by a scrap skeleton or waste parts

NOTICE which are too large or too small.
Scrap skeleton and waste parts block the conveyor belt.
Ø Scrap skeleton or waste parts may not exceed the minimum
and maximum dimensions.
Ø Set parting cuts.
Ø Before entering reverse mode, remove the waste parts from
the conveyor belt.

3.5 Clamping fixture
The workpieces are fixed in a correct position with high repetition

accuracy and clamped in a clamping fixture during processing.
A maximum of four fixtures (two for each production place) can
be mounted per production place on the workpiece changer.
Each fixture can have at most 4 pneumatic clamps plus 2 paral-
lel clamps (standard). Project-specific solutions might deviate
from this.
Depending on the workpiece, the following fixture types are dif-

ferentiated:
■ Clamping fixtures for workpieces formed by internal high
pressure.
■ Clamping fixtures for hot-formed workpieces.
Set of drawings The clamping fixture's scope of delivery includes a set of draw-
ings in the device's terminal box:
■ Fixture with identification of the clamping units, clamping cyl-
inders and sensors (Bero) as well as the fixture dimensions.
■ Identification of the measuring points and fixture reference
point run on the workpiece changer.
■ Measurement data table: The measurement data table con-
tains the reference values determined during start-up of the
fixture, which establish the reference to the machine zero
point (G500).
■ If available: Fixture-specific transport regulation.
■ Optional documentation:
− Pneumatic schematic and electrical schematic.
− Layout, input and output addresses of the KSS.
− If required, fixture-specific transport regulation.
Fixture port The fixture is mounted on the workpiece changer at the prescri-
bed fixture place and is connected to the fixture interface pneu-
matically and electrically.
All actuators of the fixture, such as clamping devices, sensors or
positioner, are configured, controlled and operated via the config-
urable control interface.
The actuators are program-controlled opened and closed in auto-
matic mode. In setup mode, the clamps are operated via switch
elements or via manual functions.
Note
Fixture interface: See "Supplement to operator's manual", "Con-
figurable control interface (KSS)", chapter "Interface description".

Actuation via KSS The cylinder in the positioner as well as the clamping devices
are controlled via the configurable control interface from the NC
program with the TC_ELEMENT_STATE NC cycle. The program-
ming is done via configurable KSS elements, such as "cylinder"
and "clamping device".
■ Sample configuration for the pneumatic cylinder in the posi-
tioner:
− The cylinder should run in (actual position); this corre-
sponds to status 2 "run in", for example, for the KSS ele-
ment, "cylinder".
− The cylinder should extend (required position); that corre-
sponds to the status 1 "extend" for the KSS element,
"cylinder".
■ Sample configuration for a clamping device:
− The clamping device should be opened, which corre-
sponds, for example, to the status 2 "Open" for the
"clamping device" KSS element.
− The clamping device should be closed, which corre-
sponds, for example, to the status 1 "Closed" for the
"Clamping device" KSS element.
Note
KSS configuration and operation: see "Supplement to operator's
manual", "Configurable control interface (KSS)".
Workpiece recognition Check workpiece sensors to see if the workpiece is correctly

inserted in the clamping fixture. Only when all sensors detect the
workpiece and loading acknowledgement has taken place by the
operator or by an external automation, will the clamping devices
be closed in the configured clamping sequence.
The workpiece query is visualized on the terminal box with

LEDs. The visualization is optional.
■ If the workpiece has been detected, the LED will lit up green.
■ If the workpiece has not been detected, the LED will not light
up.

1 LED display
Workpiece query display Fig. 65651
Usually, there is a maximum of four workpiece sensors on one

fixture. The inputs E1 to E4 identify the individual sensors. The
input E1 corresponds to the first sensor when starting from the
left. The sensors are always counted from left to right.
Reference point run to the Every fixture has a mechanical, fixed zero point (B1) that is
machine zero point measured at the factory during start-up of the fixture and entered
in a measurement data table. The mechanical zero point may be
a measuring ball, a RPS bolt, a cross-hairs or another mechani-
cal component on the fixture.
The fixture zero point B1 always refers to the reference point A1

Zero point (B1) of the fixture, example Fig. 86289
Referencing the fixture to the workpiece changer: For the

commissioning of the clamping fixture at the machine, the zero
point of the fixture B1 is measured to the reference point A1 on
the workpiece changer. B1 is referenced to A1 by determining
the deviation (offset). The measured offset values are entered in
the measurement data table.
Referencing the fixture to the machine zero point (G500):
During start-up of the clamping fixture at the machine, the meas-
ured reference values are transferred to the machine control.
Start-up of the fixture on the machine is normally performed by a
TRUMPF employee.
Notes
■ Do not change the mechanical zero point of the fixture.
■ Reference point run of the fixture, reference points, zero
points and measuring points (C and D): see Set of drawings
for the fixture, sheet 3.
■ Reference point run to reference point A1 on the workpiece
changer: see set of drawings for the fixture, sheet 3.
■ In the program, the fixture zero point B1 usually corresponds
to the programmed workpiece zero point.
■ Project-specific solutions may deviate from the default speci-
fications.

Identification Each clamping fixture is marked as follows:
■ Fixture number (coding).
■ Number of the fixture place on which the fixture is mounted.
■ Nameplate.
■ CE marking.
1 Fixture number (coding) 2 Fixture place number 3 Nameplate

Identification Fig. 86288
The nameplate contains the following information:

■ Product classification.
■ Machine number and year of manufacture.
■ Workpiece number and workpiece designation.
■ Approved operation for a machine or for a machine type.
■ Pneumatic and electric connected loads.
■ Weight and bushing position on the workpiece changer.
■ TRUMPF drawing and material number.
■ Manufacturer.

Clamping fixture for hot-formed parts
In this type of clamping fixture, hot-formed, three-dimensional

sheets are generally inserted and fixed with clamping elements.
Assemblies A clamping fixture of this type generally consists of the following

assemblies, which are structurally adapted to the workpiece:
■ Carrier frame with mounting mandrel as well as full and pass
fitting pins for positioning the fixture in the centering bushings
on the workpiece changer. So-called clamping nests are on
the carrier frame that consist of clamping and support units.
■ Cover sheet for protecting the workpiece changer.
■ Pneumatic clamping units for clamping the workpiece.
■ Support units and sensors for fixing the workpiece and
detecting its position.
■ Protective plates for protecting the fixture from laser radiation
and slag.
■ Terminal box with supply connections.
1 Terminal box 4 Carrier frame 7 Full and pass fitting pins

2 Cover plate 5 Guard plate 8 Mounting mandrel
3 Clamping unit 6 Support unit 9 Fixing screws
Clamping fixture for hot-formed parts Fig. 65645

Clamping unit Every clamping unit consists of a clamping cylinder and a clamp-
ing arm.
1 Display 3 LED indicator, clamping cylinder

2 Clamping arm
Clamping unit Fig. 65649
You can monitor the clamps for proper clamping at the display
on each of the clamps:
■ The clamp is clamped correctly when the display is extended
and the LED for the clamping cylinder lights up in green.
■ If the display is not extended, the clamp is either open or not
clamped correctly.
Note
Emergency triggering: In an emergency, the clamp can be
opened manually by pushing the display down on the clamp.

Support unit The workpiece is loaded in the loading position in the open
clamping fixture; when this is done, the workpiece is inserted in
the correct position into the support units with light pressure.
Support unit Fig. 65650
Every index pin is adjusted to the workpiece geometry when the

fixture is commissioned. Due to the manufacturing tolerances of
the formed workpiece, it might be necessary to readjust the
index pins.
The position of the support points on the fixture is corrected by
adding adjusting shims of different sheet thickness to the index
pins.

Clamping fixture for inner high-pressure
In this type of clamping fixture, hollow profiles are generally

inserted and fixed with clamping elements.
The hollow profiles are workpieces which have been formed by
the "internal high pressure forming" (hydroforming) process.
These workpieces will be referred to below as "IHU workpieces".
Assemblies Every clamping fixture of this type consists of a carrier frame

and at least one swivel frame. The positioning unit and so-called
clamping nests are located on the swivel frame.
1 Clamping nest 4 Terminal box 7 Fixture interface

2 Positioner 5 Cover plate 8 Carrier frame
3 Swivel unit with swivel frame 6 Mounting mandrel
Assemblies, IHU clamping fixture Fig. 86285
A clamping fixture consists of the following assemblies, which

can vary in detail, depending on the workpiece:
■ Carrier frame with mounting mandrel as well as full and pass
fitting pins for positioning the fixture in the centering bushings
■ Cover sheet for protecting the workpiece changer.
■ Clamping nests consisting of pneumatic clamping units as
well as support units and workpiece sensors for fixing the
workpiece.

■ Swivel unit, consisting of swivel frame and swivel axis for
swiveling the workpieces during the processing.
■ Positioner for positioning the raw parts (optional).
■ Terminal box with supply lines.
■ Fixture interface for pneumatic and electric connections.
■ Protective plates for protecting the fixture from laser radiation
and slag.
Swivel unit In the following example, two swivel units are mounted opposing
each other on the support frame of the clamping fixture.
1 Swivel unit 3 Swivel frame 4 Clamping and support unit

2 Positioner
Swivel unit Fig. 86279
The swivel unit swivels the swivel frame each by 180° with the
clamped workpiece during machining into the end position. The
swivel axis is actuated via the KSS.
The positioner as well as the clamping nests are firmly con-
nected to the swivel frame.

Clamping unit Every clamping unit consists of a clamping cylinder and a clamp-
ing arm.
1 LED indicator, clamping cylinder 3 Clamping arm

2 Display
Clamping unit Fig. 86287
You can monitor the clamps for proper clamping at the display
on each of the clamps:
■ The clamp is clamped correctly when the display is extended
and the LED for the clamping cylinder lights up in green.
■ If the display is not extended, the clamp is either open or not
clamped correctly.
Emergency triggering: In an emergency, the clamp can be
opened manually by pushing the indicator down on the clamp.
The middle clamping units can have a ball roller (optional)

instead of the thrust piece. These clamping devices close first.

The ball roller allows the workpiece to be moved into the
required position by the positioner later on.
1 Ball roller 2 Loaded bearing

Workpiece fixing Fig. 86280
Support unit The support unit consists of index pins and slats. For insertion of
the raw part into the clamping fixture, the workpiece is placed in
the correct position in the index pin.
1 Support bolt
Support unit Fig. 86904
Every index pin is adjusted to the workpiece geometry with

shims when the fixture is commissioned. Due to the manufactur-

ing tolerances of the formed workpiece, it might be necessary to
readjust the index pins.
The position of the support points on the fixture is corrected by
inserting shims of different sheet thickness under the index pins.
Positioning unit (optional) Each positioner includes a pneumatic cylinder, a positioning bolt
and a fork for positioning the workpiece.
1 Positioner 3 Fork
2 Positioning bolt
Positioner Fig. 86284
The fork is pressed forward during positioning via the geometry

of the cone at the end of the workpiece. Once the sensor for the
fork query signals that the required fork position is reached, the
pushing movement of the positioner ends.
The required position of the fork is measured and adjusted to
the zero point of the fixture at the factory. When the pneumatic
cylinder retracts, the fork is spring-loaded back into the starting
position.
Notes
■ The fork depends on the workpiece. The fork may also have
to be replaced when the workpiece is changed.
■ Run in the positioner again only after the separating cut at
the end of the processing. If the positioner is run in too early,
damage (deformation or breakage) to the workpiece can
result.

Insert and position the The cylinder is retracted in the insertion position. The cylinder is
workpiece extended in the required position.
Insertion position Required position

Position the workpiece Fig. 86905
The workpiece is placed down with the smallest funnel cross-

section from above onto the conical surfaces on the fork.
The middle clamping devices with the pressure roller close first
in the clamping sequence. After these clamping devices are
closed and the workpiece is fixed in the insertion position, the
positioning bolt presses the workpiece into the required position.
Once the workpiece is in the required position, the rest of the
clamping devices close.
Fig. 86905

3.6 Solid-state lasers
The system comes equipped with a solid-state laser from the

TruDisk Series from TRUMPF as standard. Lasers with a laser
power of 2000 W, 3000 W or 4000 W are used.
Fig. 90041
Notes
■ TruDisk laser device: see "TruDisk operator's manual".
■ For processing with the solid-state laser: see "Technical infor-
mation on solid-state laser".
Optical laser cable The machine is shipped standard-equipped with a laser light
cable ((LLK) permanently installed between the laser device and
the machine.
The laser light is coupled to and routed in an optical fiber. The
optical fiber is a thin thread of silica glass.
Note
A renewed basic adjustment of the beam guidance is required
after the LLC has been replaced, which may not be performed
by anyone other than trained specialists.

Laser network The solid-state laser has a maximum of 6 Profibus interfaces.
The machine is assigned a Profibus interface, a hardware inter-
face and a light path no. at the time the laser processing system
is commissioned.
The operator must know the number of the Profibus interface of
the laser device assigned at the time of the commissioning of
the machine if the machine is operated in a laser network.
If the laser is shipped with 2 or more light path couplings, then

the scope of delivery of the laser will also include:
■ Control panel and panel computer.
■ "Interface description TruDisk" manual.
Note
Laser device control interfaces: See "Interface description Tru-
Disk" manual.
Remote diagnostics The remote diagnostics for the laser device take place through
the remote diagnostics port on the machine.
Cooling system The laser device has an internal cooling circuit which is usually
connected to an external cooling unit or a domestic water instal-
lation.
Pilot laser The system is standard-equipped with a pilot laser (synonym:

alignment laser). The pilot laser is a laser diode which emits light
at the wavelength of 635 nm. The light beam of the laser diode
is coupled into the beam guidance of the machine through the
laser light cable.
The pilot laser projects a small red spot of light (diameter

approx. 2 mm) on to the workpiece. This means the processing
optics can be positioned quickly and easily. The pilot laser is
used as follows:
■ For aligning and adjusting the laser beam.
■ For approaching a start position.
■ For recording the contour during teaching.
■ For moving along the 3D contour of a workpiece, e.g. in
order to check a taught NC program.

4. Technical data
Working range X axis 3000 mm

Y-axis 1300 mm
Z axis 600 mm
B axis ±135°
C axis n*360°
Workpiece changer working Horizontal top edge of the fixture 650 mm
height interface
Center of the socket fitting on the 650 mm
rotary plate
Workpiece changer swiveling Rotational changer 180° forward/backward
range
rotary indexing table n*120°
Maximum axis speed Simultaneous 173 m/min
X axis 100 m/min
Y-axis 100 m/min
Z axis 100 m/min
B axis 90 rpm
C axis 90 rpm
Accuracy14 Smallest possible increment 0.001 mm
Maximum repeatability:
- Linear axes: X, Y, Z 0.03 mm
- Rotary axes: B, C 0.005°
Maximum positioning deviation15:
- Linear axes: X, Y, Z 0.08 mm
- Rotary axes: B, C 0.015°
CNC control Hard drive with RAID controller Base:Siemens 840D Solution Line
USB port
Processor: Prozessor Intel® Cele-
ron® 2000E 2,2 GHz, 2 Cores
Platform 2x SSD with 128 GB MLC flash
memory
Color monitor 19" TFT display
Technical data Tab. 3-10
14 The part precision that can be achieved depends, among other things,
on the type of workpiece, its pre-treatment, the sheet size, the material
and its position within the working area. The technical specifications
are based on different component variants, due to the modular pro-
gram of the TruLaser Cell. They depend on the options in use.
15 Purely mechanical accuracy without control compensation, measured
over the entire travel distance of the axis in accordance with VDI 3441.
B836en 2017-11-17 Technical data 3‐45

Network connection Network card (Ethernet) 100 Mbit/s
Connection RJ 45 plug
maximum cable length 100 m
Supported network protocols NET BEUI, TCP/IP, Novell server,
NTFS file system
Pneumatic connection Required line pressure min 6 bar
(without options) max. 14 bar
Compressed air consumption see the "Installation conditions"
chapter (see "Compressed air sup-
ply", pg. 2‐43)
Electrical connection Connected loads see the "Installation conditions"
chapter (see "Connected load and
fuse protection", pg. 2‐37)
Permissible beam source Laser device TruDisk 2000
TruDisk 3001
TruDisk 4001
Technical data Tab. 3-11
The following technical data is valid for a symmetrical loading of

the workpiece changer:
Rotational changer rotary indexing table

Rotary plate diameter 4000 mm 4800 mm
Maximum permissible load per 300 kg 300 kg
production place without horizon-
tal fixture port
Maximum permitted load per pro- 260 kg 260 kg
duction place with horizontal fix-
ture port (for one fixture per pro-
duction place)
Maximum permissible moment of 1270 kgm2 2700 kgm2
inertia
Rotation time 2.1 s (180°) 2.3 s (120°)
Effective width of scrap conveyor 650 mm
Permissible outer circle diameter maximum diameter: 500 mm
of the waste parts
Permissible bend height of waste maximum of 50 mm related to the outer circle diameter level
parts
Permissible sheet thickness of maximum: 3 mm
waste parts
minimum: 1 mm
Rotational changer, rotary indexing table and scrap conveyor. Tab. 3-12
3‐46 Technical data 2017-11-17 B836en

Chapter 4
Operation
1 Description of the controls and indicators 4‐8

1.1 The machine's main switch 4‐11
1.2 Control panel 4‐14
1.3 MobileControl 4‐19
Installing the MobileControl app 4‐22
Activate MobileControl at the machine. 4‐23
Switching between control and observation 4‐27
mode
Exiting MobileControl 4‐28
1.4 Access Control Key System user management 4‐29
1.5 Decentral control panel 4‐34
1.6 Status indicators 4‐37
1.7 Scrap conveyor 4‐38
1.8 Compact dust extractor 4‐40
1.9 Acknowledge the danger zone 4‐41
1.10 Mechanically lock the door 4‐42
B836en 2017-11-17 Operation 4‐1

2 Operating modes of the machine 4‐43
3 Operating the machine 4‐44

3.1 Entering the work area 4‐45
3.2 Switching the machine on and off 4‐46
Switching on the machine 4‐46
Switching off the machine 4‐48
3.3 Shutting down the machine in the event of a 4‐50
malfunction/emergency
Tripping the EMERGENCY STOP 4‐50
Cancelling the EMERGENCY STOP 4‐50
Trip the extinguisher with a manual alarm 4‐50
3.4 Check safety functionality 4‐52
Manually start the safety test 4‐53
Issue user consent 4‐54
3.5 Eliminate malfunction 4‐55
Triggering FEED HOLD 4‐55
Acknowledging FEED HOLD after opening 4‐55
the door
Acknowledging FEED HOLD after a colli- 4‐55
sion involving the nozzle
Restarting processing after knocking off the 4‐56
processing optics
3.6 Operating the workpiece changer 4‐57
Manual functions 4‐59
Rotating workpiece changer in setup mode 4‐59
RSTAcknowledge the loading operation in 4‐60
automatic mode
RW: Acknowledge the loading operation in 4‐60
automatic mode
Acknowledging malfunction 4‐61
Acknowledging clamping error 4‐61
3.7 Operate scrap conveyor 4‐62
Starting the conveyor belt 4‐63
Stopping the conveyor belt 4‐63
Starting the conveyor belt in reverse mode 4‐64
Eliminate malfunction 4‐64
4‐2 Operation 2017-11-17 B836en

4 Description of the user interface 4‐65
5 System settings 4‐71

5.1 Setting data and time 4‐71
5.2 Selecting language and measuring system 4‐71
5.3 Activate the on-screen keyboard 4‐72
5.4 Open TRUMPF Operating System (TOS) 4‐73
5.5 Close user interface 4‐73
5.6 Switching to the TruControl interface 4‐74
6 User administration 4‐75

6.1 Log on user group 4‐76
6.2 Change password 4‐77
6.3 Deleting the password 4‐77
7 Production plan 4‐78

7.1 Creating and editing a production plan 4‐81
Creating a new production plan 4‐82
Editing job data 4‐84
Disable job 4‐84
Delete the order in the production plan 4‐84
Delete programs and orders 4‐85
Deleting a production plan 4‐85
7.2 Production with the production plan 4‐86
Starting a production plan (manual loading) 4‐87
Starting a production plan (automatic load- 4‐89
ing)
Changing the program sequence 4‐90
Modifying the number of program runs 4‐91
Stopping the production plan with "Stop 4‐92
after cycle end"
Starting to run empty, ending the production 4‐93
plan
7.3 Exporting order 4‐93
7.4 Starting step-by-step cycle 4‐94
7.5 Loading and workpiece status 4‐94
Displaying the loading and workpiece status 4‐96
Changing the loading and workpiece status 4‐98
Acknowledging workpiece status with man- 4‐99
ual loading
B836en 2017-11-17 Operation 4‐3

Acknowledging the workpiece status with 4‐99
automatic loading
7.6 Remaining time display 4‐101
Configuring the remaining time display 4‐105
8 Production 4‐115
8.1 Current program 4‐115
Start program 4‐115
Pause program 4‐116
Aborting a program 4‐116
Switch screen view 4‐116
Display Switching over the axis positions 4‐117
Display NC simulation 4‐117
8.2 Preparing programs 4‐118
Import master file 4‐118
Prepare program 4‐119
Activating marking test mode 4‐123
Activating STOP after single contour 4‐124
Display the workpiece counter 4‐124
Resetting the workpiece counter 4‐124
8.4 Utility tools 4‐125
Starting utility programs 4‐125
9 Setup 4‐126
9.1 Moving the axes manually 4‐126
Moving the axis continuously 4‐126
Moving the axis incrementally 4‐126
Requesting the laser in the laser network 4‐131
Enabling the laser in the laser network 4‐131
Enabling the dynamic distance control sys- 4‐132
tem
Deactivating the dynamic distance control 4‐132
system
Positioning the additional axis 4‐133
Activating distance regulation 4‐133
ControlLineRecord characteristic curve 4‐134
Switching the kinematic transformation on 4‐134
or off
4‐4 Operation 2017-11-17 B836en

Park axes 4‐135
Displaying and resetting workpiece counter 4‐135
Running a warm start 4‐136
Focal position without FocusLine setting 4‐136
9.3 MDA 4‐138
Execute the NC blocks in the following 4‐138
block
Execute the NC blocks in a single block 4‐138
9.4 Configuration 4‐139
10 Programming 4‐144
10.1 Program management 4‐144
Selecting program 4‐146
Copying a program 4‐147
Editing a program in the text editor 4‐147
Create subroutine 4‐148
Number program 4‐150
Exporting program 4‐150
Importing program 4‐151
Delete program 4‐151
Show setup plan 4‐152
Show PDF file 4‐152
10.2 Creating and managing subroutine macros 4‐153
Creating a subroutine macro 4‐154
Processing a subroutine macro 4‐155
Deleting the subroutine macro 4‐156
Inserting the Subroutine macro 4‐156
10.3 Transformation 4‐159
Applying the actual position as the zero 4‐161
point
Moving zero point incrementally 4‐162
Select Frame and fill transformation accu- 4‐162
mulator
Deleting transformation accumulator 4‐163
10.4 Operate KSS 4‐163
Start KSS configuration 4‐163
Activate module and load module data 4‐164
Deactivating the module 4‐164
10.5 Programming system 4‐165
B836en 2017-11-17 Operation 4‐5

Starting TruTops Cell Basic 4‐165
Call up advanced shop floor programming 4‐165
11 Technology 4‐166
11.1 Laser cutting 4‐167
Selecting the setting for the "Table" selec- 4‐168
tion field
Creating a cutting table 4‐168
Edit the cutting table 4‐169
11.2 Ramp cycles 4‐170
Programming ramp cycles 4‐170
11.3 Managing the tooling status 4‐171
Activate setup state 4‐172
Creating a new setup state 4‐173
Editing the tooling level 4‐174
Deleting a setup state 4‐175
12 Maintenance 4‐177
12.2 Partial backup 4‐177
Backing up data 4‐177
12.3 File manager 4‐178
Edit and save file 4‐179
13 Diagnostics 4‐180
13.3 Displaying the software version 4‐181
13.4 Display I/O monitor 4‐181
13.5 Logging the process data for service purposes 4‐182
13.6 Starting Teleservice 4‐182
13.7 Visual Online Support (VOS) 4‐184
Starting Visual Online Support 4‐185
14 Help 4‐189
14.2 Editing bookmarks 4‐190
14.3 Starting context-sensitive help 4‐191
15 Teachen 4‐192
15.1 Teach panel 4‐194
4‐6 Operation 2017-11-17 B836en

15.2 Description of the user interface 4‐201
15.3 Activating TEACHIN operating mode 4‐203
15.5 Setting basic functions 4‐204
Automatically replacing the zero point 4‐204
Activate the imperial (inch) measuring sys- 4‐205
tem
Activate and set the NC axes 4‐205
Setting threshold values for determination of 4‐206
the geometry deviation
Configure the function for F1 and F2 but- 4‐208
tons
Configure the cycle selection for the F1 key 4‐209
Delete the configuration for the F1 key 4‐210
15.6 Recording teach points 4‐211
Teaching a straight line 4‐211
Teaching the arc with CIP 4‐212
Teaching the macro center 4‐213
Teaching macro help point 4‐213
Teaching circular contour 4‐214
Teaching a rectangle contour (square) 4‐215
Teaching oblong hole 4‐217
15.7 Creating new program 4‐219
Setting the zero point 4‐220
Approach edge incrementally. 4‐220
Incorporating the contour 4‐223
15.8 Editing a program 4‐224
Searching and replacing NC text 4‐225
Insert and process cycles 4‐225
Select value for the name variable laser 4‐226
technology table.
Selecting the laser technology table 4‐227
Inserting block numbering 4‐227
15.9 Testing and correcting the program 4‐227
Correcting the zero point 4‐228
Inserting H word 4‐228
Correct path 4‐229
Testing the program 4‐230
B836en 2017-11-17 Operation 4‐7

1. Description of the controls and
indicators
1 Decentral control panel 3 Scrap conveyor control panel 4 Main switch

2 Control panel
Rotational changer with Basic Loading safeguarding device Fig. 71412
1 Decentral control panel 3 Scrap conveyor control panel 4 Main switch

2 Control panel
Rotational changer with Comfort Loading safeguarding device Fig. 74465
4‐8 Description of the controls and indicators 2017-11-17 B836en

1 Scrap conveyor control panel 3 Control panel 4 Main switch
2 Decentral control panel
Machine with rotary indexing table (option) Fig. 71413
Operating element Requirement Explanation

MAIN SWITCH - The main switch is a power isolation device.
■ ON: The electrical power supply is switched on.
■ OFF: The electrical power supply is switched off.
EMERGENCY No The following functions are triggered by pressing the
STOP push-but- EMERGENCY STOP push-button:
ton ■ All axes motions stop at maximum braking power.
■ The drives are switched off.
■ Gas supply is interrupted.
■ The power supply for the machine (except the 24 V
voltage to the control system) will be interrupted.
■ An active program is aborted and must be restarted,
if required.
■ The installed light path is interrupted. The absorber
(beam trap) closes.
WLAN tablet PC The tablet PC is Operating the machine.
(option) switched on
Teach panel(see TEACHIN key Teach panel for TEACHIN operating mode.
"Teach panel", switch in ON
pg. 4‐194) position
Scrap conveyor MAIN SWITCH Operate scrap conveyor:

control panel Machine in ON ■ Acknowledge malfunction.
position
■ Switch off the power to the drive motor.
■ Start the reversing operation.
B836en 2017-11-17 Description of the controls and indicators 4‐9

- ACKNOWL- No persons are By pressing the button, the danger zone inside the
EDGE THE inside the safety safety cabin is acknowledged when exiting the safety
DANGER ZONE cabin. cabin.
Control elements not on the control panel Tab. 4-1

Main switch Process cooler is Operating the laser: See the "TruDisk" manual.
switched on
Key-operated switch For information regarding the operation of the laser control system,
Control panel see the "TruControl 1000" software manual.
(option) Note:
Computer panel All operations required for operating and programming the laser
(option) processing system are done from the user interface of the
machine control, with the exception of laser diagnostics and the
"Show laser device" maintenance wizard.
EMERGENCY The button is not The EMERGENCY STOP push-button on the laser device triggers
STOP push-button encapsulated. an EMERGENCY STOP only for the laser device.
Note:
If the EMERGENCY STOP push-button on the laser device is
encapsulated and therefore not operable, the EMERGENCY STOP
of the machine also affects the laser device.
Controls for the TruDisk laser device Tab. 4-2

1.1 The machine's main switch
Note
If the main switch is switched off, the illumination inside the
safety cabin will also be switched off.
The MAIN SWITCH is on the front of the machine's body.
1 MAIN SWITCH
Machine main switch Fig. 73840

Machine main switch Requirement Explanation
Decentralized electrical power supply Switch on: The laser The machine, the laser device and the
(standard) device and the laser process cooler each have their own electri-
cooler are switched cal connection.
on.
The machine's main switch only switches
Switch off: The the electrical power supply to the machine
machine control sys- on and off.
tem will be shut
The laser device and the process cooler
down.
(laser heat exchanger) each have their own
main switches (mains disconnector). For
the machine to be ready for use, all 3 main
switches must be switched on.
Central electrical power supply (option) Switch on: none The machine, the laser device and the
process cooler each have their own electri-
Switch off: The laser
cal connection. The machine's main switch
and machine control
switches the electrical power supply to all
systems have been
components on and off.
shut down.
The laser device and the process cooler
(laser heat exchanger) also each have their
own main switches. These components can
be switched on or off independently from
the machine's main switch.
Machine main switch Tab. 4-3
Under Voltage Trip key

switch
1 MAIN SWITCH 2 Key switch Under Voltage Trip

Fig. 59607

If the Under Voltage Trip key-operated switch is at inactiv,
DANGER the machine's safety circuit is bypassed. There is
dangerous voltage at all live components.
Risk of fatal injury due to electric shock!
Ø Observe the warning signs.
Ø Do not touch live parts.
Ø Only qualified electricians may work on the machine's elec-
trical equipment.
Key-operated switch inactiv activ

Under Voltage Trip The undervoltage trip is If the switch cabinet door to the
bypassed. If the switch cabinet machine's main switch is closed
door to the machine's main then there will be voltage on all of
switch is opened, there is still a the components. As soon as the
dangerous voltage on all of the switch cabinet door is opened, the
electrical components. undervoltage trip is used to switch
off the mains disconnector.
This state may only be activated
for fault-finding by properly quali- If the switch cabinet doors or the
fied electricians. switchboxes are opened with the
MAIN SWITCH ON, then there is
still a dangerous voltage. These
doors and switching devices are
labelled with warnings.
Under Voltage Trip key-operated switch Tab. 4-4

1.2 Control panel
The machine is operated via the control panel.
1 User interface 4 Operating panel

2 Teach panel 5 TEACHIN key switch
3 USB connection 6 Keyboard
Control panel Fig. 74469
Operating element Explanation

Operating panel with display Operation of machine and laser
device
Keyboard Text input for user interface
TEACHIN KEY SWITCH Activation of TEACHIN operating
mode
USB port Connection of peripheral devices,
e.g. for data transmission
Control panel Tab. 4-5

Operating ele- Name Requirement Status Description
ment
NUMBER PAD - - Number input for the user
interface.
CHANGE OF - - Changes the operational

SIGN sign in input fields without
deleting the previously
entered value.
BACKSPACE - - Moves the cursor one
character to the left each
time it is pressed. The
character to the left of the
cursor is deleted.
ESCAPE - - Undoes any entries that
were started but not com-
pleted.
ENTER - - Confirms values that have

been entered.
TOUCHSCREEN - - Locks touch-screen opera-

tion, e.g. to clean the
screen.
On machines with the
MobileControl option:
unlock the screen.
CHANGE OF - - Switches between applica-
APPLICATION tions, e.g. between the
TRUMPF Operating Sys-
tem (TOS) and the user
interface.
PAGE UP/ - - Scrolls a list up/down.
PAGE DOWN
MAGNIFYING - - Increases/decreases the

GLASS view.
TAB - - Moves the cursor to the

next input field.

ment
MACHINE ■ The control ■ Illuminates: The Switches the machine
ON/OFF system is machine is ready to drives on or off.
ready for operate. ■ The power supply of
operation. ■ Flashes: Power supply the drives is switched
■ EMER- to drives. on with MACHINE ON.
GENCY − Slow: Drives are Test cycles are per-
STOP is not ready to be formed for monitoring
active. switched on. the supply devices
− Fast: Drives have (compressed air, axes,
been switched on. etc.).
■ Off: Drives are
■ The drives are
switched off. switched off in the
event of EMERGENCY
Or: An error is pending
STOP.
(e.g. emergency stop),
drives cannot be
■ After the releasing the
switched on. EMERGENCY STOP
push-button, the drive
must be switched back
on.
LASER TEST - ■ The button is illumi- LASER TEST operating
nated: LASER TEST mode will be activated or
mode is active. deactivated.
■ Off: LASER TEST ■ In LASER TEST mode,
mode is deactivated. the laser beam and the
gas supply will be
switched off.
■ A program can be run
without a laser beam.
Laser device is ■ Illuminated: Laser is The laser is being
ready for opera- switched on. switched on or off.
tion: The ■ Off: Laser is not ■ Pressing briefly
ON/OFF button switched on.
LASER ON/OFF switches the laser on
on the laser ■ Flashing slowly: Laser or switches the laser to
device is lit up
is switched on or is in standby mode.
in blue.
standby mode. ■ Pressing for longer
■ Flashing quickly: Laser switches the laser off
control is being shut and shuts down the
down. laser control.
RESET - ■ Flashes: An error is ■ Cancels the running
pending. program.
■ Off: No errors pending. ■ Immediately ends the
production plan.
■ Acknowledges error.
■ Acknowledges EMER-
GENCY STOP after
unlocking the push-but-
ton.
FEED HOLD - ■ Illuminates: FEED Stop all machine move-
HOLD is pending. ments. The laser beam
and the gas supply are
being switched off.
■ No axis movements
are possible while
FEED HOLD is active.
■ No beam enable for
the installed light path.

ment
ACKNOWLEDG- Feed hold is - Acknowledges FEED
ING active. HOLD.
FEED STOP ■ Continues an inter-
rupted machining pro-
gram.
START ■ FEED STOP ■ Illuminates: Program is Starts the selected
is not active. active. machining program.
■ The machin- ■ Off: The program has
ing program been ended.
has been
selected.
Status display, - ■ Flashes: the light bar- The status display is valid
light barrier rier is interrupted, wait for a machine with a rota-
for loading acknowledg- tional changer.
ment.
■ Off: the light barrier
has been acknowl-
edged.
LEFT and - - Have no effect.
RIGHT naviga-
tion buttons
PLUS and ■ EMER- - Move the axes in jog
MINUS button GENCY mode.
STOP is not
Manual function of the
active.
switch: increase or reduce
■ FEED STOP value.
is not active.
FEEDRATE "Standard" user - Controls the speed of
POTENTIOME- group is active. movement of the NC axes
TER between 0 - 120 %:
Note:
The potentiome- ■ In setup mode: Feed
ter only works at speed between 0 -
0% or 100% in 4 m/min (without
the "Production" simultaneous mode).
user group; an In teach mode, the
infinitely variable maximum speed corre-
setting is not sponds to the safe
possible. speed.
■ In automatic mode:
The feed rate with
simultaneous axis
motion is between 0 -
85 m/min.

ment
EMERGENCY - - ■ Stops the movement of
STOP push-but- all axes at maximum
ton braking power.
■ Switches the drives off.
■ Interrupts the gas sup-
ply.
■ Aborts the active
machining program. It
will have to be
restarted.
■ Interrupts the installed
light path. Closes the
absorber.
■ Interrupts the electrical
power supply to the
process cooler and
Note:
After unlocking the EMER-
GENCY STOP push-but-
ton, the drives must be
switched on again: Press
the RESET button and
then the
MACHINE ON/OFF but-
ton.
Operating elements Tab. 4-6

1.3 MobileControl
The MobileControl function is a machine option. Using the Mobi-

leControl app, the live image of the user interface of the
machine is transferred to a mobile terminal. The MobileCon-
trol app allows the user to control the machine remotely (in con-
trol mode) or to monitor it (in observation mode).
Fig. 73679
Observation mode: The user interface of the machine is trans-

ferred to the tablet or smartphone as a live image. The machine
is still operated via the control panel. Observation mode is
visualized on the control panel as a blue-green bar at the upper
edge of the display.
Control mode: If the MobileControl function is active in control
mode on the machine, then the machine can only be operated
via the tablet or smartphone. Control mode is visualized on the
user interface on the control panel with a yellow-red control
frame.
Note
The TEACHIN operating mode as well as the teach panel can
be operated in control mode.

MobileControl App Remote control of the machine is carried out using a tablet PC
or smartphone and the MobileControl app supplied by TRUMPF.
Here, the MobileControl app is connected to the local WLAN net-
work of the machine.
The MobileControl app can be downloaded free of charge

from Google Play or in the Apple App-Store.
Tab. 4-7
Note
The MobileControl app has an online help. When the app is
open, it is called up via the lower button bar with the "Question
mark" button.
MobileControl software The MobileControl software is licensed and enabled by the serv-
ice engineer when the machine is commissioned or retrofit on
the machine.
The user connects the MobileControl app to the machine control
using the MobileControl Manager.
Note
If the MobileControl software is activated via the TRUMPF Tele-
presence Portal, the connection to the Telepresence Portal must
be ended before the MobileControl function can be activated on
the machine.
Wireless Operating Point Wireless Operating Point (WOP) is the router for the local WLAN
of the machine.
The MobileControl app and the machine control are connected
via the WLAN router in the electrical cabinet of the machine.
Note
The Wireless Operating Point has no connection to the
machine's network drives or to the customer's network.
Local WLAN of the machine The user interface as well as the live image of the observation
camera (option) are transmitted to the mobile terminal via the
local wireless network (WLAN) of the machine.
The WLAN connection between the MobileControl app and the
machine control is started after entering a password or PIN.
WPA key In the MobileControl manager, a WPA key is generated at the

machine once or for every new activation. The WPA key (QR
code) contains the access data for the WLAN connection: pass-
word (WPA2-Key) and network name (SSID).

The automatically generated network name corresponds to the
following scheme: "TRUMPF_machine_number (or
alias)_MCA". Instead of the machine number, the user can
assign an individually chosen network name (Alias).
Notes
■ If a mobile terminal is used for multiple machines, a new
WPA key must be generated for every new activation of
MobileControl on a machine.
■ If a new WPA key is generated, all previously connected
mobile terminals must be reconnected with the WLAN of the
machine afterwards.
Prerequisites The following conditions must be met in order for the MobileCon-
trol function to be able to be used on the machine:
■ The machine is equipped with the TRUMPF Wireless Operat-
ing Point (WOP).
■ The MobileControl software is activated on the machine.
■ The MobileControl app is installed on the mobile terminal.
The user requires a tablet PC with a camera or a iPhone. The

following devices are supported:
■ iPad Tablet with camera (minimum requirement: iOS ver-
sion 7.0).
■ iPhone (minimum requirement: iOS version 7.0).
Restrictions Remote control via MobileControl cannot be used under the fol-
lowing conditions:
■ In service mode.
■ If the machine control is connected with the TRUMPF Tele-
presence Portal.
Note
If the MobileControl software is enabled via the Telepre-
sence Portal, the connection with the Telepresence Portal must
be ended before remote control via MobileControl can be used.

Installing the MobileControl app
The MobileControl app must be installed on the mobile terminal.
Condition
■ Internet connection is active.
Downloading the 1. Open the app store and tap on the TRUMPF icon.
MobileControl app 2. Select the MobileControl app.
− Tap on Load.
− Tap on Install.
Once the icon of the app is displayed on the tablet, the app
is downloaded and installed.
Adapting the configuration 3. Tap on the "Settings" icon.

The "Configuration" menu is opened.
MobileControl app, "Configuration" menu Fig. 86901
4. Activate the following function: Under "General Settings":

"Deactivate idle mode".
5. Tap on Save.

Activate MobileControl at the machine.
Conditions
■ The machine is ready for operation.
■ TRUMPF MobileControl app is installed on the tablet PC.
■ MobileControl software is enabled.
Starting the 1. Switch on the mobile terminal.

MobileControl app 2. Start the MobileControl app.
Opening the MobileControl 3. At the machine's control panel: open TRUMPF Operat-
Manager ing System (TOS):
− Press the CHANGE APPLICATION button.
− Select TRUMPF Operating System (TOS).
4. Press Operator.
5. Press Network ....
6. Select MobileControl Manager and press Start.
The MobileControl Manager is opened.
MobileControl Manager Fig. 86052
Note
The presettings in MobileControl Manager usually do not
have to be changed.
7. Activate the following functions, assuming they are not
already activated automatically:
− "MobileControl enabled": activate or deactivate Mobile-
Control.
− "MobileControl Input Allowed": Operation should be done
using the mobile terminal. If MobileControl is deactivated,

the remote control cannot be activated in the MobileCon-
trol app.
− "MobileControl enabled on startup" (optional): MobileCon-
trol should be active when the machine is switched on.
8. If the network name (SSID) is to be changed:
− Enter the network name in the Machine Alias field and
press Set Alias.
A network name defined by the user is generated instead of
the "machine number".
Generating or displaying the Note

WPA key
If a new WPA key is to be generated, the current WPA key
must be deleted first (see online help for the MobileCon-
trol app).
9. Either
Ø To show the current WPA key: press Show WPA2-Key.
or
Ø If a new WPA key should be generated:
− Press Generate new WPA2-Key.
− To show the WPA key: press Show WPA2-Key.
10. Press OK.
The generated WPA key, consisting of the QR code, pass-
word (WPA2-Key) and network name (SSID), is shown.
Fig. 73680
11. Tap on the button with the "QR code" in the lower button bar
on the tablet.
The tablet camera will start.
12. Scan the QR code on the machine with the tablet.
The password is saved to the clipboard and can be pasted
to the tablet from there later. The network name is saved in
the app.

Connecting the 13. Tap on the "Settings" icon (gearwheel) on the tablet in the
MobileControl app with the lower button bar.
machine control
1 WLAN status 2 Network name (SSID)

Fig. 86903
14. In the "Settings" column, tap on "WLAN".

15. In the "WLAN" column, tap on the network name (SSID) of
the machine.
16. Paste the password from the clipboard:
− Tap on "Password".
− Tap on Insert.
The password is pasted from the clipboard.
17. Tap on Connect.
The WLAN connection is set up. If the status of the WLAN
connection shows a green checkmark, the tablet is con-

nected to the WLAN of the machine. Observation mode is
active.
1 Observation mode bar

Fig. 86900
Activating control mode 18. Show the MobileControl app again.
Note
Input via PIN or QR code can be selected by tapping the
Change method button. The selected method is self-holding.
19. On the tablet under "Settings", tap the Activate Remote Con-
trol button.
A QR code or, alternatively, a 4-digit PIN (depending on the
selected method) is displayed.
20. Scan the QR code or PIN.
Control mode is activated. A yellow/red control frame
appears on the user interface. The machine can now be
operated exclusively via the mobile terminal. The

touchscreen as well as the buttons on the control panel are
disabled.
1 Control frame
Fig. 86902
21. On the mobile terminal: To change from the TOS to the HMI,
tap on the "change of application" icon.
Switching between control and observation

mode
If control mode is active, the operator can switch between

control mode and observation mode via the yellow "control
mode" and "observation mode" buttons on the upper edge of the
touchscreen on the control panel. MobileControl remains acti-
vated here and the WLAN connection is maintained.

Conditions
■ MobileControl is active.
■ Control mode is active.
"Control mode" button
"Observation mode" button
Tab. 4-8
1. At the control panel: press the TOUCHSCREEN button.

The touchscreen is enabled.
2. In order to switch to observation mode, press the "observa-
tion mode" button.
Observation mode is active.
3. To switch back to control mode, press the "control mode"
button.
Control mode is active again. The machine can now be oper-
ated via the mobile terminal again. The touchscreen on the
control panel is disabled again.
Exiting MobileControl
The WLAN connection is only broken once remote control is

deactivated.
Note
If the WLAN connection is broken unintentionally, control mode
can be ended at any time with the "observation mode" button on
the touchscreen.
1. At the control panel: press the TOUCHSCREEN button.

The touchscreen is enabled.
2. Tap on "Settings" (gearwheel) on the tablet.
3. Tap on the Deactivate Remote Control button.
The WLAN connection is broken.
4. Close the MobilControl app.

1.4 Access Control Key System user
management
Access Control Key System is an option for the laser machine.

The electronic user management system from Euchner of the
Electronic-Key-System EKS Light type is an electronic access
control.
With a hardware ID key (RFID chip), the user can assign user-
specific rights to the personnel (operator, person doing set-up
work, etc.) for the machine control.
Prerequisites:
■ The option is applied on the machine.
■ The reading device for the RFID chips is mounted on the
control panel.
■ Before use, the user wrote the user ID as well as the "User
group" (user rights) to the chip.
Note
If the Access Control Key System is applied at the machine,
then user management by issuing passwords (standard) does
not work.
TRUMPF scope of delivery The scope of delivery of the Access Control Key System option
by TRUMPF includes the following components:
■ Interface adapter (analysis device) mounted in the machine's
control panel housing.
■ Reading device (key adapter) for RFID chips is mounted on
the control panel.
■ User management and assigning rights in the machine con-
trol.
User scope of delivery The following Electronic-Key-System EKS Light components do

not belong to the TRUMPF scope of delivery. The user must
procure these components from Euchner:
■ Electronic-Key-Manager - EKM management software (includ-
ing the supplementary software adapted to TRUMPF) from
Euchner for programming the RFID chips.
■ Electronic keys, RFID chips (with 116 bytes of read/write
memory).
■ Key adapter with USB interface and connection cable for the
USB interface.
■ Optional: EKS table housing for installing the key adapter.

Components Euchner order number Euchner item number
Management software Electronic-Key-Manager - EKM: - -
"EKM-Light Version" or "EKM single-user version"
Management software "EKM single-user version" on 098578 EKM single-user version
CD ROM
Compared to Light Version, the management software
"EKM single-user version" also has a database viewer
for managing the user rights.
Management software "EKM-Light Version" on 111410 Light Version
CD ROM
Supplementary software with TRUMPF input dialog box German: 099972-600 -
Note: this software must be ordered and activated in English: 099972-610
consultation with the Euchner. French: 099972-620
Spanish: 099972-630
Italian: 099972-640
Electronic keys, RFID chips (with 116 byte write and Red: 077859 EKS-A-K1RDWT32-EU
read memory)
Black: 084735 EKS-A-K1BKWT32-EU
Blue: 091045 EKS-A-K1BUWT32-EU
Green: 094839 EKS-A-K1GNWT32-EU
Yellow: 094840 EKS-A-K1YEWT32-EU
White: 123097 EKS-A-K1WHWT32-EU
Orange: 123098 EKS-A-K1OGWT32-EU
EKS key adapter with USB interface 092750 EKS-A-IUX-G01-ST01
Manual for EKS key adapter, can be ordered or down- German and English: USB & USB FSA
loaded free of charge 094485
USB driver EKS: includes a driver for the key adapter 094376 EKS USB Driver
with USB interface and a driver for the virtual serial
COM port for the Windows operating system.
USB 1.1 or USB 2.0 connection line for the EKS key - -
adapter
Optional: EKS table housing for the key adapter 113106 EKS DESKTOP CASE
Tab. 4-9
Notes
■ The downloads are free of charge. Download under:
https://www.euchner.de/Service/Downloads
■ A commercially available USB 1.1 or USB 2.0 connection
line (up to max. 3 m) is required for connecting the EKS key
adapter via the USB interface. On the EKS side the line
requires a type B USB connector; for the USB interface a
type A connector.
Programming the RFID chips The Euchner software "EKM Light Version" or "EKM single-user
version" is used to program the RFID chips.
This software has a specific input dialog box for TRUMPF
machines.

"EKM" software input dialog box Fig. 86051
Note
The software is only available from Euchner. First, a standard
version is installed for the user who must then establish contact
to receive the dialog specific to TRUMPF machines for writing
the RFID chips.
Please contact the following persons at Euchner.
Mario Deutsch
Phone: +49 711 7597-415, e-mail: mario.deutsch@euchner.de.
Thomas Raiser
Phone: +49 711 7597-319, e-mail: thomas.raiser@euchner.de.
Identification The user logs on at the start of the shift using the chips and
logs off again when finished by removing the chip from the read-
ing device. During login, the machine control saves the user
identification (user ID) in the message history (Diagnostics main
operation) as well as in the "user event logfile".
The personnel number programmed on the chip can be used by
the machine control and the operator to identify the different
users.
The machine control can evaluate the following user IDs: 1 to
65535.

Note
Call up "User event logfile": see User event logfile
User groups The machine control evaluates the following user groups:
■ "Production" user group (equivalent to Euchner authoriza-
tion 8).
■ "Standard" user group (equivalent to Euchner authoriza-
tion 7).
■ "Advanced" user group (equivalent to Euchner authoriza-
tion 5).
Programming authorization "0" is not permitted.
When the operator logs off (removes chip), the "Production" user
group is always active.
If no chip is inserted in the reading device, there is no user-spe-
cific evaluation. In this case, the "Production" user group is
active.
Note
For user rights, see: User group.

Reading device for RFID The reading device is mounted on the control panel. As soon as
chips the user inserts his chip into the reading device, he is automati-
cally registered. The corresponding user rights take effect imme-
diately.
1 Reading device
Access Control Key System on the control panel of the Fig. 84218
machine
An LED on the reading device indicates the status:
Color Description
Green User management is ready for operation. No chip is
inserted. The "Production" user group is active.
Yellow A chip is inserted in the reading device. User manage-
ment is activated via the Access Control Key System. The
logged-on user group is active.
Tab. 4-10
Note
An error message is issued if login is incorrect.
In an error case: remove the chip and press the RESET button.
Then, a chip can be inserted again.

1.5 Decentral control panel
A decentralized control panel for acknowledging the start and

loading is located on each light grid post.
1 EMERGENCY STOP push-but- 3 LOADING ACKNOWLEDG-

ton MENT
2 MULTISWITCH
Decentral control panel Fig. 62151
Notes
■ The MULTISWITCH and LOADING ACKNOWLEDGEMENT
buttons are sensor buttons which react to touch.
■ Do not press the MULTISWITCH and the LOADING
ACKNOWLEDGMENT button, only tap them briefly!
Machines with rotational The rotational changer has two decentralized control panels.
changer Both control panels are connected to each other. Operation can
be done either from the left or the right.
Machines with rotary The rotary indexing table has two decentralized control panels.
indexing table Each control panel controls its assigned loading place.

Operating element Status Explanation
EMERGENCY - Pressing the EMERGENCY STOP push-button triggers
STOP push-but- the following functions:
■ The drives are switched off.
■ The power supply for the entire system (except the
24 V voltage of the control) is interrupted.
■ An active program is aborted and must be restarted,
if required.
(beam trap) closes.
MULTISWITCH Illuminated In automatic operating mode: machining is active.
flashes The control expects the button to be tapped.
flashes slowly In automatic mode: Faulty part. Part acknowledgement
is required from the operator.

LOADING Does not light In automatic operating mode: the loading acknowledg-
ACKNOWL- up ment is active. If the safety circuit is closed and the
EDGEMENT workpiece is correctly clamped, the workpiece changer
will turn as soon as the machining currently in progress
is completed.
Illuminated Operator intervention permitted: It is possible to load
and unload the workpiece.
flashes Safety circuit is interrupted.
In setup mode: Acknowledge the light grid. Then the
workpiece changer can be turned using a manual func-
tion.
In automatic mode with an active production plan, tap-
ping the button has the effect of acknowledging the
loading. When the safety circuit is closed, the clamping
fixture closes. The workpiece changer will turn when
the machining is complete.
For machines with a Rotational changer:
The loading and interruption of the safety circuit are
acknowledged.
For machines with a Rotary indexing table:
The loading and interruption of the safety circuit for the
respective loading place are acknowledged. Only after
the loading of the second loading place (if two loading
places are active) has been acknowledged and the
machining has been completed does the rotary index-
ing table cycle.
In automatic mode in the Single job operating mode:
After the insertion of the part in the loading area,
acknowledge the light grid. If the safety circuit is
closed, the rotational changer can be turned and the
program is started with the START button.
Button continues Clamping error or reopen clamping device: If there
to flash after is a clamping error, then an error message is out-
loading acknowl- put. A FEED HOLD is triggered only after the end
edgment. of machining; the blue status display flashes.
■ In the event of a clamping error, tab on the button
again. The clamping devices open again.
■ As long as the clamping process has not yet been
completed, the clamping devices can be reopened
by tapping the button again.
Decentralized control panel control panel for the workpiece changer Tab. 4-11

1.6 Status indicators
The LED indicators are integrated into the front side of the
safety cabin, left and right. These LEDs indicate the machine
status.
■ For machines with a rotational changer: The left and right
indicators are coupled.
■ For machines with a rotary indexing table: The left indicator
shows the status for loading place 21 (left) and the right indi-
cator for loading place 22 (right).
1 Status indicators
Fig. 74928
Signal color Status Description

Red, both sta- Illuminated FEED HOLD is active, no program is active.
tus indicators
flashes Fault, EMERGENCY STOP is active.
Blue Illuminated Machining is active.
flashes The program is active but interrupted, FEED HOLD is active.
flashes slowly Faulty part: Part acknowledgement is required from the operator.
Green Illuminated Operator intervention permitted: It is possible to load and unload the work-
piece.
flashes The workpiece is due to be changed. Light barrier has been interrupted.
The control system is waiting for a loading acknowledgement.
Orange Illuminated Laser is ready for operation or laser processing is active.
not illuminated Laser is not switched on.
Status display Tab. 4-12

1.7 Scrap conveyor
1 EMERGENCY STOP push-but- 3 KEY-OPERATED SWITCH

ton
2 Illuminated push-button FAULT
Switchbox and controls for the scrap conveyor Fig. 74475
In automatic mode, the conveyor belt will start as soon as a pro-

gram is started. Once processing is complete, the conveyor belt
will stop in accordance with the lag time set.
The scrap conveyor is operated manually in setup mode.
If there is a fault or if the access door is opened while the belt is
running, then "feed hold" will be triggered.

EMERGENCY - The following happens when the EMERGENCY STOP
STOP push-but- push-button is pressed:
■ The power supply for the entire system (except the
24 V voltage of the control) is interrupted.
■ An active processing program is aborted and needs
to be restarted, if required.
■ Scrap conveyor stops.
(beam trap) closes.
MALFUNCTION flashing There is a fault. After fixing the fault, acknowledge.
Illuminated Scrap conveyor is ready for operation.
Does not light The drive motor is powered down.
up

KEY-OPERATED Left Start the conveyor belt in reverse mode: The conveyor
SWITCH belt will briefly run backwards, as long as the switch is
turned counter-clockwise.
Prerequisite:
■ The access door has been closed.
■ EMERGENCY STOP is not active.
Center Switch the drive motor off.
Right Start the scrap conveyor rotating clockwise. The key
can be removed in this setting.
Main operation Production: The conveyor belt will start
and stop automatically during the machining. If the sen-
sors in the conveyor's ascending and drop area detect
a fault, the conveyor will stop immediately. The proc-
essing of the workpiece will be finished and only then
will a feed stop be triggered.
Main operation Set up: The conveyor belt can be
started and stopped with the manual function "Waste
conveyor belt".
Operating devices for scrap conveyor Tab. 4-13

1.8 Compact dust extractor
The compact dust extractor is supplied with power via the

machine's MAIN SWITCH. The compact dust extractor is control-
led (MP12 filter control) via the machine's control system.
1 Extinguisher system control 3 Filter control display

panel
2 Manual fire alarm for the extin-
guisher system
Compact dust extractor with extinguisher Fig. 74616
Extinguisher system If the compact dust extractor is equipped with an extinguisher

system (option), a manual fire alarm and a control unit are part
of the equipment.
The extinguisher system is secured in front of the MAIN
SWITCH, and - provided the extinguisher system is switched
on - is always ready for use, even after switching the laser proc-
essing machine off.
Fire hazard in the compact dust extractor caused by

NOTICE deactivated extinguisher system.
Ø Do not switch the extinguisher system off.
Ø Switch the extinguisher system back on again, after complet-
ing the maintenance work.

1.9 Acknowledge the danger zone
1 ACKNOWLEDGE THE DANGER ZONE button

Fig. 73839

DANGER
ble route.
ton.

DANGER table.
ble route.
button.
The danger zone inside the safety cabin is monitored by the

control system. As soon as an access door is opened, the move-
ment of the workpiece changer (i.e. rotational changer or rotary
indexing table) will be disabled in all operation modes.

Movement of the workpiece changer and the starting of a pro-
gram will not be enabled again until the ACKNOWLEDGE DAN-
GER ZONE button inside the safety cabin has been pressed and
the associated access door is closed within 3 seconds.
1.10 Mechanically lock the door
The mechanical locking bar for the access door is an option.

With the help of the locking bar, the door can be secured
against unintended closing.
The locking bar is pushed forwards when the door is open so
that the door cannot be closed and it is secured in this position
with a padlock.
Mechanical door stop (option) Fig. 76787

2. Operating modes of the machine
There are the following operation modes:

■ AUTOMATIC operating mode
■ MDA operating mode
■ JOG mode
Note
The machine's operating modes are not exactly the same as the
main operations of the control system.
Automatic mode In AUTOMATIC operating mode, the machining programs are

executed fully automatically. Programs are selected and
executed in the main operation called PRODUCTION.
The machining programs can be executed in different ways:

■ In a single job: only a single job is started and executed. To
execute the next job, the program must be restarted.
■ In the production plan:
For different production locations, several jobs can be cre-
ated in the production plan. After starting the production plan,
these jobs will be alternately processed in the defined
sequence. The production plan is started once and termi-
nates when the specified number of parts has been
produced for all of the production locations. The set up of the
parts in the loading place must be acknowledged in each
case by the operator.
MDA operating mode In MDA (Manual Data Automatic) operating mode, single or mul-
tiple NC records blocks can be created and immediately exe-
cuted. MDA operating mode can only be selected in the SETUP
main operation.
JOG operating mode In JOG operating mode, the NC axes can be moved manually,
either continuously or step-by-step. JOG operating mode is
active in all of the control system's main operations.
B836en 2017-11-17 Operating modes of the machine 4‐43

3. Operating the machine
Safety The access door is used to enter and leave the machine's work
area. As soon as the door is opened, a FEED HOLD will occur.
The danger zone should only be acknowledged when leaving the
working range. FEED HOLD will only be removed if the door is
closed within the time window of 4 seconds.
While in the work area (apart from set up and maintenance
work) do not step on the scrap conveyor.

DANGER table.
ble route.
button.

DANGER
ble route.
ton.
Risk of collision in the 3D There is always a risk of collisions between the Z barrel and fix-
working range tures, table sets, or workpieces in the 3D working range of the
machine.
There is a particular risk of collision:

■ When starting the axes.
■ When starting a machining program.
■ When resuming work with an interrupted machining program.
4‐44 Operating the machine 2017-11-17 B836en

3.1 Entering the work area
Note:The following section is valid for machines with a

rotary indexing table (option).
The air sucked in from above the scrap conveyor is fed via a
system of pipes to the compact dust extractor. Air can only be
effectively extracted if the air pressure in the safety cabin is low
and if the air can circulate sufficiently around the machining posi-
tion.
To maintain these conditions, the scrap conveyor is in an enclo-
sure. To the left and right of the scrap conveyor as well as on
the body of the machine, there are deflector plates which ensure
the effectiveness of the air extraction.
For maintenance and setting work as well as during teaching, it
is necessary to enter the machine's work area. For this reason,
the deflector plate on the side of the machine's body is hinged.
This deflector plate can be manually moved out or can be set at
an angle. The platform which you may step on when in the work
area is beneath this deflector plate.
For air to be effectively extracted, the deflector plate must be set
at an angle during the processing or parts and the side panel
must be closed.
The control system monitors the setting of the deflector plate.
Production may thus only be started if the plate is hinged out.
B836en 2017-11-17 Operating the machine 4‐45

1 Side air deflector plate 3 Handles (2x) 5 Locking bar
2 Hinged deflector plate 4 Area where you may walk
Machine with rotary indexing table Fig. 74483
Stepping onto the platform 1. Open the service door and leave it open, you may wish to
lock it to prevent it from closing accidentally.
2. Open the side panel fully.
3. Hinge up the deflector plate.
Exiting the safety cabin 4. Set the deflector plate at an angle.

5. Close the side panel and lock it.
6. Go out of the safety cabin, acknowledge the danger zone
and close the door.
3.2 Switching the machine on and off
Switching on the machine
The laser machine is switched on via the MAIN SWITCH of the

machine.
When the MAIN SWITCH is switched on, all machine compo-
nents which do not have their own mains disconnectors are sup-
plied with voltage.

Components which have their own optional mains disconnector,
such as laser devices, process coolers, scrap conveyors or com-
pact dust extractors, must be additionally switched on at the
main switch of the component.
Condition
■ Laser light cable (LLC) is plugged in.
Note
The laser device has its own main switch. When the laser device
is switched on, the process cooler of the laser (chiller) is also
supplied with voltage.
When the machine is switched on, the operating status of

WARNING the axis drives is not monitored!
Uncontrolled movements of the NC axes can be the result
in the even of an error.
Ø No persons are allowed to remain the danger zone while the
machine is being switched on.
Switching on the laser 1. On the laser device: Set the key switch to the "I" position.
device 2. Switch on the MAIN SWITCH on the laser device.
3. If the ON/OFF button on the laser device is lit up in white,
the laser control can be switched on: Press the EIN/AUS but-
ton for longer than 1 second.
If the ON/OFF button is lit up in blue, the laser control is
switched on. The laser device is now ready for operation and
can be requested by the machine.
Switching on the machine 4. Switch on the gas and air supply.

5. Switch on the machine's MAIN SWITCH.
6. If the EMERGENCY STOP push-button is locked: Unlock
pressed EMERGENCY STOP push-button.
7. Acknowledge the danger zone and close the access door.
8. Switching on drives: Press the MACHINE ON/OFF button.
The drives for the NC axes are switched on and initialized.
The safety test (the safety shutdown of the NC axes) is car-
ried out.
9. Press the ACKNOWLEDGE FEED HOLD button.
Requesting the laser device 10. If the ON/OFF button on the laser device is lit up in blue, the
fieldbus connection to the laser device can be started on the
machine.
Ø On the machine's control panel: Briefly press the
LASER ON/OFF button.

or
Ø Press Setupand select "Manual functions".
− Select the Solid-state laser group.
− Press "Active optical laser cable" and select LLK.
− Press "Laser control 1" or "Laser control 2".
− Press "Request laser".
The LASER ON/OFF button flashes. As soon as the laser of
the machine is allocated, the button lights up, and the laser
status display on the enclosed protective housing is lit up in
orange.
The machine and laser device are now ready for operation.
Switching off the machine
Condition
■ The machining program is completed.
Notes
■ If the laser device is operated in a laser network, it usually
remains switched on. In this case, the laser device must be
enabled for the laser network before switching off the
machine (see "Enabling the laser in the laser network",
pg. 4‐131).
■ If the ON/OFF button on the laser device is lit up in white,
the laser control is shut down. In this case, the laser can
only be switched on again on the laser device.
■ In the case of outdoor installation of the process cooler: If
the ambient temperature is below 0°, the MAIN SWITCH of
the process cooler may not be switched off.
Shutting down the laser 1. On the control panel: press the LASER ON/OFF button for
control approx. 2 seconds.
While the laser control is shutting down, the LASER ON/OFF
button will flash quickly.
As soon as the laser control is switched off, the
LASER ON/OFF button will stop flashing. The orange-colored
laser status lamp on the enclosed protective housing is off.
Only after this may the machine control be shut down.
Switching off the machine 2. Recommendation: Set the B and C axes to 0° in MDA mode.
3. Close the user interface:
− On the user interface, press on the TRUMPF Logo.
− Select "System" tab.

− Press Exit.
− Press Shut down.
4. If the user interface and the control system has been shut
down: Switch off the MAIN SWITCH.
5. Switch off the air and gas supply.
Switching off the laser 6. Only set the main switch on the laser device to OFF once
device the ON/OFF button on the laser device is lit up in white.
7. Turn the key switch on the laser device counterclockwise and
remove.
The machine and laser device are switched off.

3.3 Shutting down the machine in the
event of a malfunction/emergency
Tripping the EMERGENCY STOP
1. Press the EMERGENCY STOP push-button.

The power supply to the machine is interrupted (24 V control
voltage is maintained).
The installed light path is interrupted. The absorber closes.
All axes motions stop at maximum braking power.
The drives are switched off.
The gas supply is interrupted.
2. If the malfunction cannot be remedied: Switch off machine.
Cancelling the EMERGENCY STOP
Condition
■ Malfunction is eliminated.
1. Unlock pressed EMERGENCY STOP push-button.

2. Switching on drives: Press the MACHINE ON/OFF button.
3. An active program or an active production plan must be
restarted.
Trip the extinguisher with a manual alarm
The extinguisher is usually triggered automatically in the event of

a fire in the compact dust extractor. The interior of the compact
dust extractor is flooded with gas. The extinguishing device can
also be triggered manually in the event of an error.

Condition
Flames and hot components!

WARNING
Burns are the consequence.
Ø Be careful and do not stand directly in front of the door of
the compact dust extractor when opening them.
Ø Have a hand-held fire extinguisher ready for use
1 Button
Manual fire alarm Fig. 42365
1. Break glass.
2. Press the button hard.
The clean gas space is flooded with gas.
3. Switch off the MAIN SWITCH Machine.
Note
Keep a fire extinguisher to hand at all times. A fire can re-
ignite if oxygen is added.
5. Inform the manufacturer.

3.4 Check safety functionality
The machine is equipped with the Safety Integrated control soft-

ware by Siemens. The functions of this safety concept work
when the safety device (safety cabin, light barrier, etc.) is open
or closed as well as during the teach process. Safety Integrated
is effective in all control operating modes.
To ensure that the Safety Integrated safety function works relia-
bly and correctly, a safety test is required every eight operating
hours. The safety test checks whether the drives of all the NC
axes are switched off electrically if there is a malfunction.
A cyclic safety test is requested every 8 operating hours. If this

requirement is active, the safety test is carried out:
■ The safety test is carried out each time the machine is
switched on.
■ With "Establish home position", the safety test is carried out
immediately.
■ At the end of the program (M30), the safety test is carried
out after confirmation by the operator (dialog).
■ If TC_SAFETY_TEST is activated in the NC program, the
safety test is carried out immediately. With endless loops, the
safety test must be requested at a suitable point in the
machining program by programming TC_SAFETY_TEST.
■ The safety test can be started manually at all times.
Note
If the safety test request is active and the safety test is not car-
ried out within 15 minutes, an error message is displayed.

Safety test for Z-axis The safety test checks the Z-axis brake. If the brake slips 2 mm
or more during the test, an error message is output. In this case,
the Z-axis drive must be exchanged immediately.
Danger due to defective brake on the Z-axis drive! The

WARNING holding function of the brake is not ensured. The Z-axis can
drop down.
Considerable material damage can result.
Ø Exchange the Z-axis drive immediately if there is an error
message; request a service call.
Note
While the safety test is active, the NC axes cannot be moved
using the teach panel for safety reasons.
Manually start the safety test
The machine is equipped with the Safety Integrated control soft-

ware by Siemens. The functions of this safety concept work
when the safety device is open or closed as well as during the
teach process. Safety Integrated is effective in all control operat-
ing modes.
To ensure that the Safety Integrated safety function works relia-
bly and correctly, a safety test is required every eight operating
hours. The safety test checks whether the drives of all the NC
axes are switched off electrically if there is a malfunction.
A cyclic safety test is requested every 8 operating hours. If this

requirement is active, the safety test is carried out:
■ The safety test is carried out each time the machine is
switched on.
■ With "Establish home position", the safety test is carried out
immediately.
■ At the end of the program (M30), the safety test is carried
out after confirmation by the operator (dialog).
■ If TC_SAFETY_TEST is activated in the NC program, the
safety test is carried out immediately. With endless loops, the
safety test must be requested at a suitable point in the
machining program by programming TC_SAFETY_TEST.
■ The safety test can be started manually at all times.

Conditions
■ At least "Standard" authorization is active.
■ The home position has been reached.
■ The safety doors are closed.
■ The program is not active.
■ FEED POTENTIOMETER larger than 0 %.
Note
While the safety test is being carried out, the NC axes may
move slightly.
1. Press Setupand select "Manual functions".

2. Select the General group.
3. Press "Safety test".
The dialog box starts.
The safety test is carried out.
Issue user consent
The NC axes must be reliably referenced. In case of a fault, the

referencing of an axis can be lost, e.g.
■ If a force takes effect on the Z tail spindle or on the motion
unit when without electrical power.
■ When switching the machine on or afterwards.
In case of a fault, the control system will generate an error mes-
sage. The operator must then check the correct position of the
NC axis and grant "user permission".
When this user permission is granted, the operator confirms that
the actual position of an NC axis displayed matches the actual
position on the machine.
Condition
■ At least the "Advanced" user group is active.
1. When the Axis is no longer referenced safely error message

appears: Press Setupand select "Manual functions".
2. Select the Setting work group.
3. Press "User consent".
4. Select axis.

5. Press the Apply permission softkey.
The NC axis has been referenced safely. The correct axis posi-
tion has thus been confirmed.
3.5 Eliminate malfunction
Triggering FEED HOLD
If a malfunction occurs while machining, a FEED HOLD can be

triggered manually at all times. The control system will switch to
safe operation stop. The following functions will then automati-
cally be interrupted:
■ The installed light path is interrupted.
■ The axes stop.
Ø Press FEED STOP button.
Acknowledging FEED HOLD after opening

the door
Every time the access door is opened, the safety device will
switch to safe operating stop (SOS) and the software will trigger
FEED HOLD.
1. Inside the safety cabin: Press the ACKNOWLEDGE DAN-

GER ZONE button.
2. Close the door.
An active program will immediately be resumed.
Acknowledging FEED HOLD after a

collision involving the nozzle
FEED STOP will be triggered if the cutting nozzle collides with

the sheet surface.

2. Move the Z axis away from the surface of workpiece using
the JOG buttons.

3. If the processing is to be continued: Press the START button.
Machining is resumed at the point of interruption.
Restarting processing after knocking off

the processing optics
If there is a collision between the processing optics and an

object in the work area, the processing optics will be separated
from the magnetic coupling. The processing optics will be held
by a catch strap. The software will trigger a FEED HOLD.
Notes
■ If the processing optics moves in the Z direction to a colli-
sion, the connection plate which breaks the plastic screws
automatically folds away (predetermined breaking point).
■ If safety elements are damaged when the optics are
detached, they must be replaced immediately.
1. Press main operation Setup.

2. Select the NC axis and release it using the JOG button.
3. Connect the processing optics to the magnetic coupling.
The machine is ready for operation again.

3.6 Operating the workpiece changer
Notes
■ Configure the workpiece change: (see "Configuration",
pg. 4‐139)
■ Display and change loading status and workpiece status:
(see "Loading and workpiece status", pg. 4‐94).
■ Work with the production plan: (see "Creating and editing a
production plan", pg. 4‐81)
Loading place and In the machine control, a distinction is made between production
production place place, fixture place and loading place.
■ Production place: Those segments on the workpiece
changer at which the workpiece is loaded and processed are
referred to as "production place". A maximum of two fixture
places are assigned to every production place.
■ Loading place: The area in front of the workpiece changer
where the workpiece is set up (loaded or unloaded) is refer-
red to as "loading place". Every loading place is assigned to
a safety area.
A number is assigned to every production place and every load-

ing place in the machine control:
Loading and production places Fig. 72867
workpiece changer Production Loading Safety range

place place
rotary indexing P1 21 A
table(RST) P2
22 B
P3
Rotational P1 20 A
changer(RW) P2
Loading and production places Tab. 4-14

Notes
■ The production place on the workpiece changer is labelled
with a sign: P1 and P2 as well as P3 for a rotary indexing
table.
■ The numbers of the loading places (20, 21 and 22) as well
as their assignment to the safety area (A or B) are hard-
wired in the control and cannot be changed by the user.
■ The safety area is only relevant for machines with an auto-
mation interface (Automation interface option).
■ Fixture place: see Configurable control interface (KSS).
Rotary indexing table For a machine with rotary indexing table there are two load-
loading places ing and unloading areas (loading place 21 and loading place 22).
The operator can optionally configure the loading and unloading
place. The following configurations are possible:
■ The workpiece is manually loaded on both loading places.
■ The workpiece is automatically loaded on both loading pla-
ces.
■ The one loading place is manually loaded and the other one
is automatically loaded.
■ It is loaded and unloaded, either manually or automatically,
onto the same loading place.
Rotational direction of the The rotational changer moves 180° back and forth between the
rotational changer loading position and the working position.
Rotational direction of the The rotary indexing table moves by 120° into the next position.
rotary indexing table
In setup mode, the rotary indexing table rotates the selected pro-
duction place (P1, P2 or P3) directly into the working position.
In automatic mode, the rotary indexing table moves n*120° to

either the left or right, depending on the selected configuration.
■ It will turn clockwise: If items are loaded on loading space
21.
■ It will turn counterclockwise: If items are loaded on loading
space 22.
Safety position for station Before the workpiece changer rotates, the NC axes automatically
change move to the safety position:
Axis Safety position

X, Y and C Remain on the current axis position.
Z Move to the top axis position.
B Rotates to +90°.
Safety position Tab. 4-15

Tip
The tool-change height can be programmed for the X, Y and C
axes with the TC_PREPARE_STARTPOS cycle.
Manual functions
Group Manual Func- Description

tion
workpiece "Production Production place 1 rotates directly to the working area.
changer place 1"
"Production Production place 2 rotates directly to the working area.
place 2"
"Production Production place 3 rotates directly to the working area.
place 3"
Setup main operation, Manual functions, "Workpiece changer" group Tab. 4-16
Rotating workpiece changer in setup mode
The workpiece changer can be rotated in setup mode using the

manual function.
Conditions
■ The danger zone has been acknowledged and the access
door has been closed.
■ At least "Standard" user group.
Notes
■ Outside of the safety cabin, the workpiece changer can
rotate with open clamps.
■ If the production place should rotate into the working area,
all clamps of the fixture must be closed beforehand.
■ A fixture's clamps are controlled by the KSS and can be
manually opened or closed via the fixture group.
1. If required: Set up the component at production place P1, P2

or P3 and press the LOADING ACKNOWLEDGEMENT but-
ton.
3. Select the clamping fixture group in the selection field and
close the clamp.
4. In the group selection field, choose Workpiece changer.

5. Press "Production place 1" or "Production place 2" or "Pro-
duction place 3".
Once the safety circuit is closed, the selected production place
will rotate into the working position.
RSTAcknowledge the loading operation in

automatic mode
The respective loading and unloading of the workpiece is

acknowledged in automatic mode. The rotary indexing table
(RST) only moves once the loading operation has been acknowl-
edged and the current processing has finished.
If a production place has been deactivated in the production
plan, this production place is cycled empty with the clamps
closed.
Condition
■ The production plan is active.
1. When the LOADING ACKNOWLEDGEMENT button is illumi-

nated in the unloading area: Remove the workpiece. Leave
the unloading area and press the LOADING ACKNOWL-
EDGEMENT button.
2. In parallel to that, set up a new workpiece in the loading
area. Leave the loading area and press the LOADING
ACKNOWLEDGEMENT button.
If both safety areas have been acknowledged and the current
processing has finished, the rotary indexing table continues to
cycle. Processing begins again in the working range.
RW: Acknowledge the loading operation in

automatic mode
The respective loading operation is acknowledged in automatic

mode.
The rotational changer will turn as soon as the loading operation
has been acknowledged and the current processing has finished.
Condition
1. If the LOADING ACKNOWLEDGEMENT button is illuminated:

Remove the workpiece and insert a new component.

2. Leave the loading area and press the LOADING ACKNOWL-
EDGEMENT button.
After the end of the current processing, the rotational changer
rotates. Processing begins again in the working range.
Acknowledging malfunction
If there is a program interruption or a FEED HOLD during the

rotational movement of the workpiece changer, the workpiece
changer stops immediately in an undefined position.
Ø Acknowledge malfunction:
Ø In the event of a program interruption, press the RESET
button.
− Restart the production plan.
− PRESS THE MULTISWITCH.
− Press the LOADING ACKNOWLEDGMENT button.
or
Ø In the event of a FEED HOLD Press the LOADING
ACKNOWLEDGMENT button.
The workpiece changer will continue with the original rotational
movement.
Acknowledging clamping error
If the LOADING ACKNOWLEDGEMENT button continues to

flash after acknowledging loading, there is a clamping error.
In this case, an error message is output. After the end of the
current processing, FEED HOLD is triggered; the blue indicator
lamp will flash.
Condition
1. Acknowledge clamping error: Press the LOADING

Reopen the fixture's clamps.
2. Lift the workpiece and then put it back in.
3. Acknowledge loading again: Press the LOADING ACKNOWL-
EDGMENT button.
The changer will rotate and processing will be continued.

3.7 Operate scrap conveyor
Production In the main operation Production, the waste conveyor belt will
automatically start when the program starts. The conveyor belt
will stop with some lag at the end of the program or when all of
the jobs in the production plan have been worked through.
■ If the sensor in the ascending area or in the discharge hop-
per detects a malfunction during part processing, the waste
conveyor belt will stop immediately. Part processing will not
be interrupted. Only once the current part has been com-
pletely processed will FEED HOLD be triggered.
■ If the sensor reports a missing scrap container, then a FEED
STOP will be triggered. If a program is active, the FEED
STOP will only be triggered once the processing of the part
is finished.
Setup In the main operation Set up, the conveyor belt can only be
started and stopped with the manual function "Waste conveyor
belt".
Reverse mode The following conditions must be met for reverse mode:
■ No fault on the scrap conveyor.
Manual Function Description

"Lubrication" Status display.
■ inactive: Lubrication cycle is not active.
■ inactive: Lubrication cycle is active.
Note: The lubrication cycle will be started automatically. The lubrication interval and
lubrication time are applied. The lubrication valve is only opened if the conveyor belt
is running and the lubrication cycle is active.
"Waste conveyor belt" Starting or stopping the conveyor belt.
■ off: stops the conveyor belt.
■ on: starts the conveyor belt in direction of run.
■ Lag: Lag is active. The conveyor belt can only be restarted again after the lag
time has expired.
■ Fault: The scrap conveyor has a fault. Fix the fault and then acknowledge it.
Prerequisites:
■ The danger zone has been acknowledged and the access door has been closed.

Manual Function Description
"Maximum idle time" The maximum permissible idle time for the conveyor belt, while at the same time
the processing of parts is still active. Only when the selected time has elapsed will a
FEED HOLD be triggered.
The time is selected using the JOG buttons PLUS and MINUS. The permissible
duration is 0 to 120 seconds.
Condition: The "Extended" user group is active.
Setup main operation, Manual functions, "Scrap conveyor" group Tab. 4-17
Starting the conveyor belt
Conditions
■ Teach mode is not active.
■ Scrap conveyor is ready for operation.

2. Select the Scrap conveyors group.
3. Set the manual function "Waste conveyor belt" to on.
The conveyor belt will start immediately.
Stopping the conveyor belt
Condition
■ Machining is not active.
1. If not yet selected, Press Setupand select "Manual functions".

2. Select the Scrap conveyors group.
3. Set the manual function "Waste conveyor belt" to off.
The conveyor belt will stop after the configured lag time has
elapsed.

Starting the conveyor belt in reverse mode
Conditions
Ø Turn the key-operated switch on the switchbox counterclock-

wise and hold in this position.
Eliminate malfunction
If scrap skeleton or waste parts get stuck on the conveyor belt,

or if the sensors detect oversized waste parts, there will be a
malfunction and the belt will stop.
If there is a fault with the conveyor belt, the blue button on its
switchbox will flash.
Property damage caused by a scrap skeleton or waste parts

NOTICE which are too large or too small.
Scrap skeleton and waste parts block the conveyor belt.
Ø Scrap skeleton or waste parts may not exceed the minimum
and maximum dimensions.
Ø Set parting cuts.
Ø Before entering reverse mode, remove the waste parts from
the conveyor belt.
1. If necessary, briefly start the conveyor belt in reverse mode

(running backwards). Fix the fault.
2. When the fault has been fixed, press the ACKNOWLEDGE
FAULT button on the scrap conveyor's switchbox.
If the button is illuminated, then the scrap conveyor is ready
again for operation.

4. Description of the user interface
1 Status line 3 Sub-operations (Tab) 5 Login status

2 Message line 4 Context buttons 6 Main activity
User interface Fig. 74946
Message line Information (gray), warnings (yellow) and alarm (red) are shown
in the message line:
■ Time when the message was issued.
■ Message number.
■ Description of the alarm or the fault.
■ Source of the error, element of the control system or of the
machine that caused the message.
Log-in status By pressing the "login status" field, the following functions can
be executed:
■ Set language, measuring system, date and time.
■ Log on and off of user group.
■ Change the password.
■ Activate the on-screen keyboard.
■ Close the user interface (HMI).
B836en 2017-11-17 Description of the user interface 4‐65

Main activities Main activity functions
Activating Production plan main operation.

The following functions can be executed:
■ Create, modify and delete production packages and
jobs.
■ Starting and editing the production plan.
■ Start the utility programs.
Activating Production main operation.

The following functions can be executed in automatic
mode:
■ Load programs.
■ Prepare programs.
■ Executing programs.
■ Modify technology parameters.
■ View and, depending on authorization, activate
manual functions.
Activating Setup main operation.

The following functions can be executed in setup
mode:
■ Move axes in jog mode.
■ Activate manual functions depending on authoriza-
tion.
■ Working in MDA mode.
Activating Programming main operation.

■ Creating, editing and managing programs.
■ Defining zero point coordinates in the transforma-
tion accumulator.
■ Opening and operating graphic editor/
TruTops Cell Basic.
Activating Technology main operation.

The operator's manual, the supplement to the opera-
tor's manual as well as the programming manual can
be referred to for help (Main Help):
■ Show Main Help.
■ Start search.
■ Creating bookmarks.
Note:
Not all chapters of the machine's operator's manual
will be displayed. The "Main Help operator's manual"
is an excerpt from the operator's manual.
Tab. 4-18
4‐66 Description of the user interface 2017-11-17 B836en

Main activity functions
Activating Maintenance/Commissioning main activity.

■ Displaying an overview of maintenance tasks and
their status.
■ Activate manual functions.
■ Calling up logbook functions.
Activating Diagnostics main activity.

■ Displaying and managing warnings, alarms and
messages.
■ Activate manual functions.
■ Display software versions.
■ Display digital inputs and outputs.
■ Starting Teleservice.
Note:
The Diagnostics button flashes when a new warning
or alarm is present.
Displaying online Help.

The online help for the operating and programming
instructions can be called up:
■ Show Main Help.
■ Creating bookmarks.
Tab. 4-19
Sub-operations Several sub-operations (special machine functions) are assigned

to each main operation, which are selected at the user interface
using what are called "tabs".
List selection When pressing the button, a selection field opens.
Display area The display area of the user interface can be made larger or
smaller:
■ If you press the button, the display area will be increased.
■ If you press the button, the display area will be
decreased.
Path ■ If you press the button, the "Path" will be opened.

■ If you press the button, the "Path" will be closed.
■ If you press the button, the higher level will be opened.

Status bar Symbol Description
Home position missing.
Approach home position
Home position has been established.
Status: production plan stopped.
Status: production plan running.
Program is active.
Program status: Stop.
Program status: Pause.
Program status: Active.
Laser device is switched off.
Laser device is switched off. The laser test is active.
The laser beam is switched off. The lasershutter is

closed.
Laser device is switched off. The laser test mode is

active.
The laser beam is switched off. Lasershutter is open.
The laser beam is switched off. The laser test is

active.
The laser beam is ignited. The lasershutter is closed.
The laser beam is ignited. The laser test is active.
The laser beam is ignited. Lasershutter is open.

Status bar Symbol Description
The laser beam is ignited. The laser test is active.
The laser beam is switched off. The central shutter is

closed.
The touchscreen is disabled.
Alarm messages have been received (the number of

messages is displayed next to the symbol).
Warnings have been received (the number of mes-

sages is displayed next to the symbol).
Maintenance symbol (maintenance work is pending).
Error has occurred.
Tab. 4-20
Program status The program bar shows the status of the program:
Symbol Program status

A program has been selected.
The program is checked and complete. The program can

be run.
Program is incomplete or faulty.
Program is active, but incomplete.
Program is valid and loaded in the production plan.
Program is loaded in the production plan. Program is

incomplete.
Program status of activated program Tab. 4-21

User event logfile The machine control creates a current "user event logfile" for the
user with the following information:
Event Additional infor- Description

mation
LaserTechnology- LTT name Technology table with modi-
TableChanged fied parameter values
LaserTechnology- LTT name Deleted technology table
TableDeleted
LaserTechnology- LTT name Newly added technology table
TableInserted
ProgramDeleted Program name Deleted NC program
ProgramInserted Program name Added NC program
ProgramOverwrid- Program name NC program was overwritten
den and replaced
ProgramUpdated Program name NC program was edited
(changed)
UserLogOn User User login (Access Con-
trol Key System option only)
UserLogOff User User log off (Access Con-
trol Key System option only)
UserIdChanged Serial number User identification
(Access Control Key System
option only)
MmcStarted - HMI was started
MmcEnded HMI was ended
Structure of the logfile Tab. 4-22
The logfile is stored under the following path: 'C:\dh\topsmanu.dir

\systrans\out\UserInteractions<number>.log'.
A logfile can have a maximum size of 1 MB. If this size is
exceeded, a new logfile is created. A maximum of two logfiles
are displayed and saved.
The logfile has the following structure: "yyyy-mm-dd
HH:MM:SS.FFF;UserId;UserLevel;User;Event;(additional informa-
tion)".
Example: "2016-12-24 11:35:12.157;1542;0;STANDARD;Program-
Deleted;TEST_PROGRAM".

5. System settings
5.1 Setting data and time
1. On the user interface, press on the TRUMPF Logo.

The dialog "Settings" is displayed.
2. Select "System" tab.
3. Press the button and modify the setting.
4. Press Apply.
The selected setting will be saved.
5.2 Selecting language and measuring

system
Note
If the Inch measuring system is selected, only the display on the
HMI will change from from metric to imperial. The control will
continue its internal calculations using the metric system.
1 "Language" selection field 2 "Unit system" selection field

Selecting language and measuring system Fig. 66861

B836en 2017-11-17 System settings 4‐71

2. Select "Language" and/or "Measuring system".
3. Press Apply.
The selected setting is active right away.
5.3 Activate the on-screen keyboard
The on-screen keyboard is activated by tapping on a text entry

field. This setting can be modified.
1 "On-screen keyboard" selection field

Activating the on-screen keyboard Fig. 66857
Selection Description
Off Deactivate the on-screen keyboard.
Activate by tapping Activate the on-screen keyboard by tapping. (default setting)
Activate by double-tapping Activate the on-screen keyboard by double-tapping.
Tab. 4-23

2. Open the "On-screen keyboard" selection field.
3. Select Off or Activate by tapping or Activate by double-tap-
ping.
4. Press Apply.
The selected setting is active.
4‐72 System settings 2017-11-17 B836en

5.4 Open TRUMPF Operating System
(TOS)
1. Press the CHANGE APPLICATION button.

2. Select TRUMPF Operating System (TOS).
TOS is displayed.
5.5 Close user interface
The user interface for the machine control system is called HMI
(Human Machine Interface).
Fig. 75037

2. Select "System" tab.
3. Press Exit.
4. Either
B836en 2017-11-17 System settings 4‐73

Ø If only the HMI is to be closed, press Exit HMI.
or
Ø If the machine is to be switched off, press Shut down.
5.6 Switching to the TruControl interface
TruControl 1000 is a program for the operation of beam sources

from TRUMPF. For operation, see "TruControl 1000 software
manual".
Condition
■ Laser device is ready for operation.
1. Press Change of application .

2. Select TRUMPF Operating System (TOS).
The user interface is not closed. The "TRUMPF Operating
System" (TOS) dialog is displayed.
3. Press Laser Application.
The user interface TruControl will open.
4‐74 System settings 2017-11-17 B836en

6. User administration
Note
If the machine has the Access Control Key System option, then
the management of users by issuing passwords does not work.
User group User groups with different rights can be logged in to the
machine's control system.
Depending on which user group is currently logged on, functions
and parameters are blocked for access or are not shown on the
user interface.
The following user groups are shown in the control as default

and can be logged into.
User group Description

"Production" Authorization for production mode without the option
of influence.
"Standard" Authorization for processing of NC programs as well
as for influencing of the production mode.
"Advanced" Complete access to the scope of functions of the
operator: authorization for setting, set up and program-
ming work.
"TRUMPF Serv- Complete access to all of the machine's functions.
ice"
User groups (standard configuration) Tab. 4-24
Password Generally, each user group has its own password. A user group
with a higher authorization than the one currently logged in is
protected by the password insofar as a password has be issued.
It is possible to issue an identical password for all user groups
(except "TRUMPF Service").
When the machine is delivered, only the "TRUMPF Service" user
group is password protected.
B836en 2017-11-17 User administration 4‐75

6.1 Log on user group
Conditions
■ Password is known.

2. Press the Log off button.
1 User group
Selecting the user group Fig. 66856
3. Select the user group:
Ø If a lower user group is to be logged in:
− Select the user group.
− Press the Log in button.
or
Ø If a higher user group is to be logged in:
− Select the user group.
− Enter the password.
− Press the Log in button.
The user interface is restarted. It is only shown for the enabled
functions and parameters for the logged-on user group.
4‐76 User administration 2017-11-17 B836en

6.2 Change password
Conditions

2. Press the Change password button.
3. Enter the old password.
4. Enter New password.
5. Confirm new password: Repeat entry.
6. Press OK.
6.3 Deleting the password
Conditions

2. Press the Change password button.
3. Enter the old password.
4. Press OK.
B836en 2017-11-17 User administration 4‐77

7. Production plan
1 Context buttons 4 Production plan button 6 Cell status button

2 Job 5 Job button 7 Program details button
3 Production place xx
Production plan Fig. 89143
Button Description
Orders Display, edit or delete jobs. Create new jobs.
Production plan Display, start, disable or delete available production plans. Create new pro-
duction plans.
Program details Display information about the active NC program with or without preview
image.
4‐78 Production plan 2017-11-17 B836en

Button Description
Cell status The status of all installed components at the machine will be displayed.
Component is active.
Pause
Component is stationary.
Production plan buttons Tab. 4-25
Context buttons Depending on the context, the following buttons will be shown:
Button Description
Starting Start the production plan. All released jobs are processed in the selected order.
Stop To end the production plan:
■ "Stop after cycle end" ends the production plan as soon as the current operation
is finished at all production places and the workpiece changer has clocked once
again.
■ "Run empty" ends the production plan as soon as all workpieces loaded have
been processed and unloaded.
Technology correction Edit the laser technology table for the selected NC program. The modification will
take effect after the production plan has been restarted.
Modifying Process the marked job.
Note: an active job can be processed. The modification will take effect the next time
the production plan has been started.
Disabling Disable job or production plan.
Note: an active job or production plan cannot be disabled.
Delete Delete job or production plan.
Note: an active job or production plan cannot be deleted.
Delete Orders Delete marked jobs.
Delete programs and Delete marked jobs and the corresponding NC programs in the NCK.
orders
Note: the jobs will be deleted. An NC program will only be deleted if it is not used
in any other job. If the NC program is currently active, it will not be deleted.
Creating Create new production plan or new job.
For preparation
Changes the status of the job to "Preparation". The tooling status is being checked;
the telegram (information) will be transferred to the PLC.
Example: "The job is processed in tightened empty form (without clamping) although
there is a clamping fixture available."
Release Release job for processing.
Finish Transfer released jobs to the NC control.
Continue Resume interrupted production plan.
Production plan context buttons Tab. 4-26
B836en 2017-11-17 Production plan 4‐79

Order status Symbol Description
Job is released for production.
Job is disabled.
Job is checked.
Job is currently being produced.
The last workpiece of this job is currently being producted.
Job is finished.
An error occurred.
NC program is missing.
Order status Tab. 4-27
Program sequence Within a production plan, the order of the jobs for processing
can be changed using the following buttons:
Button Description
Set the job at the start of the list.
Set the job at the end of the list.
Set the job one place upwards on the list.
Set the job one place downwards on the list.
Program sequence buttons Tab. 4-28

7.1 Creating and editing a production
plan
Production plan A production plan includes jobs (NC programs for part process-
ing) that are processed in the order selected by the operator.
When doing this, only the released jobs will be produced.
The operator starts the production plan. Then; the individual jobs
are automatically called up one after the other and processed.
Parts are produced until the production plan has been gone
through or until the operator ends the production plan.
Production place Production place refers to the area on the machine where the
workpiece is produced. A number is assigned to every produc-
tion place in the machine control:
Configuration Production place

Machine with rotary indexing table 1, 2 and 3
Machine with rotational changer 1 and 2
Production place Tab. 4-29
For machines with the Automation interface option:

■ A KSS module must be configured for every production
place.
■ The Synchronization automation element must be configured
in the KSS module.
Job A job consists of an NC program for part processing and the

corresponding job data. Every job is is assigned to a production
place (a synonym for a station). There is the following job data:
■ The actual number of program runs. The number can be
changed by the operator, if desired.
■ The required number of program runs. Alternatively, a contin-
uous machining can be selected. To stop continuous proc-
essing, the production plan must be stopped.
■ The number of the production place where the job is to be
produced.
■ If the machine has a configurable control interface (KSS): the
number of the KSS module.
■ The number of the KSS module.
■ All released jobs are always processed at the current produc-
tion place. Only then are the jobs of the next production
place processed.

Creating a new production plan
When a new production plan is created, at least one job must be

created, released and assigned to a production place.
A production plan is created for every production place.
For each production place, several different jobs can be created
whose loading is acknowledged at the same time.
Conditions
■ The tooling status is valid and has been activated.
■ The configuration of the workpiece change has been created.
■ The program is stored in the internal management system.
Select NC program 1. Press the Production plan main operation.

2. Press Create.
3. Select Internal management as the "storage location"
( ).
1 NC program
Create new production plan Fig. 73649
4. Select an NC program: select the checkbox next to the pro-

gram name.
5. Press Continue.

The "Job details" dialog opens.
1 Job 2 Job data

Modifying job data Fig. 89275
Creating a new job 6. Enter the following job data:

− "Required qty": Enter the number of program runs or,
alternatively, select "Continuous machining".
− "Production place": Enter the number of the production
place.
− "KSS module": On machines with KSS, enter the module
number.
7. Press Finish.
Enable job 8. Press For preparation.

9. Create the next job:
− Press Create.
− Select the NC program.
− Press Continue.
− Enter the job data.
− Press Finish.
− Press For preparation.
10. Once all jobs have been created: Press Enable.
The production plan has been created. Jobs are released.

Editing job data
The job data of an existing job is to be modified. The modifica-

tion will take effect the next time the production plan has been
started.
1. Press the Production plan main operation.

2. Either
Ø Select a job from the job list.
or
Ø
Press the Job button ( ) and select a job.
3. Press Modify.
4. Modify job data.
5. Change the program sequence, if required.
6. Press Finish.
7. Release the job.
Disable job
A disabled job is skipped during production.
Condition
■ The job is not active.

2.
3. Press Disable.
Delete the order in the production plan
All marked jobs are deleted from the production plan.
Condition
Notes
■ The programs are still on the machine control's hard drive
after the job is deleted.

■ By pressing the Delete programs and orders button, all
marked programs on the machine control hard drive will be
deleted.

2. Either
or
Ø
3. Press Delete.
4. Either
Ø If only the marked job is to be deleted: press Delete
orders.
or
Ø If all orders are to be deleted: press Select all.
All the orders or the marked ones will be deleted.
Delete programs and orders
Attention: All marked programs and jobs are deleted irrevo-

cably from the machine control's hard drive!
Condition

2. Either
or
Ø
3. Press Delete.
4. Press Delete programs and jobs.
All marked NC programs and jobs are immediately deleted.
Deleting a production plan
1. Press Production plan.

2. Press the Production plan button.
3. Select "Production place".

4. Press Delete.
The production plan for the selected production place is deleted
with all jobs created.
7.2 Production with the production plan
Risk of collision on 3D work area by transfer movements of

NOTICE the NC axes.
Ø There is a risk of collision during the transfer movement of
the NC axes when changing the job as well as at the start
and end of the program.
Ø If the program sequence is changed, note that there is a risk
of collision during the transfer movement of the NC axes.
Loading place Loading place refers to the area on the machine where the new
workpiece is loaded and the finished part is removed.
Before the production plan can be started, the loading place
must be configured and activated.
Notes
■ If there is no valid configuration for a workpiece change, the
production plan is not started.
To configure and activate the loading place, see "Configura-
tion" section: (see "Configuration", pg. 4‐139).
■ If different jobs are to be processed at a production place
(e.g. 2 different workpieces on 2 different fixtures), the opera-
tor acknowledges loading simultaneously for all workpieces
set up at this loading place.
Loading acknowledgment By pressing the LOADING ACKNOWLEDGMENT button, the

operator acknowledges the loading of the new workpiece and at
the same time the safety device for this loading place.
After the loading acknowledgment, the following sequence starts:
the fixture clamps, the workpiece changer turns to the
processing position and processing starts.
Notes
■ For manual loading: whenever the LOADING ACKNOWL-
EDGMENT button flashes, the control is expecting a work-
piece change. Then, the operator acknowledges the loading
operation by pressing the button.
■ For automatic loading acknowledgment: the loading acknowl-
edgment is carried out by the external automation compo-
nent.

Clamping fixtures On machines with fixtures that are controlled using the configura-
ble control interface (KSS), opening and closing the actuators
depends on whether a "safe movement" is configured for the
corresponding KSS module.
■ If a safe movement is configured, the actuators of the
fixture can only be moved if the guard is closed for this load-
ing place.
■ If no safe movement is configured, the actuators of the fix-
ture are also moved if the guard is not closed for this loading
place.
With manual loading: after starting the production plan, the KSS
"unloading" sequence always starts first. The clamping elements
open in order that the workpiece can be inserted into the fixture.
Automation On machines with activated automation interface (Automation

interface option), the external control specifies the loading and
unloading sequence.
Starting a production plan (manual loading)
Note: This section is valid for manual loading.

When the production plan is started, all released jobs of a pro-
duction place are produced in succession in the selected order.
The automatic run and processing start as soon as the operator
has loaded the first workpiece and pressed the LOADING
If a workpiece is already loaded when the production plan starts,

the following conditions apply:
■ The status for a workpiece already loaded must first be
acknowledged. Then, the production plan must be restarted.
■ An error message is issued if the control detects an unex-
pected workpiece status. In such a case, the workpiece sta-
tus must be changed for the loading place and then acknowl-
edged. The workpiece must be removed for the relevant
loading place and a new workpiece must be loaded.
There is an unexpected workpiece status if the workpiece
status for the relevant loading place does not match the data
management in the machine control. Reasons for this could
be an abortion of the production plan or manual intervention.
■ A workpiece loaded in the working area must have the Raw
part in order that the NC program can start.
■ A workpiece loaded at the Unload loading place with the fin-
ished part status can be removed after starting the produc-
tion plan (without acknowledgement) (the fixture opens auto-
matically).

Conditions
■ At least one order is released in the production plan.
■ At least one loading place is activated.
■ Fixtures are closed.
Notes
■ If no safe KSS movement is configured for the clamping fix-
ture, the fixtures also open at the start of the production plan
if the guard is open.
■ If a safe KSS movement is configured for the clamping fix-
ture, the guard must be closed first before the actuators of
the fixture can be moved.
■ Recommendation: When the production plan is started, no
workpiece has been loaded yet.
■ If the LOADING ACKNOWLEDGMENT button flashes, the
workpiece can be loaded.
■ The production plan is aborted by pressing the RESET but-
ton.
■ The workpiece status displayed must correspond to the work-
piece loaded.
Loading and workpiece status: (see "Loading and workpiece
status", pg. 4‐94).

2. Press Continue.
The production plan is started.
If no workpiece has been loaded yet, the clamping fixture
opens in the loading area. Then, the LOADING ACKNOWL-
EDGEMENT button flashes.
3. Load the first workpiece and press the LOADING
or
Ø If a workpiece is already loaded:
− Select the "Status" tab.
− If required (unexpected workpiece status), change the
workpiece status for the relevant loading place.
− Acknowledge the workpiece status for the loading place.
− Restart the production plan.
− Remove the workpiece and insert it again or load a new
workpiece.
− Press the LOADING ACKNOWLEDGMENT button.
The clamping fixture is closed and the workpiece changer
rotates. Processing and the automatic run start.

After the end of processing, the workpiece changer clocks
and the finished part can be unloaded.
4. While processing is active, the next workpiece can be loaded
in the loading area.
5. Load the workpieces in succession and acknowledge each
loading operation.
All released jobs are processed in succession in the selected
program sequence.
Starting a production plan (automatic

loading)
Note: This section is valid for automatic loading.

When the production plan is started, all released jobs of a pro-
duction place are produced in succession in the selected order.
If the operator starts the production plan, the automatic run is
also started if the required conditions are met.
If a workpiece is already loaded when the production plan starts,

the following conditions apply:
■ The status for a workpiece already loaded must be acknowl-
edged.
After the acknowledgement, the loaded workpieces are
clocked up to the loading and unloading place, regardless of
the workpiece status.
If a workpiece is already clamped at the Load loading place,
this fixture must be closed.
■ An error message is issued if the control detects an unex-
pected workpiece status. In such a case, the workpiece sta-
tus must also be acknowledged manually.
There is an unexpected workpiece status if the workpiece
status for the relevant loading place does not match the data
management in the machine control. Reasons for this could
be an abortion of the production plan or manual intervention.
Conditions
■ At least one order is released in the production plan.
■ At least one loading place is activated.
■ Fixtures are closed.
■ The external automation component is ready for operation.
Notes
■ Recommendation: When the production plan is started, no
workpiece has been loaded yet.

■ The production plan is aborted by pressing the RESET but-
ton.
■ The loaded workpiece must correspond to the workpiece sta-
tus displayed.
Loading and workpiece status: (see "Loading and workpiece
status", pg. 4‐94).

2. Press Continue.
If no workpiece is loaded: the production plan and the auto-
matic run are started.
If a workpiece is already loaded, the operator must acknowl-
edge the workpiece status once after being requested to do
so (message).
3. If the workpiece status needs to be acknowledged:
− Select the "Status" tab.
− Acknowledge the workpiece status for the corresponding
loading place.
The automatic run is started, regardless of the status of the
workpieces already loaded.
All released jobs are processed in succession in the selected
program sequence.
Changing the program sequence
The order of the job processing is to be modified.
1. Press the Production plan button.

1 Job 2 Program sequence buttons
Change sequence Fig. 63878
2. Select "Production place". Open directory structure.

3. Select a job and insert it at the desired position in the pro-
duction plan.
Modifying the number of program runs
Regardless of the job status, the number of program runs can

be modified for all jobs created.

2.
Press the Job button ( ).

1 Job
Changing the number of program runs Fig. 68768
3. Select a job and changed the required quantity and/or the

actual quantity.
4. Change the program sequence, if required.
Stopping the production plan with "Stop

after cycle end"
After requesting "Stop after cycle end", the current operation

(loading, processing or unloading) is still carried out at all pro-
duction places. The changer is clocked again after the loading
acknowledgment.
Then, the production plan is ended. No further workpiece change
takes place any more.
If production is then to be continued, the production plan must
be restarted, either manually at the control panel or - if available
- via the automation interface (Automation interface option).
1. Press the Stop button.

2. Select "Stop after cycle end".
After the loading acknowledgment, the workpiece changer is
clocked one more time. Then the production plan ends.

Starting to run empty, ending the
production plan
After requesting "run empty", all raw parts still loaded are proc-
essed. No new workpieces are loaded any more.
If all parts have been removed and the LOADING ACKNOWL-
EDGMENT button is pressed, the production plan is ended.
Note
If the machine is equipped with the Automation interface option
and the automation system is active, "running empty" can also
be requested by the external automation system.
1. Press the Stop button.

2. "Select Idle stroke".
One after the other, each production place turns to the
unloading area. The fixture opens.
3. Remove every part and do not insert a new workpiece any
more.
After removing the part, press the LOADING ACKNOWL-
EDGMENT button.
Once all production places have been "run empty", the produc-
tion plan is ended.
7.3 Exporting order
All or portions of the order data should be exported.
Condition
Note
When a job is exported, the NC programs and the XML files of
the KSS module are also exported.

2. Select the "Export orders" tab.
3. Either
Ø Select the order to be exported.
or
Ø If all displayed orders are to be exported: press Select
all.

4. Press Export.
5. Select and confirm the directory.
7.4 Starting step-by-step cycle
Step-by-step mode means that the workpiece changer continues

to rotate after the loading acknowledgment by one cycle only.
The mode is self-holding.
Condition
1. Press the Production plan main operation and select "Sta-

tus".
2. Press the Step-by-step button.
Step-by-step mode remains active until it is deactivated again.
7.5 Loading and workpiece status
The machine control manages workpiece statuses and status

data for production places and loading places.
There is a relationship between the workpiece status and the
configured loading place.
Workpiece status The machine control manages the following workpiece statuses:
Workpiece status Symbol Description

"Raw part" Green The workpiece is unprocessed.
"Partially processed" Green The workpiece is only partially

processed.
"Finished part" Green The workpiece is completely proc-

essed.
"No component" Gray There is no workpiece in the fix-

ture.

Workpiece status Symbol Description
"Contains errors" Red The workpiece is faulty.
Loading and workpiece status Tab. 4-30
In the following conditions, the machine control marks the work-

piece as faulty:
■ The part was not processed completely ("partially processed"
status).
− In the event of a program abortion.
− By pressing the LASER TEST button during processing.
■ After an ObserveLine error.
Notes
■ After starting the production plan, the operator must acknowl-
edge the workpiece status once. Only then can the automatic
run be started.
■ The processing program can only start if the workpiece at
the processing location has the "Raw part" status.
■ A workpiece status can only be changed and acknowledged
for the workpiece at the loading and unloading place. The
set status changes with the workpiece. The status can only
be checked for the processing location.
Error handling If the machine control identifies a faulty part, an error message
is output according to the selected strategy:
■ No reaction: No error message is to be output in the event of
a faulty part.
■ Acknowledge after every error: An error message is to be
output for every faulty part. The workpiece status must be
acknowledged.
■ Acknowledge after several errors: An error message is only
to be output when the defined number of faulty parts is
reached. The workpiece status must be acknowledged.
The troubleshooting strategy is defined in the configuration dialog
at "Missing part handling" (see "Configuration", pg. 4‐139).

Displaying the loading and workpiece
status
While the production plan is active, the loading and workpiece

statuses can be shown and also acknowledged, if required.
For machines with automation interface (Automation interface
option), the status of the automation components is also shown.
Condition
Note
The Acknowledge toolpiece status button (position 7) is only dis-
played if the acknowledgement request is active.
Loading status and workpiece status for machines with rotational changer Fig. 85676

Loading status and workpiece status for machines with rotary indexing table Fig. 85675
Position Legend Description

1 Loading and unloading status The status is displayed for every loading place.
2 Processing status The status is displayed for the processing location.
3 Components status The statuses of the automation components is displayed.
4 Step-by-step button Activate step-by-step mode.
"Run empty" "Run empty" status display.
"Stop after cycle end" "Stop after cycle end" status display.
5 Workpiece status The workpiece status of each production place is shown.
6 Automation status The status of the automation interface is displayed.
7 Acknowledge workpiece status button The current workpiece status is acknowledged after an
interruption.
Legend Tab. 4-31
Ø Press the Production plan main operation and select "Sta-

tus".
The "Status" dialog is opened.

Changing the loading and workpiece status
When the production plan is started, when a fixture or a work-

piece is run in, it may be necessary to change the workpiece
status. Then, the selected workpiece status must be acknowl-
edged.
Conditions
■ Production plan is not active.
1. Press the Production plan main operation and select "Sta-

tus".
2. Press the Change workpiece status button.
The workpiece status is displayed for the loading and unload-
ing places and for the working position.
Changing the workpiece status Fig. 86043
3. Select the loading place and select the workpiece status.

4. Press OK.
The workpiece status changes.
5. Press the Acknowledge workpiece status button.
6. If the production plan is to be started:
− select "Production plan".
− Press Continue.

Acknowledging workpiece status with
manual loading
If the workpiece status needs to be acknowledged, a message is

displayed with an acknowledgement request. The workpiece sta-
tus must be acknowledged in the following situations:
■ After starting the production plan if a workpiece is already
loaded.
■ After manual intervention by the operator.
■ After aborting the production plan.
Conditions
Notes
■ In the event of an error, the blue status indicator flashes
slowly.
■ The workpiece at the loading place must have the Raw part
status.
1. If the control issues an error message:

Press the Production plan main operation and select "Sta-
tus".
3. Restart the production plan.
The workpiece changer rotates the workpiece into the
unloading position.
4. If a workpiece is already inserted in the fixture in the loading
area, it must be lifted and re-inserted.
5. Press the LOADING ACKNOWLEDGMENT button.
The production plan continues.
Acknowledging the workpiece status with

automatic loading
Before the automatic run is started, that the workpiece status

and the tooling status of the workpieces at the machine must
match must be ensured.
During automatic operation, clocking of the workpieces continues
after acknowledging the workpiece status, regardless of the sta-
tus (Raw part, Partially processed, Finished part, Faulty part)
unloading station.

Workpiece transport only takes place if a workpiece loaded at
the loading station is clamped. If the fixture is not closed, an
error message is issued. In such a case, the workpiece status
must be clamped manually.
Conditions
■ Clamping fixtures must be closed.
1. If the control issues an error message:

Press the Production plan main operation and select "Sta-
tus".
3. If the production plan is to be started:
− select "Production plan".
− Press Continue.
The automatic run starts as soon as the external automation
component has loaded the first workpiece.

7.6 Remaining time display
The remaining time display is an option for the laser processing

machine. It shows the operator the time left ("remaining time")
on a screen.
The helps the operator see, for example, how much time there is
before the setting up of the next workpiece.
The "Remaining time display" option is available in two variants:
Basic and Comfort.
Screen The screen for the remaining time display is on the outside at
the safety cabin. The screen is optional and is not part of the
standard scope of delivery of the "Remaining time display"
option.
During the processing, the remaining duration is visualized on
the screen.
The differences in the display for variants Basic and Comfort are
described below.
1 Monitor
Fig. 76782

Remaining time The remaining time for the tool change is the time from the start
of the part processing until the next loading acknowledgment by
the operator.
The basis for the calculation of the remaining time is the piece
rate, which is the result of the processing time plus non-produc-
tive time for the set up of the workpiece.
Resetting the remaining time The remaining time saved in the control is reset under the fol-
display lowing conditions and recalculated:
■ If the production plan is changed.
■ If the production plan is restarted within the shift.
■ If the processing sequence changes.
■ For a workpiece change on one station.
■ For a change of the feed at the potentiometer or in the pro-
gram.
Notes
■ The remaining time display only changes when the change in
the production plan becomes effective.
■ While feed hold is present, the remaining time display
pauses.

Basic remaining time display The still remaining time until the setting up of the next workpiece
is shown.
Once the processing of a workpiece starts, the remaining time
display counts backwards parallel to processing. Simultaneously,
the green progress bar visualizes the duration.
1 Progress bar 3 Current time

2 Remaining time
Remaining time display Basic Fig. 86048
After the first processing run-through of all stations (synonymous

to production place), the machine control is familiar with the
processing sequence as well as the processing times for each
workpiece and calculates the remaining time from this.
With each further processing cycle, the controller calculates an
average value of the piece rate and, in this way, optimizes the
remaining time.
Note
The remaining time display Basic is a standard function and can-
not be configured.

Comfort remaining time The following functions are included in the scope of delivery of
display the variant Comfort:
■ Configuration of shift and day shift plans.
■ Calculation of the required quantities per workpiece and shift.
■ Visualization of the remaining time for setting up of the next
workpiece.
■ Visualization of the shift goals per station and workpiece.
1 Remaining time progress bar 4 Remaining shift time

2 Remaining time 5 Current time
3 Shift goal progress display
Remaining time display Comfort Fig. 86049
Remaining time display: While the production plan is active,

the screen shows and visualizes the remaining time.
Once the processing of a workpiece starts, the remaining time
display counts backwards parallel to processing. Simultaneously,
the green progress bar visualizes the duration.
Shift goal: The current shift plan is the basis for calculating the
required quantities per workpiece and shift. When calculating the
shift goal, breaks in the shift plan as well as earlier running out
of workpieces are considered.
The shift goal is reset and recalculated under the following con-
ditions:
■ When a shift is manually started or extended.
■ If the piece rate for a workpiece is recalculated or changed.
■ When a shift plan is changed.
The progress display visualizes the shift goal with the following
information for each station:
■ Designation of the job.
■ Actual quantity per shift.
■ Required quantity per shift.
■ Shift goal progress bar.
■ Remaining shift time.

Different colors signal the status.
Signal color Description

Blue The required quantity per shift has been reached.
Yellow warning The actual quantity per shift is within the tolerance
triangle range of -5% of th planned required quantity.
Red warning tri- The planned required quantity per shift has not
angle been reached.
Shift goal progress bar Tab. 4-32
Configuring the remaining time display
Note
The configuration of the remaining time display for the variant
Comfort is described below.
Production plan In the "Production plan" main operation, the operator can enter
the piece rates for all released orders as well as creating and
editing shift and day shift plans.
1 Released orders 3 Piece rate per workpiece

2 Program name 4 Remaining time per order
Production plan: piece rates and remaining time Fig. 77362
Piece rate The control calculates the remaining time per order and shift
from the entered piece rate per workpiece, multiplied by the
required quantity per shift.

Operation mode The operation mode for the shift change can be switched over:
■ "AUTO" operation mode (default setting): The shift change is
automatically done in accordance with the current shift plan.
■ "MANUAL" operation mode: The shift change is performed
manually. The operator starts and stops the shift.
Shift plan The shift plan is a week plan. It is valid for all shifts of the cur-
rent week insofar there is no day shift plan for the current day.
Day shift plan The operator can create a day shift plan that is only valid for the
current day.
Creating a new shift plan
A new week shift plan is to be created. For this, the following cri-
teria must be defined:
■ Working days.
■ Shifts per working day: for example, early shift, late shift,
night shift, special shift, etc.
■ Begin and end of shift.
■ Definition of pause times.

Condition
1 Active operation mode 3 Shift begin

2 Weekdays 4 Shift end
Shift plan Fig. 77364
Button Description
Start shift Manually begin shift.
Note:
This will cause the shift goal to be recalculated.
Stop shift Manually stop shift.
Note:
Extend shift Manually extend the current shift in "AUTO" operation mode.
Changing the operating mode Activate the "AUTO" or "MANUAL" operation mode.
Create new shift Create a new week shift.
Edit shift Edit the week shift.
Delete shift Delete one shift in the week shift plan.
Create day shift plan Create and edit the day shift plan for the current working day.
The shift plan for the current day is copied and can then be further edited
as a day shift plan.
Context button Tab. 4-33
1. Press the Production plan main operation and select "Shift

plan".
2. Press Create new shift.
The "Edit shift" dialog is opened.

1 Define shift 2 Add pause
Editing the shift Fig. 77365
A new goal is added with the Plus button.

The Minus button is used to delete the goals.
3. Create a new shift, for example, early shift:
− Activate working days.
− Enter the begin and the end of the shift.
− Add pauses and enter the pause times.
− Press OK.
4. Create the next shift:
− Press Create new shift and enter Late shift.
− Define the late shift.
− Press OK.
5. Create the next shift:
− Press Create new shift and enter Night shift.
− Define the night shift.
− Press OK.
The week shift plan for the current week has been created and
is effective right away.
Editing shift plan
The shift plan can be changed at any time. The production plan
must not be stopped or interrupted for this.

Condition

plan".
2. Select the shift that is to be edited.
3. Press Edit shift.
4. Edit the shift plan:
− Activate or deactivate the working days.
− Change the begin and end of the shift.
− Add or delete pauses.
− Edit pause times.
5. Press OK.
The changed shift plan is effective right away. The shift goal will
be recalculated.
Recreate the day shift plan
A day shift plan is to be created that deviates from the shift plan.
Condition

plan".
2. Press Create day shift plan.
The shift plan for the current day is copied and can then be
further edited as a day shift plan.
3. Select shift and press Edit shift.
− Edit the shift plan.
− Press OK.
The newly created day shift plan is effective right away. The
remaining time display is reset.
Editing the day shift plan
This current day shift plan is to be edited.

Condition
Note
The "Day shift plan" tab is only visible if a day shift plan has
already been created.
1 Active operation mode 3 Shift begin

2 Current day shift plan 4 Shift end
Day shift plan Fig. 77366
Button Description
Shift begin Manually begin shift.
Note:
Stop shift Manually stop shift.
Note:
Extend shift Manually extend the current shift in "AUTO" operation mode.
Create new shift Create a new day shift plan.
Edit shift Edit the day shift plan.
Delete shift Delete early shift, late shift or night shift in the week shift plan.
Delete day shift plan Delete the day shift plan for the current day.
1. Press the Production plan main operation and select "Day

shift plan".
2. Select shift and press Edit shift.

− Edit the shift plan.
− Press OK.
The change of the day shift plan is effective right away. The
remaining time display is reset.
Deleting day shift plan
The week shift plan becomes effective again as soon as the day
shift plan is deleted.
Condition
1. Press the Production plan main operation and select "Day

shift plan".
2. Press the Delete day shift plan button.
The day shift plan is deleted.
Editing piece rates
The "Piece rate" is the processing time plus the non-productive

time for a workpiece.
Condition
1. Press the Production plan main operation and select "Piece

times".
The programs in all the released manufacturing orders in the
production plan are displayed.
2. Press the Edit piece rates button.

The "Edit piece times for programs/parts" dialog opens.
Fig. 77363
3. Enter the "Piece rate" in seconds for the respective work-

piece.
4. Press OK.
The piece rate is saved. The value is effective until the new
value has been entered. The shift goal will be recalculated.
Changing the operation mode
The "AUTO" operation mode corresponds to the default setting.

The shift change is performed automatically in this operation
mode in accordance with the created shift plan. Shift begin and
end are defined when the shift plan is created.
The operation mode can be changed in "MANUAL". The
operator must manually begin and stop the shift again in "MAN-
UAL" operation mode.
Condition
Notes
■ The shift goal is calculated at the beginning of the shift in
"MANUAL" operation mode on the basis of the current shift
plan.
■ If the operator forgets to begin the shift in "MANUAL" opera-
tion mode, the shift will be automatically begun as soon as
the first workpiece is processed.

plan".
2. Press the Change operation mode button.
The other operation mode becomes effective right away until the
mode is changed again.
Extending the shift
Operators can extend their own shift before it ends in the

"AUTO" operation mode if, for example, the required quantity
has not yet be reached.
Condition
■ The "Production" or "Standard" authorization is active.
Notes
■ If a shift is manually extended, the shift time and therefore
also the required quantity of the subsequent shift is automat-
ically reduced.
■ The shift can be extended at a maximum of 30 minutes
before the end of the shift.

plan".
2. Maximum 30 minutes before the end of the shift: press the
Extend shift button.
The automatic shift change is immediately invalid for the current
shift.
The shift will be ended only when the Stop shift button is
pressed or when the next shift end has been reached.
Manually beginning and ending the shift
Conditions
■ The "Production" or "Standard" authorization is active.
■ The "MANUAL" operation mode is active.

plan".
or
Ø Press the Production plan main operation and select
"Day shift plan".

2. To start the shift: press the Start shift button.
The shift remains active until the Stop shift button is pressed.

8. Production
8.1 Current program
NC programs can be loaded via network drives or USB-Memory-

Stick.
A filter can be set for the program selection. Press the button
to reset the filter.
Start program
A program will be started in single job mode. A single job always

means that only one workpiece is processed. To process the
next workpiece, the program must be restarted with the START
button.
Conditions
■ The safety door is closed.
1. Press Production and select "Current program".

2. Press Program selection.
3. For the "Storage location", select Internal management.
All programs created in the Internal management system will
be displayed.
4. Select the program.
5. If the laser technology table is to be changed: Press Technol-
ogy correction.
6. Press Continue.
The NC program will be loaded to the machine control sys-
tem.
7. Press the START button.
The program starts.
B836en 2017-11-17 Production 4‐115

Pause program
If required, the active program can be halted during machining.
Condition
■ Program is active.
1. Press FEED STOP button.

2. To continue the machining: Press the ACKNOWLEDGE
FEED HOLD button.
Aborting a program
An active program should only be aborted if absolutely neces-

sary.
Condition
Ø Press the RESET button.

The program is aborted and must, if necessary, be restarted.
Switch screen view

3. Open the "View" field with .
4. To display the NC simulation and the process data, select
NC simulation + process data.
or
Ø To display the NC simulation, select NC simulation + NC
blocks.
or
Ø To display the current position of the NC axes, select Dis-
play axes + NC blocks. Select MKS or WKS.
or
Ø To display the sequence of the NC blocks or the NC pro-
grams, select Call sequence of NC programs and NC
blocks.
4‐116 Production 2017-11-17 B836en

Display Switching over the axis positions
In the Production main operation, the display of the actual axis

position for each station can be switched between MKS
(machine coordinate system) and WKS (workpiece coordinate
system).
1 Selection field axis display

Fig. 68891
1. Open the selection field with the button.

2. Either
Ø To display the axis positions in MKS: select Main axes.
or
Ø To display the axis positions in WKS: select Main axes
(workpiece coordinate system).
The actual position of the NC axes is shown.
Display NC simulation
TruTops Cell Basic is an option of the laser processing machine.

In the NC simulation + process data view, the tool path of the
workpiece for the selected program is shown as a simulation.
Condition
■ A program has been selected.
B836en 2017-11-17 Production 4‐117

2. Open the "View" selection field and select NC simulation +
NC blocks.
Fig. 74947
8.2 Preparing programs
Import master file
To be able to edit a program on the machine it must be saved to

the disc of the industrial PC and it must be divided into its com-
ponent parts (main program, subprograms and tables).
The editing program will be imported as a master file into the
"Internal management" . During the import, the master file will be
separated into its parts.
The file can be imported from a USB-Memory-Stick or from a
network drive.
Note
If all of the files in a folder are to be imported, press Select all.
1. Press Production and select "Prepare program".

or
Ø Press Program and select "Manage programs".
2. For the "Storage location", select Drives.
3. Select drives via "Path" or via the folder structure.
4‐118 Production 2017-11-17 B836en

5. Press Import.
6. Press Import.
The master file will be imported into the Internal manage-
ment.
Prepare program
In parallel to the main time, the operator can prepare another

NC program for editing.
Load program 1. Press Production and select "Prepare program".

2. Load a program from the Internal management.
or
Ø Import a program via Drive.
Editing a program 4. If the technology parameters are to be changed:

− Press Technology correction.
− Select the page of the table.
− Modify parameters.
− Press Save and close.
5. If the NC program is to be edited using the NC Editor:
− Press Program and select "Manage programs".
− Select the program.
− Press Edit.
− Select "Text editor" or "TruTops Cell Basic".
− Press Open.
− Edit the program and save. Close the editor.
Checking the NC program Note

If programs are changed or split up, a syntax check will be
carried out automatically in the background. When this is
done, only the TRUMPF-specific components of the control
system are checked, such as the laser technology tables.
The syntax can be manually checked at any time.
6. To check the program, press Check.
The syntax check is carried out. Any syntax errors are dis-
played.
B836en 2017-11-17 Production 4‐119

8.3 Manual functions
Machine functions are called "Manual functions" if their status

(switch state) can either be displayed or altered in automatic
mode.
The manual functions are collected in groups.

tion
Workpiece coun- "Production Status display: The number of parts made at the production place is
ter place" (number) shown.
Note:
With the "Advanced" user group, the workpiece counter can be changed.
Laser machining "STOP single Requests a program stop after each single contour.
contour" ■ Active: program stop is requested.
■ off: default setting, function is deactivated.
"Analyser" Recording for service purposes.
■ On: default setting.
■ Off: recording ended.
"Test marking" Switches marking test mode on or off.
■ off: default setting.
■ On: switches on marking test mode (see the "Activating marking test
mode" section).
"Real time test The NC program is executed in test mode with 1 % laser power. The gas
mode" supply is then active.
■ On: real time test mode active.
Cutting process "Gas pressure Increasing or reducing the gas pressure by 10 % in each case:
gas override" ■ To increase the gas pressure, press the JOG PLUS button.
■ To reduce the gas pressure, press the JOG MINUS button.
"Gas pressure" Status display: Shows the current cutting gas pressure in bar.
"Post flushing Enter the post flushing time in seconds.
time"
"Post flushing Set the post flushing pressure in bar:
pressure" ■ To increase the gas pressure, press the JOG PLUS button.
■ To reduce the gas pressure, press the JOG MINUS button.
Process param- "Contour check- Status display: The current contour offset in the beam direction is shown.
eters ing"
Transformation "Transformation" The status of the transformation is shown.
4‐120 Production 2017-11-17 B836en

tion
Laser "Laser Test" Activating or deactivating LASER TEST operating mode:
■ on: LASER TEST is activated.
■ off: LASER TEST is deactivated.
"Laser reset" Acknowledging errors in the laser control system:
■ On: error will be acknowledged.
"Alignment laser" Switches the alignment laser (pilot laser) on or off:
■ on: switch alignment laser on.
■ off: switch alignment laser off.
Distance control "Recording the Record characteristic curve for distance control.
system characteristic
Condition:
curve"
The distance regulation must be switched on.
"Distance control Switches the distance regulation ControlLine on or off.
system"
"Collision detec- Sets the reaction time of the distance regulation after detecting a collision
tion" until FEED HOLD is triggered. The reaction time is self-holding (see the
Set-up section, Setting the reaction time for the distance regulation).
■ Slow 2 D: slow reaction time for the machining of flat sheets.
■ Medium 3 D: medium reaction time for 3 D machining.
■ sensitive: fast reaction time for special applications.
Solid-state laser "Active laser Read in the number of the active laser light cable (LLK).
light cable" ■ LLK1: Laser light cable number 1.
■ LLK2: Laser light cable number 2.
"Active laser Status display: Device number of the active laser.
control system"
"Active light Status display: Number of the active laser light path.
path"
"Laser control Read in number of the active laser.
system 1" ■ Connect: The machine control system will connect to the laser control
"Laser control system.
system 2" ■ Ready for operation: Laser control 1 (2) is ready for operation.
■ off: Laser control 1 (2) is not active.
"Request laser" The laser is assigned via the laser network interface of the machine or is
enabled in the laser network again.
■ Enabled: Laser is not assigned to the machine.
■ Request: Laser is assigned to the machine and is ready for operation.
The assignment is active until the laser is enabled again by the manual
function.
B836en 2017-11-17 Production 4‐121

tion
Solid-state laser "Number of Status display: Device number of the active laser.
active lasers"
"Status active Indicates the operating status of the active laser.
lasers" ■ Ready for operation: Laser is ready for operation.
■ Undefined: No communication between the machine and the laser con-
trol system.
■ off: Laser device is switched off.
■ Start-up: Laser control system starts up.
■ Malfunction: A malfunction is registered. An alarm is output.
Note:
The cause of the error is displayed via the "Alarm" dialog, Cause softkey.
The user interface display changes from the machine control to the user
interface of the TruControl 1000 laser control system to the "Diagnostics"
dialog.
Dynamic cutting "Operating mode Status display: current operating mode of the additional axis
optics status" ■ On: Additional axis is enabled and active.
■ Off: Additional axis is deactivated.
"Position" Status display: the current position of the additional axis (up, center, down)
"Axis position" Status display: the current position of the additional axis in mm
workpiece - Manual functions: (see "Manual functions", pg. 4‐59)
changer
Follow groups and manual functions configured with the KSS (project-specific).
Producing manual functions Tab. 4-35
Call manual functions
1. Press Production and select "Manual functions".

2. Open the field with and select group.
3. Press "Manual function".
4‐122 Production 2017-11-17 B836en

Activating marking test mode
With the "Marking test mode" function a contour is engraved on

the workpiece. This can be used, for example, to compare the
actual contour with the nominal contour. The control system uses
the "Marking" laser technology table internally instead of the LTT
"Cutting large/medium/small contours".
For laser technology tables that the user creates, the "marking"
laser technology table also needs to be created. The parameters
for marking are automatically available for all TRUMPF laser
technology tables.
Conditions
■ LASER TEST mode is deactivated.
■ The machining program has been created.
Note
The LASER TEST operating mode (LASER TEST button illumi-
nates) has a higher priority than the "Marking test mode" func-
tion.

2. In the group field, select the Laser machining.
3. Press "Test marking".
4. Press the ENTER button.
The LASER TEST button flashes.
The program starts. The first time TC_LASER_ON is acti-
vated, the "Marking test mode" dialog opens.
7. Press Continue.
The test run is started. The contour is engraved on the work-
piece.
B836en 2017-11-17 Production 4‐123

Activating STOP after single contour
To check the laser cut, with the "STOP single contour" manual
function, a targeted stop can be requested in the program. The
machining will stop after each single contour.
Condition

2. In the group field, select the Laser machining.
3. Press "STOP single contour" and set to active.
4. To start machining: press the START button.
The machining will start and stop after the first
TC_LASER_OFF.
5. To restart machining, press the ACKNOWLEDGE FEED
HOLD button.
Display the workpiece counter
Condition
Displaying the counter 1. Press Production and select "Manual functions".

reading 2. In the group field, select the Workpiece counter.
3. Press "Production place 0".
The number of workpieces made will be displayed.
Changing the counter 4. To reduce the counter level: press the MINUS button.
reading
or
Ø To increase the counter level: press the PLUS button.
Resetting the workpiece counter
Condition

2. In the group field, select the Workpiece counter.
4‐124 Production 2017-11-17 B836en

3. Press "Production place 0".
The number of workpieces made will be displayed.
4. Press the MINUS button and the PLUS button
simultaneously for about 2 seconds.
The counter reading is reset to 0.
8.4 Utility tools
Utility programs can be activated and started in the "Utility tools"

sub-operation.
The following dialog-driven utility programs can be started:

■ CP_HEAD_SETUP: utility program for setting up the process-
ing optics as well as the machine.
■ CP_FIXTURE_SETUP.LST: utility program for setting up the
clamping fixture.
Note
Performing setting work: see "Setting work" chapter.
Starting utility programs
1. Press Production, select "Utility tools".

2. Select utility program.
3. Press Execute.
The utility program is started.
B836en 2017-11-17 Production 4‐125

9. Setup
9.1 Moving the axes manually
In jog mode, the axes can be moved manually either with the
JOG PLUS and JOG MINUS buttons or with the teach panel.
If the teach panel is installed, the JOG buttons have no effect.
Moving the axis continuously
Conditions
■ FEED HOLD must not be active.
1. Press Setup and select "Move axes".

2. Select "Travel mode", "Continuous".
3. If there are several groups of axes, select a group.
4. Select axis.
5. Press JOG PLUS or JOG MINUS.
The axis moves as long as the button is pressed.
Moving the axis incrementally
Position the axis according to the increment selected. The incre-

ment indicates by how many mm the selected axis is positioned
each time the button is pressed.
Conditions
■ FEED HOLD must not be active.
Note
It is not possible to move the axes incrementally using the teach
panel.
1. Press Setup and select "Move axes".

2. Select "Incremental" for "Travel mode".
3. Enter increment in mm.
4‐126 Setup 2017-11-17 B836en

4. Press ENTER.
5. If there are several groups of axes, select a group.
6. Select axis.
7. Press JOG PLUS or JOG MINUS.
The axis is positioned.
Special machine functions are called "Manual functions" if their

status (switch state) can be altered in setup mode.
The manual functions are collected in groups.

tion
General "Safety test" The dialog starts. Start the safety test (see "Manually start the safety test",
pg. 4‐53).
"Machine home Move the axes to their home position:
position" ■ on: axes immediately move to their home position.
■ not available: basic setting missing.
Note:
After the machine is switched on, the "Approach home position" dialog box
automatically starts.
"Optics replace- Release the magnetic coupling.
ment"
Distance control "Recording the Record characteristic curve for distance control ControlLine.
system characteristic
Prerequisite:
curve"
The distance regulation is switched on.
"Distance control Switches the distance regulation ControlLine on or off.
system"
"Collision detec- Set the reaction time of the distance regulation after detecting a collision
tion" until FEED HOLD is triggered. The reaction time is self-holding.
■ 2D series production: Fast reaction time for processing flat sheets.
■ 2D prototype: Slow reaction time for machining flat sheets.
■ 3D series production: Average reaction time for 3D processing.
■ 3D prototype: Fast reaction time for 3D processing.
B836en 2017-11-17 Setup 4‐127

tion
Solid-state laser "Active laser Read in the number of the active laser light cable (LLK).
light cable"
Note: ■ LLK1: Laser light cable number 1.
A maximum of ■ LLK2: Laser light cable number 2.
2 LLK can be
connected.
If 2 laser devi- Prerequisite:
ces are con- ■ The machine and laser device are ready for operation.
nected, the
machine control ■ LLK is fully installed.
makes a distinc- "Active laser Status display, number of the active laser is displayed.
tion between control system"
laser control 1
and laser control "Active light Status display, number of the active laser light path is displayed.
2. path"
system.
■ Ready for operation: Laser control system 1 is ready for operation.
■ off: Laser control system 1 is not active.
system.
■ Ready for operation: Laser control system 2 is ready for operation.
■ off: Laser control system 2 is not active.
"Request laser" The laser is assigned via the laser network interface of the machine or is
enabled in the laser network again.
■ Enabled: Laser is not assigned to the machine.
■ Request: Laser is assigned to the machine and is ready for operation.
The assignment is active until the laser is enabled again by the manual
function.
"Number of Status display, device number of the active laser is displayed.
active lasers"
"Status active Indicates the operating status of the active laser.
lasers" ■ Ready for operation: Laser is ready for operation.
■ Undefined: No communication between the machine and the laser con-
trol system.
■ off: Laser device is switched off.
■ Start-up: Laser control system starts up.
■ Malfunction: A malfunction is registered. An alarm is output.
Note:
The cause of the error is displayed via the "Alarm" dialog, Cause softkey.
The user interface display changes from the machine control to the user
interface of the TruControl laser control system to the "Diagnostics" dialog.
4‐128 Setup 2017-11-17 B836en

tion
Laser "Laser Test" Activating or deactivating LASER TEST operating mode:
■ on: LASER TEST is activated.
■ off: LASER TEST is deactivated.
"Laser beam" Laser beam status display:
■ on: The laser beam is switched on.
■ off: The laser beam is switched off.
"Laser reset" Acknowledging errors in the laser control system:
■ On: error will be acknowledged.
"Alignment laser" Switches the alignment laser (pilot laser) on or off:
■ on: switch alignment laser on.
■ off: switch alignment laser off.
Cutting process "Cutting gas" Select the cutting gas and adjust its pressure.
gas
"Gas pressure" Status display: The current cutting gas pressure in bar is shown.
Control Interface "Data channel" Switch the data channel for the configurable control interface (KSS) on or
off.
Suction system "Suction system" Switches the suction system on or off. After the configured delay, the
extraction system will switch off. The applied lag time is 10 minutes.
Note:
The exhaust system cannot be switched on if an EMERGENCY SHUT-
DOWN is active.
"Purging" Manually start the purging cycle.
Setting work "Park axes" The dialog starts. Deactivate one or more axes (see "Park axes",
pg. 4‐135).
"Set position" ■ Reference the B and/or the C axis to an absolute position of 0°.
■ Carry out a controlled warm start.
"Lubrication Triggers the lubrication cycle manually. The lubricating pinions are lubri-
cycle" cated for 20 seconds.
With each movement, all NC axes are lubricated permanently via a lubri-
cating pinion that is supplied by the central lubrication unit. A lubrication
cycle is triggered every 96 operating hours automatically by default. The
lubrication cycle can be carried out manually at all times.
■ On: lubrication pulse is triggered.
Note: the control system monitors the movement of the axes. If there is
no movement within 60 minutes in the defined monitoring window, then an
operation message will be displayed.
"No. of lubrica- The number of lubrication cycles performed is displayed.
tions"
"Reset lubrica- The counter for the lubrication cycles will be reset.
tion counter"
"Focal position" Setting value for the focal position on machines withoutFocusLine.
The required focal position is entered manually.
B836en 2017-11-17 Setup 4‐129

tion
Dynamic cutting "release" Enable additional axis for dynamic cutting optics.
optics ■ Yes: additional axis is activated and enabled.
■ No: Additional axis is not enabled. The axis is in the neutral position
(nominal value).
"Operation Status display: The status of the additional axis is controlled from the NC
mode" program.
■ On: Additional axis is active (corresponds to TC_ADC_ON).
■ Off: Additional axis is not active (corresponds to TC_ADC_OFF).
"Position" Status display. Actual position of the additional axis:
■ +9 mm: top position.
■ +/ 0 mm: Additional axis in neutral position at "nominal value".
■ -9 mm: bottom position.
"Top axis posi- Move the additional axis to the upper end position.
tion"
"Center axis Move additional axis to the neutral position. This position corresponds to
position" the nominal value.
"Lower axis Move the additional axis to the lower end position.
position"
workpiece - Manual functions: (see "Manual functions", pg. 4‐59)
changer
Scrap conveyor - Manual functions: (see "Tab. 4-36", pg. 4‐130)
Transformation "Transformation" Switches the transformation on or off.
■ Off: Transformation is deactivated.
■ BC: The transformation for the TCP is active, this corresponds to the
TC_TRAFO_ON command.
Setup main operation, Manual functions Tab. 4-36
Call manual functions

2. Open the field with and select group.
3. Press "Manual function".
4‐130 Setup 2017-11-17 B836en

Requesting the laser in the laser network
The machine can be connected to a laser network with a maxi-

mum of 2 solid-state lasers.
The machine is supplied with a laser light cable (LLK) as stand-
ard. It is optionally possible to connect 2 laser light cables (LLK1
or LLK2).
Conditions
■ Laser light cable (LLC) is plugged in.

2. Select the Solid-state laser group.
3. Press "Active optical laser cable" and select LLK.
4. Press "Laser control system 1".
or
Ø Press "Laser control system 2".
5. Press "Request laser" and set to Request.
The laser device is assigned to the machine.
Enabling the laser in the laser network
The machine can be connected to a laser network with a maxi-

mum of 2 solid-state lasers.

2. Select the Solid-state laser group.
3. Press "Request laser" and set to Enable.
The laser device is enabled in the laser network.
B836en 2017-11-17 Setup 4‐131

Enabling the dynamic distance control
system
"Dynamic cutting optics" are equipped with an additional axis for

dynamic distance regulation (ADC). If work is done with dynamic
distance regulation, the additional axis must be enabled.
Condition
■ The dynamic cutting optics are ready for operation.
Notes
■ At the beginning of every NC program, the dynamic distance
regulation must be activated with the TC_ADC_ON cycle.
■ The drive of the additional axis references automatically
after switching on the machine unless the doors are closed
or when the doors are closed for the first time. The upper
position of the additional axis defines the reference position.
During the reference point run, the additional axis moves to
the upper end position or remains in this position.
■ In teach mode, the additional axis moves to the neutral posi-
tion as soon as an enable key is pressed on the teach panel.

2. Select the Dynamic cutting optics group.
3. Press "Enable" and set to On.
Dynamic distance regulation is enabled.
Deactivating the dynamic distance control

system
In case of, for example, an error, the additional axis for dynamic
distance regulation (ADC) can be deactivated. The cutting optics
can also be used without additional axis.
Note
If the optics without additional axis, the TC_ADC_ON cycle is
omitted in the NC program or is commented out (;TC_ADC_ON)

3. Press "Enable" and set to No.
The distance regulation is deactivated. The additional axis moves
to the neutral position.
4‐132 Setup 2017-11-17 B836en

Positioning the additional axis
The additional axis can be manually positioned.
Condition
■ The dynamic cutting optics are ready for operation.

3. Position the additional axis:
Ø To move the axis to the upper position: press "Axis posi-
tion, top".
or
Ø To move the axis to the neutral position: "Axis position,
center"
or
Ø To move the axis to the lower position: press "Axis posi-
tion, bottom".
The additional axis moves in position.
Activating distance regulation
The distance control must be re-activated:

■ after the machine has been switched on.
■ after replacement of optics or nozzles.
■ after replacement of the sensor body.
Condition
■ At least 30 seconds have passed after the mounting of the
focusing optics.

2. Select Distance regulation group.
3. Press "Distance control" and set to on.
The distance control has been activated.
B836en 2017-11-17 Setup 4‐133

ControlLineRecord characteristic curve
The distance control system of the processing optics works using

a characteristic curve. This characteristic curve has to be
recorded again:
■ After switching on the machine.
■ After replacing the optics or nozzle.
■ After replacing the sensor body.
Conditions
■ At least 30 seconds have elapsed since installing the
machining optics.
■ The active transformation type matches the configuration at
the machine.
■ New nozzle.
■ The distance regulation is switched on.
Note
The characteristic curve may also be recorded using the NC
cycle DIAS_3D.
1. Position the processing optics approx. 1 mm above the work-

piece surface.
4. To switch the distance control on: Press "Distance control"
and set to on.
5. Press "Record characteristic curve".
6. Set the speed potentiometer to 100%.
The characteristic curve is recorded. The distance control system
is ready for operation.
Switching the kinematic transformation on

or off
Note
When the kinematic transformation is turned on, the last stored
transformation type remains active until another transformation
type is programmed.

2. Select the "Transformation" group.
4‐134 Setup 2017-11-17 B836en

3. Press "Transformation" and set to BC.
Park axes
Condition
■ The axes to be parked are active and applied as parking
axes at the system.
Note
Each NC axis must be parked individually.

4. Press "Park axes".
5. Select axis.
6. Press Apply.
The selected axis is deactivated.
7. Switch off the MAIN SWITCH.
8. Disconnect the axes from the electrical power supply.
Displaying and resetting workpiece counter
The workpiece counter is an option of the laser processing

machine. The workpiece counter displays the number of pro-
duced tools per production place.
Condition
■ Workpiece counter option is applied.

2. Select the Workpiece counter group.
The applied production places and the workpiece quantity is
shown.
3. If the workpiece counter is to be reset:
− Press "Production place x".
− Use the JOG MINUS button to set the value for the
quantity to 0.
B836en 2017-11-17 Setup 4‐135

Running a warm start
A warm start can be necessary for various reasons. A controlled

warm start can be carried out using the manual "Warm start"
function.
The drives are switched off, and the NC axes remain in their cur-
rent actual position. The laser remains switched on.
Condition

2. Select the Additional functions group.
3. Press "Warm start"
The control system shuts down in a controlled manner and
carries out a warm start.
4. After a restart of the control system:
− Acknowledge any error messages with the RESET but-
ton.
− Switch on the drives, press the MACHINE ON/OFF but-
ton.
The drives are switched on. The machine is ready for operation
again.
Focal position without FocusLine setting
Only valid for machines without FocusLine.

For machines without FocusLine, the precise focal position is
determined by cutting trials. The focal position depends on the
material type and on the sheet thickness.
The focal position is manually set to a fixed value before the
machining.
Condition
■ The focal position for the workpiece to be machined is
known.
Notes
■ The parameter "FocusLine setting value" in the laser technol-
ogy table has no effect in this case.
■ It is not possible to adjust the focal position during the
machining.
4‐136 Setup 2017-11-17 B836en

The permitted focal position adjustment range depends on the
focal length of the dynamic cutting optics.
Focal length Permissible focal position adjust-

ment range
f = 200 mm -12.5 mm to +8.0 mm
f = 150 mm -5.25 to + 5.25
Tab. 4-37

3. Press "Focal position".
4. Set the value for the focal position with the MINUS or the
PLUS button.
The setting is valid immediately.
B836en 2017-11-17 Setup 4‐137

9.3 MDA
In MDA (Manual Data Automatic) mode, single or multiple NC

blocks can be created and executed immediately in single block
or block-by-block mode.
Note
The control system saves the programmed NC blocks perma-
nently.

Execute the NC blocks in the following

block
Conditions
■ Teach mode is deactivated.
Note
"Block-by-block" mode is preset.
1. Press Setup and select "MDA".

2. Enter the NC text using the keyboard.
3. Press Start.
MDA operation starts. NC blocks will be executed up to the pro-
grammed stop.
Execute the NC blocks in a single block
Conditions
■ Teach mode is deactivated.
1. Press Setup and select "MDA".
4‐138 Setup 2017-11-17 B836en

2. Enter the NC text using the keyboard.
3. Select "Single block".
4. Press Start.
MDA operation will start. The first NC block will be executed.
5. To run each of the other NC blocks, press Start.
9.4 Configuration
In the configuration dialog, the user defines how to change the

workpiece at the machine.
The workpiece change can be carried out manually or automati-

cally:
■ Manual workpiece change: With a manual workpiece
change, the operator loads the workpiece. After processing,
the operator removes the finished part.
■ Automatic workpiece change: The workpieces are loaded
and unloaded by an external automation component that is
controlled via the machine's automation interface (Automation
interface option).
■ If there are several loading places at the machine, mixed
mode consisting of manual and automatic loading and
unloading is also possible.
Configuration of workpiece The area in front of the workpiece changer where the workpiece
change is set up (loaded or unloaded) is referred to as "loading place".
A number is assigned to every loading place.
The configuration of the workpiece change depends on the con-
figuration of the machine. A valid configuration means at least
one loading place must be activated.
The following parameters can be defined for every loading place:

■ Load: The new workpiece is loaded at this loading place
(before processing).
■ Unload: The completed workpiece is unloaded at this loading
place.
■ Load and unload: The new workpiece is loaded at this load-
ing place and the completed workpiece is unloaded.
■ No action: This loading place is deactivated.
B836en 2017-11-17 Setup 4‐139

A With rotary indexing table B With rotational changer
Loading place Fig. 89267
Configuration of automation On machines with automation interface, the following parameters

interface are also configured:
Parameter Description Valid for

"Beam threshold value on" Defines the threshold for the evaluation of Automation interface
whether the laser bean is switched on or off. If Basic
the laser power drops below the entered Comfort
threshold, the LASER_BEAM_IS_ON signal Professional
(laser beam on) is reset.
"Handling defective part" Defines the strategy of the automation system Automation interface
when defective parts are recognized. Comfort
Professional
■ No reaction
■ Acknowledge after every error
■ Acknowledge after several errors
"Number of defective parts" Only relevant for the Acknowledge after sev- Automation interface
eral errors strategy:Number of permissible Comfort
defective parts. If this number is exceeded, the Professional
automation reacts in accordance with the
selected strategy.
4‐140 Setup 2017-11-17 B836en

Parameter Description Valid for
"Activate automation" Activate or deactivate external automation. Automation interface
Comfort
■ Activate: The workpieces are put in the fix-
Professional
ture by the external automation component
and also taken out again. The external
safety device is effective.
■ Deactivate: The workpieces are manually
loaded. The machine's safety device is
effective.
"External safety device" The checkbox is status information. The check-
box is activated if the external safety device is
active.
Automation interface configuration parameters Tab. 4-38
Note
These parameters are only displayed if the Automation interface
option is applied.
Configure loading and unloading place
This section is valid for machines without automation inter-

face.
Condition
1. Press Setup main operation and select "Configuration".

The configuration dialog starts. The user interface shows the
respective machine configuration and the corresponding load-
ing places.
2. In the "Workpiece change configuration" selection field, select
the parameters for the "loading place".
The configuration is completed and is effective immediately in all
the machine's operating modes.
Configure loading and unloading place
This section is valid for machines with automation interface

(automation interface option).
B836en 2017-11-17 Setup 4‐141

Condition
Note
The "External safety control system" parameter is a status dis-
play.
For machines with a rotary indexing table:
Activate automation Fig. 77308
For machines with rotational changer:
Activate automation Fig. 79717
1. Press Setup main operation and select "Configuration".

The configuration dialog starts. The user interface shows the
respective machine configuration and the corresponding load-
ing places.
2. If the automation interface is to be activated: select "Activate
automation".
3. In the "Workpiece change configuration" selection field, select
the parameters for the "loading place".
4‐142 Setup 2017-11-17 B836en

4. Optional: Enter the threshold for the laser power at the
"Beam threshold value on" parameter.
5. Define the parameters for handling of defective parts:
− Select the "Defective part handling" strategy in the selec-
tion list.
− If the Acknowledge after several errors strategy is
selected: Enter the "Number of defective parts" after
which there should be a reaction.
The configuration is completed and is effective immediately in all
the machine's operating modes.
B836en 2017-11-17 Setup 4‐143

10. Programming
10.1 Program management
The "Internal management" is the program management on the

machine's operating PC.
Programs can be managed and edited at the "Manage pro-

grams" sub-operation:
■ Load master files into the "internal management" (operating
PC hard disc).
■ Export master files to a network directory.
■ Create and process main programs.
■ Create a subroutine and sub program macros.
■ Change to TruTops Cell Basic programming system.
■ Fill the transformation accumulator.
■ Show setup schedule as PDF file.
■ Show any PDF file.
■ Teaching.
4‐144 Programming 2017-11-17 B836en

1 Internal management 4 PDF file 6 Folder structure
2 Hard drive/USB 5 Path 7 Program selection
3 Filters
Manage programs Fig. 71606
Notes
■ For the program selection, a filter can be set with the but-
ton.
■ Only empty folders can be deleted.
■ Programs that are saved in a production plan as orders can-
not be deleted.
Network directory The machine's operating PC can be integrated into a network.

Files can be imported and exported via the network.
Due to the active firewall, files can no longer be imported via the
network directory '\topsmanu.dir' into the "Internal management".
The import is only possible with a USB-Memory-Stick or via an
external network directory.
The export of files via the network directory '\topsmanu.dir' con-
tinues to be possible.
B836en 2017-11-17 Programming 4‐145

KSS modules During import of the NC program, the associated KSS modules
associated with the program will also be imported.
If an error occurs during import of the KSS modules, the module
must be separately imported.
Importing KSS module; see: "Supplement to operator's manual",
TruLaser Cell, document number M265.
Setup plan When importing programs from the TruTops programming sys-
tems, the setup plan can be called up and displayed as a PDF
file.
Selecting program
Condition
1. Press Program and select "Manage programs".

All NC programs that are stored in the "internal management
system" are displayed in the list.
Creating a new program
New programs can be created, for example by copying an exist-

ing program.
Newly created programs contain a standard program header
which can be edited in the text editor.
Notes
■ Only main programs can be created at the machine control.
■ Main programs with subprograms can be imported. Subpro-
grams can be edited at the user interface.

3. Press New.
or
Ø Select the program which should be copied.
Press Copy.

4. Enter the program name.
5. Press OK.
The program has been created and can be edited now.
Copying a program
Conditions
■ Program status "OK" .

2. Select Copy.
3. Press Rename.
Note
The file type *.tpp or *.lst must be retained.
4. Enter the new file name. Press OK.
Editing a program in the text editor
Programs created in the internal management system can be

edited in a text editor.
Programs that are saved in a production plan as order can also
be processed.
Conditions
Notes
■ NC cycles and commands which change the path of a tool
and which are not supported by TruTops Cell Basic cannot
be interpreted by the graphic editor. The program will abort.
■ Context-dependent, online help for the NC cycles can be dis-
played in the selection field.
1. Press Programming main operation.

3. Press Edit.

4. Select "Text editor".
The Editor opens.
5. Press Open.
6. Editing NC text.
A yellow bar on the left border marks the changed NC block.
7. To save the changes, Press Save.
or
Ø To close the table, Press Save and close.
Create subroutine
Note: The following description is valid for one local subrou-

tine (UP).
"Subroutine macro" (see "Creating and managing subroutine
macros", pg. 4‐153).
In the program editor, a sub program can be created after selec-
tion of a main program. The sub program is firmly assigned in
this main program and is only effective in this main program.
There are three possibilities to create a new sub program:

■ A block sequence marked in the main program can be
stored as a sub program. The marked NC blocks are deleted
in the main program; in place of them, an NC block with the
sub program name is added as activation in the main pro-
gram.
■ If no NC blocks are marked, an empty sub program will be
created. In this case, the NC block must be manually added
into the main program.
■ An existing sub program can be copied. The copied sub pro-
gram is also only effective in this main program. The NC
block with the sub program activation must be manually
inserted into the main program.
If a new subroutine is created, the control automatically gives it
a temporary program name: SP1, SP2 etc.
Recommended sub program name: SP_NAME, "SP" for Sub-
programm.

Conditions
■ The main program has been created and stored in the inter-
nal management.
Notes
■ The program name can be renamed, if need be. If the pro-
gram name is changed, the NC block with the program acti-
vation (program name) in the main program must be man-
ually changed.
■ During deletion, the sub program is permanently deleted from
the hard drive. The NC block with the program names must
be manually removed from the main program.

4. Press Edit.
The program editor opens.
5. Either
Ø Mark NC blocks which are to be saved as a new sub
program.
or
Ø If an empty sub program is to be created: do not make
any NC blocks in the program.
6. Press New sub program.
The control creates a subroutine with, for example, the pro-
gram name SP1. The marked NC blocks are deleted in the
main program. An NC block with the activation SP1 is added
in its place.
7. If the program name is supposed to be modified:
− Select the subroutine.
− Press the Rename subroutine button.
− Enter the new program name and confirm.
− Change the NC block with the program name in the main
program.

Number program
Condition
■ The program has been selected and the text editor has been
opened.
1. Open "Selection field" and choose Numbering.

2. Enter the "Start number" and "Increment size" for the num-
bering.
3. Press Number.
The NC blocks will be renumbered.
4. To save the changes, Press Save.
or
Ø To close the table, Press Save and close.
Exporting program
Programs created or changed on the machine can be exported

to a network drive or to a USB-Memory-Stick. A master file will
be produced during the export.
For the export file, a file type of *LST or *TPP can be selected.
Condition
Notes
■ The LTT valid for the program will only be exported if the
associated tooling status is been selected.
■ If all of the programs in the folder are to be exported: press
Select all.

2. If not yet selected, For the "Storage location", select Internal
management.
4. Press Export.
5. Select "file type".
6. Select export folder.
7. If a new folder is to be created for the export:
− Press New folder.
− Enter folder name.
− Press OK.

8. Press Apply.
The program will be saved as a master file to the selected
export folder.
Importing program
Programs that are externally created or changed can be

imported into the program manager by a USB-Memory-Stick or
another external network directory.
Note
If all of the programs in the folder are to be imported: press
Select all.

2. Select "Path" or "Folder".
The "Program selection" dialog opens. All programs in the
selected folder will be displayed.
4. Press Import.
5. Press Apply.
The selected programs are saved in the "internal management".
Delete program
Conditions
Note
Programs that are saved in a production plan as orders cannot
be deleted.

4. Press Delete.
5. Press Delete.
The program will be deleted from the "internal management"
(from the industrial PC's disc).

Show setup plan
Conditions
■ The setup plan is stored as a PDF file in the same folder as
the *.LST master file.
■ The PDF file has the same file name as the master file: e.g.,
"MyProgram.LST" and "MyProgram.PDF".

2. Select the external management.
4. Press the Set-up plan button.
The setup plan is shown.
Show PDF file
Any PDF file can be shown.
Note
PDF files are only shown in the folder structure if the "Show
PDF" function has been activated.

2. Select the external management.
3. Activate the "Show PDF" box.
4. Mark "PDF file" in the folder structure.
5. Press the Display button.
The PDF file will be shown.

10.2 Creating and managing subroutine
macros
Subroutine macros are globally effective subroutines which, once

created, can be called up in more than one main program. In
comparison: local subroutines (UP) are only effective in the one
main program where they have been assigned.
Users can create and manage their own subroutine macros.
1 Subroutine macros selection list 2 Macro included in the program

Managing the subroutine macro Fig. 77358
Button Description
Editing Processing and existing or new subroutine macro.
New Create a new subroutine macro.
Copy Copy the selected subroutine macro.
Delete Delete the selected subroutine macro.
Tab. 4-39
Importing the subroutine Only one subroutine macro can be saved with the same name in
macro each case in the program management on the operating PC.
Therefore, the following should be noted when importing main
programs:
■ When importing a main program with a subroutine macro
that already exists in the program management, the macro
will not be imported with the main program.
■ If a subroutine macro was changed outside the program
management, the macro must either be imported under a

new name or the macro that exists in the program manage-
ment must be deleted before the import.
Note
If main programs with subroutine macros are imported to another
machine, for example, to a TruLaser Cell 8030 (L45), then the
subroutine macro will become a local subprogram (UP).
Exporting the subroutine When exporting a main program with a subroutine macro, the
macro macro is exported with the main program.
Deleting the subroutine Note the following when deleting subroutine macros:
macro ■ If a subroutine macro is deleted which is not linked to any
main program, the macro and the NC code will immediately
and permanently be deleted from the hard drive without
warning.
■ If a subroutine macro is to be deleted which is linked to at
least one main program, a query appears. If the subroutine
macro is deleted in this case, only the macro is deleted,
while the program and NC code are kept as a local subrou-
tine (UP).
Subroutine macro Subroutine macros are called up in the NC program by inserting

programming the program name to the desired position in the NC program as
an NC block.
Subroutine macros can be programmed with or without transfer
parameters.
Note
Programming subroutine macros: see the machine programming
manual.
Creating a subroutine macro
A new subroutine macro can be created by copying an existing

macro or by creating and editing a new macro.
When a new subroutine macro is created, the editor places the
prefix "SPM_" in front of the macro name. This prefix should not
be changed by the user.
"SPM" stands for SubProgrammMakro.

Condition
Creating a new subroutine macro Fig. 77357
1. Press the Programming main operation; select "Manage mac-

ros".
2. Creating a new macro:
Ø Select an existing macro in the selection list.
− Press Copy.
or
Ø Press New.
3. Enter new macro name. Keep the SPM_ prefix.
4. Press OK.
A new subroutine macro is created.
Processing a subroutine macro
The subroutine macro can only be edited in the macro editor.
Condition
Note
The subroutine macro is write-protected in the program editor.

ros".
2. Select the macro in the "Programm macro" selection list.
3. Press Edit.
Opens the macro editor.

4. Editing NC text.
5. Press Save and close.
The subroutine macro can now be inserted in the main program.
Deleting the subroutine macro
If a subroutine macro is deleted, it is retained as a local subpro-

gram (UP) under the same name with the prefix SPM in the pro-
gram management: only the macro is deleted; the program code
is retained. The local subroutine continues to be effective in the
main program with which it is linked.
Condition

ros".
2. Select the macro in the "Programm macro" selection list.
3. Press Delete.
The subroutine macro is either deleted or converted into a local
subroutine.
Inserting the Subroutine macro
With the program editor, subroutine macros can be inserted into

the main program.
Conditions
■ The macro has been created; macro status "OK" .

2. Select the main program.
3. Press Edit.

A list is displayed of subroutine macros which are assigned to
the main program.
1 Available subroutine macros

Using the subroutine macro Fig. 77360
5. Press Use macro.
A list is displayed of subroutine macros that are available in the

control.
Inserting a subroutine macro Fig. 77359

6. Select subroutine macro.
7. Press OK.
The subroutine macro is now assigned to the main program.
8. Insert an NC block in the main program at the desired posi-
tion with the name of the subroutine macro.
For example: N200 SPM_Example_1.

10.3 Transformation
Note
The values displayed for the actual position of the NC axes are
dependent on which coordinate transformation (Frame) is active:
the machine coordinate system (MKS), the workpiece coordinate
system (WKS) or an active zero point offset.
1 Zero point offset status 5 Applied axes 9 Frame Flip

2 Transformation status 6 Actual value, display, axes 10 Frame Scale
3 Transformation accumulator 7 Marked axes 11 Frame Rotation
selection list 8 Frame Translation
4 Transformation accumulator
Transformation Fig. 83720

Column Symbol Description
"Axis current value" - The entered values corresponds to the actual position of the NC axes.
By pressing the Apply current value button, the actual positions of all
marked axes in the selected transformation accumulator are applied as
zero point coordinates.
"Translation" Zero point offset for the respective axis by translation, based on the cur-
rently set translation accumulator.
The saved Frame is activated during the start of the program as zero
point offset for the selected transformation accumulator.
"Revolve" Zero point offset for the respective axis by rotation, based on the currently
set transformation accumulator.
"Mirror" Flip the marked axis, based on the currently set transformation accumula-
tor.
"Scale" Scaling factor for the respective axis by rotation, based on the currently
set transformation accumulator.
Tab. 4-40
Transformation accumulator There are four transformation accumulator: G54, G55, G56 and
G57.
In each transformation accumulator, a zero point or a new Frame
can be saved. The saved zero point or Frame is activated in the
NC program by programming of, for example, SET_G54.
There are the following possibilities to fill the transformation

accumulator:
■ By applying the actual positions of all marked axes.
■ By manually entering the zero point coordinates in the text
input fields for translation and/or rotation.
■ By flipping of individual axis coordinates.
■ By scaling of individual axis coordinates.
If the "Offer all accumulators for selection" checkbox is activated,

the following will be shown in the "Transformation accumulator"
selection list:
■ The transformation accumulator G54, G55, G56 or G57.
■ Current Gxx: Status display for the last activated zero point
offset.
■ TRANS/ROT/ATRANS: Status display for translation and rota-
tion, based on the selected transformation accumulator.

Note
If the "Offer all accumulators for selection" checkbox is not acti-
vated, the four transformation accumulators will be shown in the
selection list:
Kinematic transformation The kinematic transformation defines the way in which the NC
axes move to the programmed position.
Symbol Description
Kinematic transformation is switched on: if the orientation
axes (B and C1) are rotated, the geometrical axes (X, Y
and Z) perform balancing movements.
Kinematic transformation is switched off: if the orientation
axes are rotated, the geometrical axes do not perform bal-
ancing movements.
Tab. 4-41
Applying the actual position as the zero

point
Kinematic transformation is generally switched on if the actual

positions of the NC axes are to be applied as zero point coordi-
nates in the transformation accumulator.
■ The axis values correspond to the WKS coordinates when
transformation is switched on.
■ The axis values correspond to the MKS coordinates when
transformation is switched off.
Conditions
■ No zero point offset may be active: the display in the
"Actively adjustable zero point offset" field is empty.
1. Switch on kinematic transformation.

2. Move the NC axes to the position that is to be saved as zero
point.
3. Press Programing, select "Transformation".
4. Open the "Transformation accumulator" selection field.
5. Select a transformation accumulator e.g. G54.
6. Mark the NC axes whose positions are to be saved.
7. Press the Apply actual values button.
The actual positions of the marked axes are saved in the trans-
formation accumulators.

Moving zero point incrementally
The Frame values saved in the transformation accumulator for

translation or rotation can be changed step by step (incremen-
tally).
Condition

4. Select the text input field whose value is to be incremented.
5. Either
Ø If the software keyboard opens: press OK.
or
Ø Press the Increment value button.
6. Enter the increment in the "Increment (+/-)" field. Note the
operational sign.
7. Press OK.
The entered value is added to or subtracted from the value of
the selected text input field.
The calculated Frame value is immediately saved in the transfor-
mation accumulator.
Select Frame and fill transformation

accumulator
A new Frame can be created by translation, rotation, flipping or

scaling. The Frame is saved in the selected transformation accu-
mulator and later activated in the NC program by a zero point
offset.
Condition

4. If a new Frame is to be created by "Mirror": Select NC axis
whose coordinates are to be mirrored.

or
Ø If a new Frame is to be created by "Scaling": enter a
scaling factor for the respective axis.
or
Ø If a new Frame is to be created by translation or rotation:
activate the NC axes and Frame values in the respective
input field.
The selected Frame is saved in the selected transformation
accumulator.
Deleting transformation accumulator
Condition

4. Press the Delete all values button.
All axis coordinates are set to 0 in the selected transformation
accumulator. The values for scaling are set to 1. The value
"OFF" is set for the Frame mirroring.
10.4 Operate KSS
Note
Module configuration, Interface description as well as automation
interface: see supplement for TruLaser Cell Operator's manual,
document number M265.
Start KSS configuration
Ø Press Programming; select "CCI configuration".

The KSS configuration start page opens.

Activate module and load module data
If a program is to be started with KSS activation, the module

data must be previously transferred to the control (the PLC). The
module data is active in the control until the module is removed
from the control.
Several modules can be active at the same time in the control.
Conditions
■ Module is created, elements and sequences are configured.
■ Production plan is not active.
■ User group "Standard" or "Advanced" is active.
1. Press Programming; select "CCI configuration".

2. Select the module in the left column.
3. Press Activate/deactivate.
The module has been activated but not yet loaded in the
PLC.
4. Press Apply data.
The module data is transferred to the PLC. Manual functions,
diagnostics functions as well as error texts are generated.
Deactivating the module
The module is deactivated in the PLC. The module data remain

loaded in the PLC.
Condition
1. Press Programming; select "CCI configuration".

2. Select the module in the "Active module" column.
3. Press Activate/deactivate.
The module is deactivated. The module status changes to gray.

10.5 Programming system
Starting TruTops Cell Basic
TruTops Cell Basic is an option for the laser processing machine.
Conditions
■ TruTops Cell Basic is applied.
■ The NC program was created using TruTops Cell.
■ The machine configuration agrees with the configuration in
the simulation program.

3. Press Edit.
4. Select "TruTops Cell Basic".
5. Press Open.
TruTops Cell Basic opens; NC program and machine configura-
tion are shown.
Call up advanced shop floor programming
The "Advanced shop floor programming" (option) can be called

up from the control panel of the machine.
To do this, the operator connects to a TruTops computer/server
outside the machine network.
1. Press Programming and choose "Programming system".

2. Select "Unit system".
3. Enter "Server name", "Domain", "User" and "Password".
4. Either
Ø Press Connect.
or
Ø To change the configuration, press Configuration.

11. Technology
Laser technology tables All technology parameters for laser processing are transferred to
the control in the form of a laser technology table. The laser
technology table is called up in the processing program by pro-
gramming NC cycles.
A distinction is made between the following technology tables:

■ Technology tables for laser cutting (LTT).
Notes
■ The user can create his own tables, e.g. by copying existing
tables and editing the processing parameters.
■ Technology tables from TRUMPF are write-protected.
■ Technology tables are global tables. Modifications in a
technology table are active in all programs where this
table is programmed.
Technology parameters and For technology parameters and programming, see the "Tru-
programming Laser Cell programming manual" in the chapter "Laser process-
ing", section "Laser cutting".
For laser technology tables for cutting (LTT),. see "TruLaser Cell
data collection".
Embedded Help For every parameter in the table, context-sensitive help can be
displayed.
■ Embedded Help is opened using the button.
■ Embedded Help is closed using the button.
If the button for the Embedded Help is opened, pressing the
input field for the parameter concerned will result in a description
of the parameters being displayed.
4‐166 Technology 2017-11-17 B836en

11.1 Laser cutting
Cutting parameters The processing parameters are programmed in so-called laser

technology tables for cutting (LTT).
1 "Tables" selection field 3 "Technology" selection field

2 Selection 4 Cutting parameters
Laser cutting technology table Fig. 67415
Naming convention The table name consists of 2 characters:
Description
First part: Viewer name The Viewer name is manually entered by the user. It may not have more
than 12 characters. The naming should adhere to the following TRUMPF
conventions:
■ Material: "Material", "Thickness", "System of dimensions", "Material
standard".
■ Process: "Gas type", "Processing type", Index". The user can use the
digits 5 to 9 for the "Index". The digits 0 to 4 are reserved for TRUMPF
tables.
Second part: Key extension The Key extension automatically generates the control for the active tool-
ing status. The extension contains the following information in the following
sequence:
■ Laser: "Nominal laser power", "Laser type".
■ Beam formation: "LLK diameter", "Collimation focal length", "Focusing
focal length", "Type of optics".
■ Machine: "Machine group", "Machine length" for the main axis.
■ Workpiece: "Type of workpiece", "Material".
Cutting table naming convention Tab. 4-42
B836en 2017-11-17 Technology 4‐167

Selecting the setting for the "Table"
selection field
For displaying the technology tables, a presetting can be

selected in the "Tables" selection field.
Setting Selection
"Should the table for the selected "Yes": The current program table will be loaded and marked in the focus in
program be selected?" the "Tables" selection field.
"No": The last selected table will be loaded and marked in the focus in the
"Tables" selection field.
"Tables for the current tooling sta- Only the tables that belong to the current tooling status are displayed.
tus"
"All tables" All tables are shown.
"Tables" selection field Tab. 4-43
1. Press Technology, select "Laser cutting".

2. Press the Settings button.
3. Either
Ø If the table of the current program is to be selected:
select "Yes".
or
Ø Select "No".
4. Choose setting:
Ø Select "Tables for the current tooling status."
or
Ø Select "All tables."
5. Press Apply.
The selected setting is active until a different setting is selected.
Creating a cutting table
A new cutting table can always only be created for the current
state of tooling.
Generally, a new table is created by copying an available table.
4‐168 Technology 2017-11-17 B836en

Condition
■ The tooling status for which table should be created has
been activated.
Note
The current tooling status is taken into account when copying a
technology table. Tooling-relevant parameters of the table are
replaced by parameters of the tooling status.

2. Select the table to be copied.
3. Press Copy table.
− Enter table name.
− Press Copy.
4. Select technologies:
Ø In the "Technologies" field, choose the table page.
or
Ø Select the table page with the Previous technology or
Next technology buttons.
5. Modify parameters.
Edit the cutting table
Process parameters are changed by changing the entries in the

table of the programmed cutting table.
Parameters can only be changed in the tables that the users
have created themselves. Tables from TRUMPF are write-pro-
tected.
Notes
■ Modifications in a cutting table are effective in all programs in
which this table is programmed.
■ If the parameters of a cutting table are to be reset to default
values, press the Default values button.

2. In the "Tables" field: Select a table.
3. Select the technology (machining process):
Ø In the "Technologies" field, choose the table page.
or
Ø Select the technology with the Previous technology or
Next technology buttons.
B836en 2017-11-17 Technology 4‐169

4. Modify parameters.
The modifications take immediate effect.
11.2 Ramp cycles
Programming ramp cycles
A ramp cycle for piercing is defined via calibration points. A max-

imum of six calibration points can be programmed per ramp
cycle.
The "Ramp cycle number"parameter is programmed in the LTT,
"Piercing".
Note
The user can program the cycle numbers 81 to 99. The cycle
numbers 1 to 80 are reserved for TRUMPF applications.
1 Cycle number 3 Calibration point

2 Graphic representation of ramp 4 Cycle parameter
cycle
Ramp cycles Fig. 67416
1. Press Technology and select "Ramp cycles".

2. Enter the "cycle number".
3. For each calibration point, enter "Laser power", "Time",
"Pulse frequency" and "Pulse power".
4‐170 Technology 2017-11-17 B836en

4. Press Accept cycle.
5. Enter the cycle number in the LTT.
11.3 Managing the tooling status
The laser processing machine can be operated with differing

configurations. For each configuration, a tooling setup must be
created.
The machine's tooling statuses are created, managed and acti-
vated in the "Tooling status administration" sub-operation
(Laser Tooling Management).
Notes
■ The machine will be commissioned with at least one tooling
status by a service engineer.
■ Only those parts of the machine can be commissioned for
which there is an application.
■ The display of the components and their tooling parameters
as well as the activation of the input fields depends upon
which user group is currently set.
Tooling setup The following components belong to a tooling setup:

■ "Component" laser device.
■ "Component" beam formation/LLK.
■ "Component" Processing optics for laser cutting.
■ As well as additional components according to the machine
configuration.
Commissioning the Default parameters are stored for all of the machine's variable
components components in the control system. The parameter blocks are col-
lected together as a tooling setup. When creating the tooling
setup, the user can change the approved parameters.
The individual components, e.g. the processing optics, will gener-
ally be commissioned using service programs.
Note
Service programs: see chapter "setting work".
Component serial numbers When the machine is commissioned, the parameters for all com-
ponents are set under their serial number.
If components with identical serial numbers are configured for
different setup states, the parameter values will also be transmit-
ted.
B836en 2017-11-17 Technology 4‐171

Setup status display Symbol Description
Active setup state.
■ The tooling status has been activated.
■ The components have been commissioned.
Active setup state.
■ The setup state has been activated in the PLC.
■ The components have not (yet) been commis-
sioned.
Invalid setup state:
■ The setup state does not match the machine's
state.
■ Invalid or missing parameters.
Setup state activated, waiting for response from PLC.
Without Icon No tooling status selected.

Setup status Tab. 4-44
Activate setup state
An activated tooling setup will remain active until a different tool-

ing setup is activated.
If the machine's configuration is changed, for example if process-
ing optics with a different focal length are to be used, then
before starting the laser processing, the newly selected tooling
setup must be activated.
The machine control system will not check whether the
active setup state matches the machine's actual state for all
components.
Conditions
■ The setup state has been created, the components have
been commissioned.
■ The setup state corresponds to the machine's configuration.
The activated setup state or the component parameters do

NOTICE not correspond to the machine's configuration.
Destruction of the beam guidance components.
Ø Check that the activated setup state matches the machine's
actual state.
1. Press Technology, select "Tooling status management".

All of the created setup states will be displayed.
2. Select tooling status.
4‐172 Technology 2017-11-17 B836en

1 Selected tooling status
Fig. 75035
3. Press Activate.
The selected tooling status is being loaded. The setup state is
valid and active as soon as the green icon appears.
Creating a new setup state
If a new setup state is created, the components which belong to

that state must then be commissioned.
For the commissioning, the parameters for all components are
preset with the default values. When the service programs are
run, the actual parameter values will be determined and saved to
the current setup state.
The selectable components (laser, beam shape and process

adapter) are arranged in a hierarchical tree structure on the user
interface.
■ First, the components will be collected to make up a "setup
state".
■ Then the components will be commissioned using service
programs.
■ Depending on the combination of the components, certain
sets of parameters can then be manually changed.
B836en 2017-11-17 Technology 4‐173

Conditions
■ There are applications for the components on the machine.

2. Press New.
3. Enter a "Name" for the tooling setup.
4. Press Continue.
5. One after another, select the components and enter their
serial number or device number.
For the laser device, enter the "Laser light path number".
6. Press Continue.
or
Ø If the setup state is complete: Press Finish.
The setup state will be created. The setup state is valid as soon
as all of the necessary service programs have been run and all
of the relevant parameters have been set.
Editing the tooling level
A tooling setup can be edited, by changing the parameters ena-

bled for the components involved.
All parameters are either preset to default values or have been
determined during commissioning.
The default value and the permissible upper and lower limits for
a parameter will be shown on the user interface.
4‐174 Technology 2017-11-17 B836en

Conditions
■ The setup state has been created.
Fig. 75036

3. Press Edit.
4. Select component: e.g. laser device.
5. Check the parameters and change if necessary. In the
"Description" field, a comment may be added.
6. Press Apply.
Deleting a setup state
The setup state and with it the commissioning of the com-

ponents will be irrevocably deleted in the control system.
Conditions
■ The tooling setup has been activated.

3. Press Delete.
Query: Should the selected tooling setup be permanently
removed from the management system?
B836en 2017-11-17 Technology 4‐175

4. Press Delete.
The setup state will be deleted.
4‐176 Technology 2017-11-17 B836en

12. Maintenance
The following functions can be called in the Maintenance main

operation:
■ Manual functions: Display status.
■ Partial backup: Performing data backup.
■ Data manager: Managing files.

tion
Welding gases "Helium" Gas valve
"Monitoring" No effect
Manual maintenance functions (status display) Tab. 4-45
12.2 Partial backup
Backing up data
The user data stored on the hard disks in drives "C" and "D" can
be backed up daily, weekly or monthly, either on the internal
hard disk drive of the control system or on an external network
drive.
Notes
■ If the data is saved to the internal hard disk drive, only the
TRUMPF Service engineer can access the data backup in
the C:\tcommc\ directory.
■ To back up the data in such a way that the user can access
the data backup, the data should be saved on a network
drive.
1. Press Maintenance, select "Partial backup".

2. Press "Perform partial backup when starting up the user
interface".
3. Select backup location:
Ø To back up the data to a network drive, select Network
drive in the "Backup path" selection field.
− Select folder and storage medium.
− Press Apply.
B836en 2017-11-17 Maintenance 4‐177

or
Ø To save the data to the internal hard disk, select Internal
hard disk in the "Backup path" selection field.
4. Enter the maximum number of backups (7 backups are
standard). The respectively oldest backup will be deleted
when the maximum number of backups in the backup path is
reached.
5. In the "Maximum of one backup" selection field, select either
Daily, Weekly or Monthly.
At the next start-up, the data will be saved according to the
selected interval and in the selected backup path.
12.3 File manager
In the data manager, files can be stored and edited on the hard
disk drive of the machine control and on external drives. Access
depends on the currently set authorization.
1 Source directory 2 Target directory

Data manager Fig. 68773
Button functions
Update Update list display
Copy file Select copy file.
Edit file Edit selected file.
New folder Create new folder in target directory or in
source directory.
4‐178 Maintenance 2017-11-17 B836en

Button functions
Rename Rename file.
Note: Only files on external drives can be
renamed.
Delete Delete file or folder.
Note: Only empty folders can be deleted.
Buttons Tab. 4-46
Edit and save file
Condition
1. Press Maintenance, select "Data manager".

2. If the file is to be saved to a different drive:
− Select a folder in the "Source" selection field.
− Select a folder in the "Target" selection field.
− Select file.
− If the file is to be edited before copying it: press Edit file
and edit the file.
− Press Copy File.
The file is saved to the target folder.
3. If the file is (only) to be edited:
− Select a folder in the "Source" selection field.
− Select file.
− Press Edit file.
B836en 2017-11-17 Maintenance 4‐179

13. Diagnostics
13.1 Displaying all messages
All current messages are displayed. All messages can be filtered

by the type of message (alarms, warnings, messages).
1. Press Diagnostics and select "Pending messages".

2. To display the details of a message:
− Select message and press Message details.
− Select "Cause", "Effect", "Measure" or "Error location".
3. To end the display, Press Close.
13.2 Displaying all messages
All messages are displayed. Messages can be filtered out from

these messages according to message types and the period of
the message.
1. Press Diagnostics and select "Message history".

2. To filter out certain types of message, select "Alarms", "Warn-
ings", "Infos" or "Acknowledgeable messages".
3. To display the details of a message:
− Select message and press Message details.
− Select "Cause", "Effect", "Measure" or "Error location".
4. To update a message:
− Select message.
− Press Update message.
5. To end the display, Press Close.
4‐180 Diagnostics 2017-11-17 B836en

13.3 Displaying the software version
1. Press Diagnostics and select "Display version".

2. In the "Machine" field, select the machine type.
A table with all software versions will be displayed.
13.4 Display I/O monitor
The I/O monitor displays all of the machine's digital inputs and
outputs and the configured automation components.
1. Press Diagnostics and select "I/O monitor".

2. In the "Configuration" field, select Machine components.
The states of the inputs and outputs will be displayed.
B836en 2017-11-17 Diagnostics 4‐181

13.5 Logging the process data for service
purposes
To diagnose the ControlLine distance control, for service pur-

poses, a recording can be started.
1. Press Diagnostics and select "Manual functions".

3. Press "Record".
Recording starts.
4. After the end of the recording:
− Press the MACHINE ON/OFF button.
− Press the RESET button.
The machine is ready for operation.
13.6 Starting Teleservice
Teleservice are used to establish a connection between the

machine control and TRUMPF Technical Service. The customer
service employee can use Teleservice to localize problems and,
in some cases, to eliminate them directly.
The Teleservice for the machine and laser device is started via
the user interface of the machine control system.
Condition
■ For Teleservice via Internet: UDP Port 500 and
UDP Port 4500 permitted to access Internet over LAN.
Note
The teleservice session must be previously coordinated with
Technical Service.
Establishing the connection 1. Start the Teleservice via the machine's user interface:
− Press Diagnostics, select "Remote diagnostics".
− Press Execute.
or
Ø Start Teleservice via TOS:
− Press Trumpf Operating System.
− Press Start, Teleservice.
2. Press Connect.

pcANYWHERE starts and establishes the connection
between the machine control and the TRUMPF Telepre-
sence Portal.
Teleservice is active if, under "Telediagnostics status", the
state Program not in RAM changes to Wait for call.
When all status symbols are green, the connection has been
established.
One or more status symbols are red.
Ø In the case of "Default Gateway reachable", local network

settings at TRUMPF are faulty.
Ø In the case of "mGuard configured", Telepresence-Box
(mGuard) at TRUMPF defective.
Ø In the case of "VPN Tunnel established", check the fire-
wall configuration.
Ø In the case of "TRUMPF Telepresence Portal", the Tele-
presence Portal status at TRUMPF is faulty.
Ending the connection 3. Press Disconnect.

The connection is terminated.
4. To close the Telepresence portal:
− Press HMI.

13.7 Visual Online Support (VOS)
Visual Online Support The Visual Online Support (VOS) is a teleservice function. In
real time (instant messaging) image, audio and video can be
transmitted wirelessly in both directions between the customer
and TRUMPF Technical Service.
Images and audio are transmitted between the Technical Service
Telepresence Portal and the customer's tablet PC or smartphone
via the machine's local WLAN, the TRUMPF Wireless Operat-
ing Point.
After transmission, the image and audio material can be edited
and information can be added. This thus makes targeted instruc-
tions possible via image processing and audio analysis of
machines and automation components.
Note
In connection with a Basic service contract or within the war-
ranty period, Visual Online Support is free of charge.
Costs will arise for the user if there is no maintenance contract
and if support is required outside of the warranty.
Wireless Operating Point The Wireless Operating Point (WOP) is the machine's local
WLAN.
The tablet PC or smartphone are connected to the WOP via the
WLAN router in the machine's switch cabinet.
Note
The Wireless Operating Point has no connection to the
machine's network drives or to the customer's network.
VOS App The Visual Online Support function uses a tablet PC or a smart-
phone and the VOS app supplied by TRUMPF.
The VOS app can only access the machine's local WLAN
(WOP).
The VOS app is free of charge from Google Play and

Apple App-Store.
Tab. 4-47

Prerequisites Visual Online Support requires that the machine is equipped with
a TRUMPF Wireless Operating Point.
The user needs a tablet PC with a camera or a smartphone.

The following devices are supported:
■ An iPad Tablet with a camera or an iPhone iPhone (minimum
requirement: iOS version 7.0).
■ An Android Tablet PC with a camera or a smartphone (mini-
mum requirement: Android version 4.0).
Starting Visual Online Support
To start Visual Online Support, a teleservice date & time must

first be agreed with Technical Service.
For Visual Online Support, the following steps are required:

■ First, start the TRUMPF Telepresenc Portal on the machine.
■ When the connection has been established, start the
VOS app on the tablet PC or smartphone.
■ Then set up the connection between the VOS app and the
machine's WLAN (WOP).
■ As soon as the connection has been established, the user
can take & edit photos or videos or can speak to or chat
with the TRUMPF Technical Service employee. Images and
sound are transmitted synchronously. Images can be edited
both by the user as well as by technical service staff.
■ When the teleservice session is finished, end the connection
to the Telepresence Portal.
Conditions
■ At the machine:
− The Visual Online Support option has been installed.
− The machine is equipped with a WLAN router from
TRUMPF (Wireless Operating Point).
■ The VOS app has been installed on a tablet PC or smart-
phone.
Notes
■ The connection between the VOS app and the machine's
local WLAN (WOP) will be disconnected no later than one
hour after the telepresence connection has been closed and
each time that the machine is restarted.
■ The VOS app can be disconnected from the machine's
WLAN at any time.

Starting Teleservice 1. On the machine's user interface:
− Press Diagnostics, select "Remote diagnostics".
− Press Execute.
A new QR code will be generated each time that the Telepre-
senc Portals is started or after the machine has been
switched on.
QR code for Visual Online Support Fig. 78922
2. Press Connect.
If all of the symbols light up green, the connection between
the machine and the Telepresence Portal has been estab-
lished.
Establish a connection 3. Once the Teleservice connection has been established, start
between the VOS app and the VOS app:
the WOP.
Tap the TRUMPF icon in the tablet PC or smartphone.

VOS app menu Fig. 78923
4. Tap on Change Network.
5. If an Android tablet or Android smartphone is used: scan
the QR code on the machine.
By scanning the QR code, the connection between the
VOS app and the machine's WLAN (WOP) is started auto-
matically.
6. If an iPad or iPhone is used: scan the QR code on the
machine.
− To copy the password to the clipboard, tap on "Copy
passwort to clipboard".
− Tap on the "Settings" icon (gearwheel).
− Select the network name (SSID) of the machine.
− To paste the password from the clipboard, tap "Pass-
word", "Insert" and "Connect".
The connection between the VOS app and the machine's
WLAN (WOP) is started.
Using online support 7. Tap on New Session on your tablet PC or smartphone.

Once the green checkmark appears next to the TRUMPF
logo, the connection to customer service has been estab-
lished and data transmission is active.
8. While in contact with the customer service employee, photo-
graph the problem, film and discuss it.

VOS app menu "Image transmission" Fig. 78924
Close the teleservice 9. At the end, close the VOS app.

connection 10. On the machine's user interface, close the Telepresence por-
tal.
− Press Disconnect.
− Press HMI.
The teleservice connection will be closed.

14. Help
Online help The documentation for the machine can be called up as Online
help.
Displaying help text:

■ The display is opened using the button.
■ The display is reduced using the button.
Button Description
Search Search for a specific term in the online help.
The pages found are displayed in a list.
Double-click to open the desired page on the list.
Index Displaying index.
To jump to the desired page: double-click to open the
desired page.
Bookmark Insert a bookmark on the page opened.
The bookmarks are saved in sequence.
To open a page with bookmarks: double-click to open
the desired page.
Start page Open the start page of the online help.
Forward Displays the next page that has already been viewed.
Back Displays the previous page that has already been
viewed.
Functions in the online help Tab. 4-48
Programming instructions In the text editor, for all of the NC commands and cycles marked
for context-sensitive help in blue, context-sensitive help can be called up.
B836en 2017-11-17 Help 4‐189

14.1 Starting online help
1. Press Help.
2. In the "Area" selection field, select the respective instructions.
3. Open the chapter with and choose the section.
or
Ø Press Search.
− Enter search string.
− Press Apply.
or
Ø Press Index.
− Enter the index term.
− Press Apply.
The help text will be displayed.
14.2 Editing bookmarks
For quick access to select help subjects, the user can set and
then call "bookmarks".
Creating bookmarks 1. Start online help and open the subject or page.
2. Press Bookmark.
3. Press Add current page.
The bookmark will be created.
Calling up a bookmark 4. Press Bookmark.

5. Select bookmark.
6. Press Go to.
Jump to the selected page.
4‐190 Help 2017-11-17 B836en

14.3 Starting context-sensitive help
In the text editor, for all of the NC commands and cycles marked
in blue, context-sensitive help can be called up.
1. Select the NC program.

2. Press Edit.
4. Press Open.
5. In the selection field, select Programming instructions.
6. Select NC block. Put the cursor in front of the command
marked in blue.
The help text will be displayed to the left of the editor.
B836en 2017-11-17 Help 4‐191

15. Teachen
Risk of crushing and hitting during teaching!

WARNING
Ø During teaching, do not step on the rotational changer.
Ø During teaching, do not move between barrel and body of
machine.
Ø During teaching, do not touch area between surface of work-
piece and nozzle tip.
Ø While the program is running in test mode, keep sufficient
distance from the fixture.
Machining programs for 3D Machining programs that were created using the TruTops Cell
laser processing programming software are imported into the machine's control
and are usually executable and process-sure immediately,
depending on the complexity of the workpiece and the experi-
ence of the programmer. The NC program generated with Tru-
Tops Cell must be tested on the machine and, if need be, be
corrected by teaching with TruTops Cell Basic (option).
The corrections taught in this way are not lost. A taught or cor-
rected program can in turn be loaded into TruTops Cell and sub-
sequently edited.
Manual 3D programming If the user has no 3D programming software, the contour to be

machined must be programmed manually (taught).
Teaching means that the positioning information for the NC con-
trol is calculated for any contour by the step-by-step movement
and the saving of selected points (teaching points). During teach-
ing, any geometric contours as well as standard inner contours
(circle, elongated hole, rectangle, square) can be programmed.
The contour that is drawn or scribed on the workpiece is run
over visually and the teach points are recorded. The control sys-
tem uses the axis coordinates of the recorded teach points and
the interpolation mode to calculate the shape of the contour to
be machined. The control writes the positioning information in
the NC program and the operator supplements the required NC
cycles and technology parameters.
The respective processing optics that are later to be used for
machining are used for teaching. The teach points are applied in
the teach panel.
Workpiece and contour The contour that is to be machined must be drawn or inscribed
on the surface of the workpiece so that it is clearly visible. It is a
good idea to use a template to do this. The accurate identifica-
tion of contour transitions (e.g. the transition of an arc into a
straight line) makes it easier to establish teach points and
increases production accuracy.
4‐192 Teachen 2017-11-17 B836en

When recording a contour, it is important to observe the follow-
ing:
■ Always place the zero point at a distinctive position on the
workpiece or fixture which can be easily reached with the
TCP. The programs are then transferable.
■ Place the safety and loading positions outside of the work-
piece/fixture area in order to avoid a potential collision
between the processing optics and the workpiece/fixture.
■ Teach and cut inner contours before outer contours.
■ The cutting optics may not move over an already cut-out
contour during machining. The distance regulation regulates
the Z axis in the beam direction, in which case a collision
would occur.
■ Clearly mark contour transitions.
■ Ensure a constant machining speed. In order to avoid
scorching, the speed must be kept as constant as possible
during machining. For this reason, required compensation
motions of the B and C axes should be executed over longer
sections of travel.
■ Align the TCP at right angles to the workpiece surface. To
obtain a clean, high-quality cut (with the exception of inten-
tionally angled cuts), the processing optics must always be
aligned perpendicular to the workpiece surface during
machining.
■ To achieve a high level of machining accuracy and repeata-
bility, the workpiece must be positioned on the fixture, on
which it will later be machined using a fixed index point. The
fixture must be installed axially parallel to the work table.
B836en 2017-11-17 Teachen 4‐193

15.1 Teach panel
A holding magnet is on the rear of the teach panel.
1 Enable key left 4 Display

2 STOP button 5 Enable key right
3 Function key 6 6D mouse
Teach panel Fig. 69855
The teach panel is used for teaching 3D parts. The following

functions can be executed with the teach panel:
■ Manually move the machine axes in the teaching operating
mode or in jog mode.
■ Record teach points.
■ Execute all the functions that are relevant for teaching.
4‐194 Teachen 2017-11-17 B836en

Operating elements ■ STOP button: All axis movements are safely stopped by
pressing this button. After the axes are in the idle state, the
drives are de-energized. A machine stop is triggered.
■ Function key: By pressing a key, a function is requested or
a status is issued.
■ Display: Visualization of a pending or executed action.
■ Enable key on the left and the right of the housing: The
axes can only be moved if at least one of the enable keys is
kept pressed.
■ 6D mouse: The axes are moved with the 6D mouse.
Display In the display, pending actions as well as prompts in the form of

symbols are shown in real time. If an action has ended, the cur-
rent status will be shown two seconds per action.
The display always show the active interpolation type.
Function key Each function key is assigned one function. If the control issues
the enable, the function requested by the operator will be carried
out immediately.
The buttons with the blue LEDs show a status. The status can
be changed with the button or on the user interface in the >Pro-
gramming > Teaching menu.
Button Function Display screen

F1 The user can assign his own selected function to this
button (see "Configure the function for F1 and F2 but-
tons", pg. 4‐208).
Note: Special functions can be assigned to the button
for specific projects.
F2
H WORD Insert H word. The distance regulation moves the noz-

zle tip on the workpiece surface and measures the
nozzle distance when doing so. The measured nozzle
distance is added as H word in the current NC block.
B836en 2017-11-17 Teachen 4‐195

ZERO POINT Sets the zero point. The current axis coordinates are
set in the program with SET_G54 as zero point. There
are two ways of doing this. Which variant is used is
selected beforehand at the user interface in the
>Teaching > Settings menu.
■ Either: the first SET_G54 NC block is to be overwrit-
ten in an available program.
■ Or: a current position in the program is to be set
with SET_G54 workpiece zero point.
Notes:
■ Before the overwriting of the workpiece zero point,
the kinematic transformation is automatically acti-
vated should it not already be active.
■ The taught zero point is immediately effective.
MODE Select "Replace block" or "Add block". -
LED on: the current NC block is replaced.
LED off: a new NC block is added after the current NC

block.
BLOCK Select block sequence: single block of block-by-block. -

SEQUENCE
LED on: single block is active. Only one NC block is
processed at a time. To continue the program, the
START button must be pressed again after each NC
block.
LED off: block-by-block is active. All the NC blocks of a

program will be processed one after the other.
DISTANCE Distance regulation: switch on or off. -

CONTROL SYS-
LED on: distance regulation is active.
TEM
LED off: distance regulation is not active.
KSS LED flashes: the control waits for the confirmation by

the operator.
The fixture's clamping elements which are controlled by
the KSS only open or close after the operator presses
the button.
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STOP Pause RESET or program.
The active program is resumed by pressing the START

button at the interruption place or at the start of the
program.
■ If the STOP button is pressed once, the program
will be resumed at the interruption place.
■ If the STOP button is pressed twice, the program
will be resumed from the start of the program.
PLAY / START Start the program or continue after an interruption.
TEACH IN Add teach point with the current axis coordinates.

Note:
The interpolation type must be selected.
FLAG Set Flag. An NC block is written with the com-

ment ;TODO in the program at the current position.
If the button is pressed several times in succession in
the same NC block, the comment ;TODO is incre-
mented, e.g.: press twice ;TODO1, press three
times ;TODO2 and so on.
Note:
For postprocessing of the program, the com-
ment ;TODO can be replaced by "Search" and
"Replace" by another NC text, for example, by
TC_LASRER_ON.
AXIS GROUP Select the axis group for the 6D mouse. Depending on -
the setting selected here, single axes or several axes
will proceed with the 6D mouse.
The axis group Single, 3D or TOOL is previously
selected at the user interface.
Note:
The mode of operation of the 6D mouse depends on
the selected axis group: Operate 6D mouse.
Axis group 3D: Several axes are to be moved; for
example, select axis group XYZ.
Axis group Single: Only one axis is to be moved; for
example, select axis group X.
Axis group TOOL: The axes are to be moved in beam

direction or in the opposite direction.
The axes that have been moved are shown in color in

the display.
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INTERPOLA- Select interpolation type. -
TION
G01: Insert a straight line (default setting).
CIP: Insert arc. One after the other, starting point, inter-
mediate point, and end point are taught.
"Macro center". The R parameters R1 to R5 are

inserted into the current NC block.
"Macro help point". The R parameters R6 to R8 are

inserted into the current NC block.
Function keys Tab. 4-49
Selecting the axis group The axis group defines the mode in which the axes are to be
moved with the teach panel. An axis group can be one or more
axes.
The control differentiates between the following axis groups

whose mode is preset on the user interface:
■ Axis group Single: Only the axis moves that receives the
strongest deflection signal for the 6D mouse.
■ Axis group 3D: The selected axes move synchronically.
■ Axis group TOOL: Move the linear axes in beam direction or
in the opposite direction. The orientation of the B and C axes
remain unchanged during this.
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Operate 6D mouse The 6D mouse uses an optical sensor to control the NC axes.
Individual axes or axis groups are moved by deflection of the
sensor.
The speed at which the axes move depends on whether one or

both enable keys are pressed.
■ If one enable key is pressed, the axes move slowly.
■ If both enable keys are pressed, the axes move faster.
The 6D mouse is manually pushed, pulled or turned in the direc-

tion in which the axis is to be moved.
Axis group In direction Deflection

Axis group Single X+ Push the 6D mouse to the left.
X- Push the 6D mouse to the right.
Note Y+ Pull the 6D mouse forwards.
If the kinematic transformation is Y- Push the 6D mouse backwards.
active, the other axes make com-
Z+ Pull the 6D mouse up.
pensating movements around the
tool center point. Z- Push the 6D mouse down.
B+ Tilt the 6D mouse to the left.
B- Tilt the 6D mouse to the right.
C+ Turn the 6D mouse counterclockwise.
C- Turn the 6D mouse clockwise.
Axis group 3D in PLUS Diagonally pull the 6D mouse forwards.
in MINUS Diagonally push the 6D mouse backwards.
Axis group TOOL in direction of Pull the 6D mouse up.
the beam
opposite to the Push the 6D mouse down.
direction of the
beam
Operating the axes with the 6D mouse Tab. 4-50
B836en 2017-11-17 Teachen 4‐199

Fig. 69856
Note
If the 6D mouse is pushed diagonally, the axes move synchro-
nously if "3D" is selected as the axis group.
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15.2 Description of the user interface
This dialog opens if Teachen operating mode is selected:
1 Active "axis group" 6 Active "interpolation" 10 Program status

2 "Single block" on/off 7 "Display" selection field 11 Context buttons
3 "Transformation" on/off 8 Axes actual position 12 "Geometry deviation display"
4 "Replace block" on/off 9 Active axes 13 NC editor
5 "ControlLine" on/off
Teaching user interface Fig. 69858
B836en 2017-11-17 Teachen 4‐201

Program status symbols Symbol Description
Marks an interruption place or a re-entry place:
■ Interruption place: the program stops at the marked NC
block.
■ Re-entry place: the program can be continued at the
marked NC block with START.
By tapping on any NC block, the position for the re-entry
in the program can be selected.
Note:
The NC blocks before the marked NC block are run
through in simulation when a program is started. Starting
from the marked NC block, all following NC blocks are
actually executed.
Marks the current NC block.
Program status symbols Tab. 4-51
Context button Depending on the context, the following buttons will be shown:
Button Description
Stop Stop the program.
Play / Start Starts the program or continues the program after an interruption.
Note
The program does not need to be saved beforehand.
Inserting points Inserts the teach point.
Action Another button bar is opened in which the other buttons can be supplemented for
project-specific actions or user-defined MACROS.
Cycles "Cycles editor" is opened. The following actions can be performed:
■ Selection of NC cycles, parameter input and transfer into the program.
■ Selection of laser technology table (LTT).
Settings The "Settings" dialog box is opened. The following settings can be configured:
■ Select editor functions.
■ Activate and rename axes. Define the number of digits after the decimal point.
■ Define the thresholds for the error indicator of the distance regulation ControlLine.
Save The current program is saved in "internal management".
Notice!
If "No" is pressed for saving, all changes made since the last saving will be lost.
ControlLine calibration Record characteristic curve for distance control.
Setting the zero point Set the zero point: the current actual coordinates are set with SET_G54 as zero
point in the program.
■ Either: overwrite the first SET_G54 block.
■ Or: set the zero point at the current position in the NC program.
H word Insert the H word: the nozzle distance measured with the distance regulation is writ-
ten as H word in the current NC block.
Automatic orientation Align the TCP perpendicular to the workpiece surface (AUTO_ORI).
Technology The "Technology selection" dialog box is opened. Select the laser technology table
and save in the current cycle or as variable in the program.
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Teach functions buttons The function of the following buttons is identical with the func-
tions of the corresponding button on the Teachpanel.
Button Display functions

"Axis group" Single Select the axis group.
3D
TOOL
"Single block" Single block active.
Block-by-block active.
"Transformation" Kinematic transformation activated

(WKS)
Kinematic transformation deacti-
vated (MKS)
"Replace block" Replace the marked NC block.
Insert new NC block.
ControlLine Distance regulation switched on.
Distance regulation switched off.
Buttons for teach functions Tab. 4-53
15.3 Activating TEACHIN operating mode
The axes can be moved with open protective devices using the
teach panel in jog mode in the TEACHIN operating mode.
The following functions are activated automatically in teach

mode:
■ The laser automatically switches to LASERTEST: The shutter
switch of the installed light path (LLK) is disabled.
■ The axes can only be moved with the teach panel if at least
one of the enable keys is pressed.
■ The axes move at a safely reduced speed.
■ Automatic movements of a device controlled via the KSS are
only executed after the KSS key on the teach panel has
been pressed Function key or the corresponding warning
message has been acknowledged on the user interface.
Conditions
■ TEACHIN key is present.
1. Set the TEACHIN key-operated switch at the control panel to

"ON".
B836en 2017-11-17 Teachen 4‐203

2. Press Programming; select "Teaching".
3. Press the enable key on the teach panel.
Only after the enable key has been pressed once is the
TEACHIN operating mode activated.
15.4 Starting online help
The machine's programming manual can be displayed as online

help.
Ø Select Programming manual in the "Display" selection field.

The complete programming manual is shown.
Tip
Besides this activation of the online help, there is a further con-
text-sensitive access for the processing of NC cycles in the
"Cycles editor" (see "Insert and process cycles", pg. 4‐225).
15.5 Setting basic functions
The settings described below are valid for teach mode and are
selected on the user interface. They are active in all programs.
Automatically replacing the zero point
When setting the zero point, the first SET_G54 NC block should
be overwritten in the current axis coordinates in the NC program.
If the following conditions are present, then this setting should

not be selected:
■ For processing in two-station operation.
■ If there are several zero points in the program.
Note
If the automatic zero point search has not been activated, then
the zero point is inserted at the current place in the program
with the SET_G54 cycle.
1. Press Settings.
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2. At the "Editor" tab: activate "Automatic zero point search dur-
ing replacement".
3. Press OK.
The selected setting is effective immediately.
Activate the imperial (inch) measuring

system
Axis coordinates can be recorded and displayed during teaching

as inch values.
Notes
■ The control (always) calculates internally in the control sys-
tem measuring system.
■ The processing of the NC blocks depends on which measur-
ing system has been programmed: G70 (inch programming)
or G71 (metric programming).
1. Press Settings.
2. At the "Editor" tab: activate "Record and display axis coordi-
nates in the imperial (inch) measuring system".
3. Press OK.
The taught coordinates are recorded and displayed as inch val-
ues.
Activate and set the NC axes
At the "Axes" tab, the axes are activated whose coordinates are
to be recorded during teaching. The user can select the following
settings for the coordinate output in this menu:
■ Activate or deactivate the axes. For deactivated axes, no
axis coordinates are recorded and output in the program.
■ Issue project-based names. The entered name is output in
the program. The axis name that deviates from the standard
is marked in orange in the axis actual display.
■ Define interpolation parameters for individual axes.
■ Select the number of digits after decimal point for the coordi-
nates output.
Note
An R parameter must be selected for the X, Y and Z axes.
B836en 2017-11-17 Teachen 4‐205

1 Active axes 3 R parameter "Main axes"
2 "Adapt axis names" 4 Number of "Digits after decimal
point"
Activating and managing NC axes Fig. 71168
1. Press Settings.
2. Select the "Axis" tab:
− Activate or deactivate the axes.
− If need be, enter the axis names.
− Select the settings for "Main axes" and "Number of digits
after decimal point".
3. Press OK.
Setting threshold values for determination

of the geometry deviation
A possible geometry deviation of the loaded workpiece compared

to the programmed contour can be recorded with the distance
regulation. While the contour is being moved along, the distance
regulation keeps the nozzle distance consistent and visualizes
the axis correction in beam direction.
At the "Threshold values" tab, the permitted threshold values can

be entered for the checking of geography deviation:
■ The "Warning level geometry deviation" parameter defines at
which nozzle distance the lower tolerance limit has been
reached.
■ The "Error level geometry deviation" parameter defines at
which nozzle distance the permissible tolerance limit has
been reached.
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If the value 0 has been entered for both parameters, the signal
display is deactivated.
The geometry deviation should be checked in the following

cases:
■ To run in a new workpiece
■ For a batch change
■ For frequent nozzle collision
The measurement results are shown on the user interface by

signal colors as well as measured values.
1 Geometry deviation visualization 2 Measured deviation in beam

direction
Geometry deviation display Fig. 71170
Signal color Description

Green The measured geometry deviation is within the per-
missible tolerance.
Yellow The measured geometry deviation has reached the
threshold value (warning level).
Red The measured geometry deviation is outside the per-
missible tolerance. Check what the cause for this is.
Geometry deviation signal colors Tab. 4-54
The geometry deviation is also visualized in the display of the

teach panel. If the threshold value is exceeded, a vibrator that is
integrated in the teach panel will be activated for a few seconds.
Display screen Description

Geometry deviation function is not active.
The measured geometry deviation is within the per-

missible tolerance.
B836en 2017-11-17 Teachen 4‐207

Display screen Description
The measured geometry deviation has reached the
threshold value (warning level). The workpiece surface
is lower in the beam direction than the programmed
contour.
The measured geometry deviation has reached the

threshold value (warning level). The workpiece surface
is higher in the beam direction than the programmed
contour.
The measured geometry deviation is outside the per-

missible tolerance. The workpiece surface is lower in
the beam direction than the programmed contour.
The measured geometry deviation is outside the per-

missible tolerance. The workpiece surface is higher in
the beam direction than the programmed contour.
Teach panel display screen Tab. 4-55
1. Press Settings.
2. Select "Threshold values".
3. Enter threshold values for the "Warning level" and "Error
level" parameters.
4. Press OK.
Configure the function for F1 and F2

buttons
Users can configure the functions for the F1 and F2 keys them-
selves. No functions are assigned to these keys in the factory.
The following functions can be selected by the user:
■ NC cycles: The user can assign the F1 key with a selection
of NC cycles (see "Configure the cycle selection for the F1
key", pg. 4‐209).
■ Automatic orientation: align perpendicular to the workpiece
surface (AUTO_ORI).
■ ControlLine calibration: Record characteristic curve for dis-
tance regulation.
■ Transformation: Switching the Kinematic transformation on or
off.
The selected functions are visualized and immediately performed
by pressing the buttons in the teach panel display. The key
assignment is self-holding until a new selection has been made.
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Each key can only be assigned one function. Different functions,
except for the NC cycles, can be selected for keys F1 and F2,
for example: Transformation for the F1 key and ControlLine cali-
bration for the F2 key.
Pre-assignment Fig. 75651
1. Press Settings.
2. Select "F key" tab.
3. Either
Ø Open the "F1 key" selection list and select function.
or
Ø Open the "F2 key" selection list and select function.
4. Press OK.
The key assignment is immediately effective.
Configure the cycle selection for the F1 key
The user can select the enabled cycles in the cycle editor in
order to assign this function to the function key F1.
After selection of the cycle with the F1 key, the F2 key is used
to insert the cycle at the current position in the NC program.
Note
Before every NC cycle, only one parameter configuration can be
saved. If cycle parameters have to be changed, then the most
recently saved parameters are overwritten.
Adding cycle from the 1. Press the Cycles button.

selection list for the F1
The cycles editor is opened.
button
B836en 2017-11-17 Teachen 4‐209

2. Select the cycle and press Add to F1.
3. Press Cancel.
Assigning cycle to button F1 4. Press Settings.

6. In the "F1 key" selection list, select NC cycles.
7. Select the desired NC cycle to be assigned to the button. If
necessary, edit the transfer parameters.
8. Press OK.
The selected cycle can be selected with the F1 button immedi-
ately and inserted in the program with the F2 button.
Delete the configuration for the F1 key
The configured NC cycles can be deleted again in the cycle

selection for the F1 key.
Fig. 75652
1. Press Settings.
3. Open the "F1 key" selection list and select NC cycles.
4. Mark the cycle that is to be deleted.
5. Press Remove cycle.
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15.6 Recording teach points
Note
The interpolation type can be selected on both the teach panel
as well as on the user interface.
Teach points When teaching a path, individual path points are approached
with the machine axes. The paths between two path points are
interpolated by calculation. Here, different types of interpolation
can be selected.
The control calculates the contour path by recording individual
teach points (axis coordinates) in combination with the selected
interpolation type.
The start point for all interpolation types is the respectively cur-
rent axis position.
The individual teach points must be recorded in a specified order

according to the contour and interpolation mode (movement
type). The following interpolation types are possible:
■ Straight line end point (G01).
■ Help point and end point of an arc (CIP)
■ Macro center as measuring point or as center of a standard
inner contour.
■ Macro help point as measurement point or as help point for
a standard inner contour.
Note
Usually, teaching is done with the active kinematic transfor-
mation (synonymous with 5-axis transformation). The kine-
matic transformation must be activated manually.
Teaching a straight line
A straight line is defined – starting at the start position – by a

point set in the direction of travel (straight line end point).
The current position of the axes marks the beginning of the
straight line. The end point of the straight line is taught as a
point and written into the program with the G01 motion block.
B836en 2017-11-17 Teachen 4‐211

Condition
■ Kinematic transformation is active.
Note
The interpolation type G01 is the default status. G01 are active
until another interpolation type is selected.
1. Move the TCP from the start point to the end point of the
straight line.
2. If G01 is not active: select G01 interpolation type.
3. Press TEACH IN button.
An NC block is inserted at the current position in the program
with the G01 command: G01 X = ... Y = ... Z = ... B = C = ...
Teaching the arc with CIP
An arc is defined by the start position, any help point and the
end point. The help point must be on the arc.
The arc is calculated with the CIP circular interpolation.
Condition
1. Approach help point on the arc.

2. Select the CIP help point interpolation type.
An NC block is inserted with the CIP command and the inter-
polation parameters I1, J1 and K1:
CIP I1 = .. J1 = .. K1 = ..
4. Approach the arc end point.
The current NC block with CIP is supplemented with the axis
coordinates of the end point:
CIP I1 = .. J1 = .. K1 = .. X = .. Y = .. Z = .. B = .. C = ..
Tip
The help or end point can be individually corrected by reteach-
ing. (see "Correct path", pg. 4‐229)
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Teaching the macro center
The "macro center" interpolation type is used to teach a contour

center, for example, a circle or a rectangle center or a
measuring point.
Condition
R parameter Coordinate
R1 X axis
R2 Y axis
R3 Z axis
R4 B axis
R5 C axis
Center coordinates Tab. 4-56
1. Approach point.
2. Select the "Macro center" interpolation type.
An NC block is inserted in the current position in the program
with the center coordinates R1 = .. R2 = .. R3 = .. R4 = .. R5
= ...
Tip
The center can be corrected by reteaching. (see "Correct path",
pg. 4‐229)
Teaching macro help point
The "Macro help point" interpolation type is used to insert a help

point which, for example, can be used for the following function:
■ For the calculation of the position and direction of standard
inner contours: square, oblong hole and rectangle.
■ For calculation of measurement functions.
Condition
R6 X axis
R7 Y axis
B836en 2017-11-17 Teachen 4‐213

R8 Z axis
Help point coordinates Tab. 4-57
1. Approach help point.

2. Select "Macro help point" interpolation type.
An NC block is inserted at the current position in the program
with the help point coordinates R6 = .. R7 = .. R8 = ...
Tip
The help point can be corrected by reteaching. (see "Correct
path", pg. 4‐229)
Teaching circular contour
These circles are programmed using the TC_CIRC2 NC cycle.

The cycle switches the laser beam on and off.
A circle is defined by the coordinates of the center point as well
as the corresponding transfer parameters.
Condition
Note
Parameter definition; see online help.
Teaching the center 1. Approach the center of the contour.

An NC block is inserted in the current position in the
program with the center coordinates R1 = .. R2 = .. R3 = ..
R4 = .. R5 = ...(see "Teaching the macro center", pg. 4‐213)
Inserting and editing the 4. Press Cycles.

TC_CIRC2 cycle 5. In the cycle editor, select cycle TC_CIRC2 at path 'Lasersch-
neiden'.
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Parameter input TC_CIRC2 Fig. 71602
6. Enter transfer parameter (mandatory parameter) and correc-

tion parameters (optional parameters).
7. Press OK.
Two NC blocks are inserted in the program at the current posi-

tion with the command TC_CIRC2:
R11 = 0.000 R21 = 0.000 R22 = 0.000 R23 = 0.000 R24 = 0.000 R26 =
0.000 R27 = 0.000 R28 = 0.000
TC_CIRC2 (20.000, 2.000, 0.500, 1, 10, 100, TM_LTTNAME)
Tab. 4-58
Tip
The center coordinates can be corrected by reteaching. (see
"Correct path", pg. 4‐229)
Teaching a rectangle contour (square)
Rectangles or squares are programmed using the NC cycle

TC_RECT2. The cycle switches the laser beam on and off.
A rectangle or square is defined by the coordinates of the center
point, the help point and the corresponding transfer parameters.
Condition
Note

B836en 2017-11-17 Teachen 4‐215

Teaching help point 4. Approach contour's help point.

An NC block is inserted at the current position in the pro-
gram with the help point coordinates R6 = .. R7 = .. R8 = ...
(see "Teaching macro help point", pg. 4‐213)

TC_RECT2 cycle 8. In the cycle editor, select cycle TC_RECT2 at path 'Lasersch-
neiden'.
Parameter input TC_RECT2 Fig. 71603

10. Press OK.

tion with the command TC_RECT2:
R11 = 0.000 R21 = 0.000 R22 = 0.000 R23 = 0.000 R24 = 0.000 R26 =
0.000 R27 = 0.000 R28 = 0.000
TC_RECT2 (1.000, 2.000, 2.000, 0.500, 0.500, 1, 10, 100,
TM_LTTNAME)
Tab. 4-59
Tip
The center and help point coordinates can be corrected individu-
ally by reteaching. (see "Correct path", pg. 4‐229)
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Teaching oblong hole
An oblong hole is programmed using the TC_OBLONG2 NC

cycle. The cycle switches the laser beam on and off.
The oblong hole is defined by the coordinates of the center
point, the help point and the corresponding transfer parameters.
Condition
Note

Teaching help point 4. Approach contour's help point.

(see "Teaching macro help point", pg. 4‐213)

TC_OBLONG2 cycle 8. In the cycle editor, select cycle TC_OBLONG2 at path 'La-
serschneiden'.
Parameter input TC_OBLONG2 Fig. 71604

B836en 2017-11-17 Teachen 4‐217

10. Press OK.

tion with the command TC_OBLONG2:
R11 = 0.000 R21 = 0.000 R22 = 0.000 R23 = 0.000 R24 = 0.000 R26 =
0.000 R27 = 0.000 R28 = 0.000
TC_OBLONG2 (1.000, 2.000, 2.000, 0.500, 0.500, 1, 10, 100,
TM_LTTNAME)
Tab. 4-60
Tip
The center and help point coordinates can be corrected individu-
ally by reteaching. (see "Correct path", pg. 4‐229)
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15.7 Creating new program
Generally, a processing program for a 3D contour is created with

a programming system, for example, with TruTops Cell.
If no 3D programming system is available, the contour can be
manually programmed by teaching.
Creating a new program

3. Press New.
4. Enter the program name.
5. Press OK.
A new program is created with the following Header:
N100 ;$ProgramName$
N110 ;------ TruLaser Cell 8030
;insert variable
N120 TC_RESET Revert
N130 G71 Metric programming
N140 TC_USERDYN(4.0,4.0); OVL, Set the calculation factor;
ACC make a selection
Note:
TC_USERDYN is only evalu-
ated if
TC_DYNAMIC_LEVEL(1) is
programmed.
N150 TC_DYNAMIC_LEVEL(0)
N160 TC_OST(5.0)
N170 TC_ADC_ON(10) Activate ADC axis
N180 TRAORI(1) Switch on transformation
N190 TC_LASER_REQUEST(1) Request laser in the network
N200 SET_G54( 0.00, 0.00, 0.00, Setting the zero point
0,0,0 )
N210 ; TM_LTTNAME = "????" Define table name
N220 F = 173000 Feed Rate
N230 ;GOTOF ENTRY_LASER
N240 TRAFOOF Switch off transformation
N250 G500 Activate machine zero point
N260 G01 Z = 600.00 F = 173000 Define safety position
N270 G01 B = 0.00 C = 0.00 Align the B and C axes
N280 TRAORI(1) Switch on transformation
N290 G54 Setting the zero point
B836en 2017-11-17 Teachen 4‐219

N300 ; END_OF_HEADER
N310
N320 M00 Program stop
;insert contour machining
N330
N340 ; END_OF_PROGRAM
N350 TC_LASER_OFF(2) Switching off the laser
N360 TC_RESET Revert
N370 M30 End of main program
Standard program Tab. 4-61
6. Afterwards: Activate teach mode, teach the zero point and

then teach the contour.
Setting the zero point
A zero point is set for the current axis position. The current axis
coordinates are written in the program with the SET_G54 cycle.
The zero point offset is immediately effective.
Condition
Notes
■ The zero point is always taught with active transformation.
■ If the zero point that is available in the program is to be
used, then the "Automatic zero point search during replace-
ment" must be activated in the >Settings > Editor menu.
1. Move the TCP to zero point position

2. Switch on the distance regulation system.
3. On the teach panel Press the ZERO POINT button.
Zero point is set with SET_G54. The zero point offset is immedi-
ately active.
Approach edge incrementally.
A possible variant is described below how a workpiece edge

(inner or outer) can be incrementally approached with the laser
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beam switched on. To approach the workpiece edge, two teach
points are set and the macro EDGE_APPROACH is inserted:
■ The Macro center defines the position on the workpiece sur-
face where the distance regulation is switched on and the
contour machining started.
■ The Macro help point defines the laser ignition position
beyond the workpiece surface. The laser is switched on by
laser method 12 (cutting without distance regulation).
During the machining, the workpiece edge is approached as fol-

lows:
■ First, approach the taught macro center above the workpiece.
■ Then, the TC_SHEET_THICK cycle is applied to approach
the tool center point with distance regulation in the beam
direction. The Z axis moves to the nozzle distance (synonym:
cutting distance) programmed in the LTT.
■ Then the axes move from the center macro to the taught
macro help point outside the workpiece surface (in the beam
direction, offset to the macro center).
■ Outside the workpiece surface, the laser is switched on, the
distance regulation remains switched off.
■ The macro center is approached with the laser beam
switched on (but without distance regulation).
■ Once the macro center is reached, the distance regulation is
switched on. The contour machining starts.
Condition
Teaching the macro center 1. Switch off the distance regulation.

2. Approach the position on the workpiece surface at which the
distance regulation is to be switched on during the machin-
ing.
R4 = .. R5 = ...
Teach macro help point 5. Approach the laser ignition position outside the workpiece
surface.
Insert the macro "Approach 8. Press Cycles.

edge incrementally"
B836en 2017-11-17 Teachen 4‐221

9. Select EDGE_APPROACH macro at the path 'Laserschnei-
den' in the cycle editor.
The following NC blocks are inserted at the current position:
TC_SHEET_THICK (TM_LTTNAME)
G01 X=IC(R6-R1) Y=IC(R7-R2) Z=IC(R8-R3)
TC_LASER_ON (12,TM_LTTNAME,0,100)
G01 X=IC(R1-R6) Y=IC(R2-R7) Z=IC(R3-R8)
TC_LASER_ON (11,TM_LTTNAME,0,100)
Tab. 4-62
Result of the programming:
... ...
... ;approach edge incrementally
N .. R1 = ... R2 = ... R3 = ... R4 Center coordinates
= ... R5 = ...
N .. R6 = ... R7 = ... R8 = .. Help point coordinates
N .. G01 X=R1 Y=R2 Z=R3 B=R4 Approach center coordinates
C=R5
N .. TC_SHEET_THICK The distance regulation is
(TM_LTTNAME) switched on. The TCP moves
to the cutting distance pro-
grammed in the LTT. As soon
as the cutting distance has
been reached, the distance
regulation is switched off.
N .. G01 X=IC(R6-R1) Y=IC(R7-R2) Approach the laser ignition
Z=IC(R8-R3) position outside the workpiece
at sheet height (corresponds to
the help point)
N .. TC_LASER_ON Switch on laser (without dis-
(12,TM_LTTNAME,0,100) tance regulation)
N .. G01 X=IC(R1-R6) Y=IC(R2-R7) Approach center coordinates
Z=IC(R3-R8) without distance regulation at
sheet height
N .. TC_LASER_ON Switching on the distance reg-
(11,TM_LTTNAME,0,100) ulation
Tab. 4-63
Tip
The R parameter values for help and center can be corrected, if
need be. (see "Correct path", pg. 4‐229)
4‐222 Teachen 2017-11-17 B836en

Incorporating the contour
If there is still no programmed tool path or an NC program, the

contour must be completely re-taught. To do this, it is necessary
to precisely draw the contour on the workpiece.
Conditions
■ Zero point is set.
Notes
■ Recommendation: to prevent a collision of the processing
optics with the workpiece or with the fixture, a suitable safety
position should be taught before the first contour is
approached.
■ For the teaching of a new contour: deactivate "Replace NC
block" mode.
■ The procedure described below is meant as an example.
The contour is recorded in the order of the subsequent process-

ing sequence: first the inner contours are taught, then the outer
contour.
A Workpiece zero point 7 End point of straight line

1 Safety position 8 End point of straight line
2 Circle center 9 Arc help point
3 Rectangle center 10 Arc end point
4 Rectangle help point 11 End point of straight line
5 Outer contour starting point 12 End point of straight line
6 End point of straight line 13 Contour machining end point
Example of recording contour Fig. 71599
Teaching safety position 1. Approach suitable safety position.
B836en 2017-11-17 Teachen 4‐223

2. Record a teach point with the G01 interpolation type.
Teaching circular contour 3. Approach the center of the circular contour.

4. Select the Makro Mittelpunkt interpolation type and record a
teach point.
5. Either now or later: insert the TC_CIRC2 cycle and process
the parameter.
Teaching the rectangle 6. Approach the center of the rectangle contour.

contour 7. Select the Makro Mittelpunkt interpolation type and record a
teach point.
8. Approach the help point of the rectangle contour.
9. Select the Makro Hilfspunkt interpolation type and record a
teach point.
10. Either now or later: insert the TC_RECT2 cycle and process
the parameter.
Teaching the outer contour 11. Approach outer contour and record the teach points for the
switching on of the distance regulation and the laser beam.
12. Approach the first end point of the straight line (pos. 6) and
record a teach point with the G01 interpolation type.
13. Approach the second end point of the straight line (pos. 7)
and record a teach point with the G01 interpolation type.
14. Approach the third end point of the straight line (pos. 8) and
15. Approach the help point on the arc (pos. 9) and record a
teach point with the "CIP help point" interpolation type.
16. Approach the end point on the arc (pos. 10) and record a
teach point with the "CIP end point" interpolation type.
17. Approach the end point of the straight line after the arc
(pos. 11) and record a teach point with the G01 interpolation
type.
18. Approach the next end point of the straight line (pos. 12) and
19. Approach the outside end point of the straight line (pos. 13)
and record a teach point with the G01 interpolation type.
The contour is completely recorded. The operator inserts the
required NC cycles. Thereafter, the program must be tested and,
if necessary, corrected.
15.8 Editing a program
The NC text can be expanded or edited as desired in an existing

or newly created program in the NC editor.
■ Manually edit NC texts.
■ Insert and process NC cycles.
4‐224 Teachen 2017-11-17 B836en

■ Select and replace laser technology tables.
■ Supplement block numbering.
Searching and replacing NC text
During teaching, a comment (;TODO ;TODO1 etc.) can be

inserted, for example, by pressing the FLAG button.
Regardless of this, any NC text can be replaced by search and
replace.
1. Select Search and replace in the "Display" selection field.

2. Enter the NC texts in the "Search for" and "Replace with"
input fields.
For example, the comment ;TODO is to be replaced by an
M00 program stop.
3. Optionally, the "Search direction upwards" can be activated.
4. Either
Ø Press Replace.
or
Ø Press Replace all.
NC text is replaced.
Insert and process cycles
The cycle editor is split up into function groups, such as 'Prog-

rammablauf', 'Laserschneiden', 'Positionieren' etc. At the respec-
tive path, the NC cycles are summarized that belong functionally
to this group.
The associated cycle description is automatically shown as
online help for a marked cycle.
Notes
■ If the marked NC block is to be replaced: activate the
"Replace block" function.
■ If a new NC block is to be inserted: deactivate the "Replace
block" function.
■ Regardless of the NC cycle, any NC text can be edited,
replaced or deleted.
1. Either
Ø Mark the NC block that is to be modified.
B836en 2017-11-17 Teachen 4‐225

or
Ø Mark the NC block after a new NC block has been
inserted.
2. Press Cycles.
3. Select function group and mark the cycle; e.g.: select 'La-
serschneiden' and TC_LASER_ON.
NC cycle parameter input TC_LASER_ON Fig. 71593
4. Process cycle parameters.

5. Press OK.
The cycle is inserted as its own NC block:
TC_LASER_ON(1, TM_LTTNAME, 10, 100).
Select value for the name variable laser

technology table.
The TM_LTTNAME variable is generally assigned a "table name"

value at the program start. The table is effective in all cycles in
which this variable is programmed.
During the course of the program, the variable can be assigned
a new value again and again.
1. Either
Ø Paste TM_LTTNAME = "????" NC block.
or
Ø Mark TM_LTTNAME = "????" NC block.
2. Press Cycles.
3. In the cycle editor, select the TM_LTTNAME variable at the
'Laserschneiden' path.
4. Press Technology.
5. Select the "LTT" tab.
6. Activate "TM_LTTNAME".
7. Select table and press Apply.
8. Press OK.
Either a new NC block with the variable table name is inserted,
e.g.: TM_LTTNAME = "123456".
4‐226 Teachen 2017-11-17 B836en

Or the TM_LTTNAME = "????" NC block is supplemented with
the table name.
Selecting the laser technology table
Alternatively to programming a variable for the table name, the

name of the laser technology table can be programmed directly
in the NC cycle.
1. Mark the NC block in which the table name is to be supple-

ments or changed.
2. Press Cycles.
3. Press Technology.
4. Select the "LTT" tab.
5. Activate "Specific".
6. If need be, a filter can be set.
7. Select table and press Apply.
8. Press OK.
The table name is supplemented in the cycle.
Inserting block numbering
If the processing of the program has been completed, a continu-

ous block numbering can be inserted for all NC blocks.
1. Select Number in the "Display" selection field.

2. Enter the "Start number" and "Increment" for the block num-
bering.
3. If the commented out NC blocks are also to be numbered:
activate "With comment"
4. Press the Numbering button.
All NC blocks receive a block number.
15.9 Testing and correcting the program
Each new workpiece must be "run-in" on the machine. This

includes testing and correcting the programmed tool path and
transfer path, checking for collisions, checking workpiece geome-
try and the insertion or correction of process parameters.
B836en 2017-11-17 Teachen 4‐227

A program created by teaching or with a 3D programming sys-
tem program must be tested on the machine with the workpiece
and, if necessary, be corrected.
■ Correct the zero point.
■ Correct individual teach points.
■ Correct R parameter.
■ Insert H words.
■ Insert additional path and transfer points.
Correcting the zero point
A zero point that is present in the program should be corrected.
Condition
1. Either
Ø If the first zero point that is present in the program is to
be corrected:
− In the >Settings > Editor menu: activate "Automatic zero
point search during replacement".
or
Ø If another zero point present in the program is to be cor-
rected: deactivate "Automatic zero point search during
replacement".
− Activate "Replace block" mode.
− Mark the NC block that is to be replaced.
2. Move the TCP to zero point position
3. Switch on the distance regulation system.
4. Either
Ø On the teach panel Press the ZERO POINT button.
or
Ø On the control panel:
− Press Actions.
− Press Set zero point.
The zero point coordinates are corrected. The zero point offset is
immediately effective.
Inserting H word
By inserting a H word, a nozzle distance can be programmed

block-by-block that varies from the laser technology table.
4‐228 Teachen 2017-11-17 B836en

1. Mark NC block.
2. Either
Ø At the teach panel: press the H WORD button.
or
Ø On the control panel:
− Press Actions.
− Press H word.
An H word is supplemented in the marked NC block.
3. To activate the H word, press the ENABLE KEY.
The TCP moves to the sheet surface and measures the nozzle
distance.
Correct path
A programmed tool path can be corrected by TruTops Cell Basic

(option) or also by reteaching.
Condition
Note
If a new NC block is to be inserted: deactivate the "Replace
block" mode.
If an available NC block is to be overwritten: activate the
"Replace block" mode.
Correct the R parameter 1. Position the TCP.

2. Mark NC block with R parameters.
3. Either
Ø Select the "Macro center" interpolation type.
or
Ø Select "Macro help point" interpolation type.
The R parameters of the marked NC block are overwritten.
Correcting the available 5. Activate "Replace block" mode.

teach point 6. For example, move the TCP to the NC block to be changed
in the single block mode.
7. Select the G01 interpolation type.
B836en 2017-11-17 Teachen 4‐229

Press TEACH IN button.
Overwrite the marked NC block with the current axis coordi-
nates.
Inserting teach points 8. Deactivate the "Replace block" mode.

9. Position the TCP to, for example, insert a transfer point
between two contours.
10. Select the G01 interpolation type.
Press TEACH IN button.
A new NC block is inserted at the current position.
Save changes 11. Press Save.

The program is saved in the 'Inneren Verwaltung'.
Testing the program
The program can be tested in "Single block" mode or in "Block-

by-block" mode:
During the test run, the geometry deviation between the pro-
grammed contour and the actual workpiece geometry can be
checked at the user interface.
Conditions
■ Program has been created.
■ The workpiece zero point has been corrected.
Notes
■ As long as the program is active, it cannot be processed in
the NC editor.
■ Start the program in single block mode with the teach panel
during the first test run.
■ Before testing, save the program.
Risk of injury while a program is being tested, especially if

WARNING the clamping elements open and close a fixture.
Ø While a program is being run in test mode, keep sufficient
distance to the fixture.
Ø Do not step between the machine body and the barrel while
a program is being run in test mode.
1. Reduce the feed rate at the potentiometer to about 10%.

2. Either
4‐230 Teachen 2017-11-17 B836en

Ø Position the TCP at the contour start.
or
Ø Position the cursor in the NC editor at the program start.
3. Starting the program
Ø On the teach panel Press the START button.
or
Ø On the control panel: Press Start.
The program will run through in single block or in block-by-
block.
Note
If No is pressed in the "Save" dialog box, all changes made
since the last saving will be lost.
4. If the program is completely tested and corrected: Press
Save.
The program is saved in the 'Inneren Verwaltung'.
B836en 2017-11-17 Teachen 4‐231

4‐232 Teachen 2017-11-17 B836en
Chapter 5
Setting work
Safety notes 5‐3
1 Overview of setting work 5‐4

1.1 Overview of cutting process setting work 5‐4
2 Tooling the processing optics 5‐6

2.1 Removing the processing optics 5‐6
2.2 Installing processing optics 5‐7
3 Checking the C and B axes and referencing 5‐10

manually
3.1 Checking the B and C axes 5‐10
3.2 Referencing the C and B axes manually 5‐13
4 Test sheet holder 5‐14
5 Smart Optics Setup 5‐17

5.1 Swiveling the test sheet holder into the setup 5‐22
position and mounting a test sheet
B836en 2017-11-17 Setting work 5‐1

5.2 Swiveling the test sheet holder into the parking 5‐23
position
5.3 Approaching the start or reference position 5‐24
5.4 Resetting the reference position 5‐25
6 Wizard 5‐27
6.1 Test sheet holder: Starting the utility program 5‐29
6.2 Smart Optics Setup station: Starting the utility 5‐31
program
6.3 Defining new reference optics 5‐33
7 Cutting process setting work 5‐34

7.1 Centering the beam 5‐34
Mounting the protective cover 5‐36
Installing the setting device 5‐37
Dismantling the setting device 5‐38
Centering nozzle to beam 5‐38
7.2 Determining and setting the focal position 5‐41
Start focus search 5‐42
7.3 Calibrate the B and C axes 5‐46
7.4 Determining the joint offset 5‐50
Determining the Z-axis joint offset 5‐51
Determining X axis and Y axis joint offset 5‐53
8 Calibrating the measuring equipment 5‐57

8.1 Mounting and activating the sensor 5‐59
8.2 Calibrating the sensor 5‐60
9 Setting up the clamping fixture 5‐63

9.1 Starting the utility program 5‐66
9.2 Checking the measuring sequence (option) 5‐68
9.3 Entering the required position 5‐69
9.4 Measuring the required position 5‐71
9.5 Measuring the actual position 5‐72
9.6 Determining the correction frame 5‐74
5‐2 Setting work 2017-11-17 B836en

Safety notes
Setting work in service mode may be carried out only by spe-
cially trained service personnel.

DANGER
Severe skin burns and eye injuries may occur.
Ø Setting work that requires 100% laser power may be carried
out only by specially trained service personnel.
Ø Protective gloves and laser safety glasses must always be
worn during setting work if the laser is switched on.
Ø The customer may have to take additional precautions to
secure the danger zone (e.g. using partition walls of sheet
steel or polycarbonate).
Danger class ■ The danger class of the laser system in service mode is
class 4.
■ The setting work which the operator is allowed to carry out is
conducted in normal mode of the machine. The danger class
of the laser system in normal mode corresponds with
class 1.
B836en 2017-11-17 Setting work 5‐3

1. Overview of setting work
The setting work listed below is carried out by the operator in

the machine's normal mode. The protective devices are active
here.
The utility programs of the setting work are controlled and
started menu-driven via a Wizard dialog.
Valid from machine serial release S04.00.
Reference optics The absolute position 0° for the B and C axes is referenced
when the machine is commissioned using the so-called reference
optics. Therefore, any further calibration of the B and C axes
must be carried out with the reference optics.
If only one set of processing optics is used on the machine,
these optics are the reference optics.
If several sets of processing optics are used on the machine,
any other mounted optics can be defined as the reference optics
if required, but not without an important reason.
Note
If new reference optics are defined using the wizard, the
tooling statuses of all other processing optics become inva-
lid. In such a case, the joint offset must be re-determined
for all other optics.
1.1 Overview of cutting process setting

work
The following setting work must be carried out in the order

described here. Here, a distinction is made between reference
optics and other cutting optics which are used on the machine.
Setting work When?

Manually checking and referencing Manual check ■ After every collision of the proc-
the B and C axes essing optics.
Setting work for the reference optics:
Centering nozzle to beam Dialog-driven utility program ■ After cleaning or exchanging the
(CP_HEAD_SETUP) lens in the processing optics.
Determining and setting the focus Dialog-driven utility program ■ In the event of cutting problems.
position (CP_HEAD_SETUP)
Note: This is skipped for machines
without FocusLine.
Calibrate the B and C axes Dialog-driven utility program ■ After every collision of the proc-
(CP_HEAD_SETUP) essing optics.
■ After manually referencing the B
and C axes.
5‐4 Overview of setting work 2017-11-17 B836en

Setting work When?
Determine tool length (Z axis joint Dialog-driven utility program ■ After calibrating the B axis and
offset) (CP_HEAD_SETUP) C axis.
Determining the joint offset of the X Dialog-driven utility program
and Y axes (CP_HEAD_SETUP)
Setting work for all other cutting optics:
Centering nozzle to beam Dialog-driven utility program ■ After cleaning or exchanging the
(CP_HEAD_SETUP) lens in the processing optics.
Determining and setting the focus Dialog-driven utility program ■ In the event of cutting problems.
position (CP_HEAD_SETUP)
Determine tool length (Z axis joint Dialog-driven utility program ■ After calibrating the B axis and
offset) (CP_HEAD_SETUP) C axis.
Determining the joint offset of the X Dialog-driven utility program
and Y axes (CP_HEAD_SETUP)
Cutting process setting work Tab. 5-1
B836en 2017-11-17 Overview of setting work 5‐5

2. Tooling the processing optics
Media adapter The supply lines for the processing optics are connected to the
media adapter of the Z barrel.
Media adapter connections Fig. 71428
Symbol Description
Beam guideway ventilation
Cutting gas
CAN bus
Dynamic additional axis (ADC)
Connection not assigned.
Magnetic coupling
Sensor
Media connections legend Tab. 5-2
2.1 Removing the processing optics
1. Switch off the alignment laser.

2. Move the Z barrel to a good change position.
3. Press Setup, "Manual functions".
4. Select the General group.
5. Press "Optics replacement".
The magnetic coupling releases.
6. Remove the processing optics:
5‐6 Tooling the processing optics 2017-11-17 B836en

− Remove the medium connections.
− Release the catch strap.
− Take off the processing optics and seal the beam orifice
with a protective cover or optical adhesive tape.
7. Seal the beam guidance on the angular gear with a protec-
tive cover or optical adhesive tape or mount different optics.
2.2 Installing processing optics
The processing optics are stuck on the B/C gear of the Z barrel
with a magnetic coupling and fastened with 3 knurled screws.
Conditions
■ The setup state has been created.
Notes
■ As soon as the valid tooling status is activated, the additional
ADC axis of the optics references automatically.
■ If new optics are put into operation on the machine, for
which there is yet no valid tooling status, a new tooling sta-
tus must be created first.
■ Damaged or contaminated pole and contact surfaces on the
magnetic coupling lead to a malfunction.
■ Tooling status: (see "Managing the tooling status", pg. 4‐171)
The electromagnetic of the magnetic coupling at the Z

DANGER barrel presents a danger of life for persons with
pacemakers!
from the magnetic coupling on the Z barrel.
maintenance or setting work on the Z barrel or on the proc-
B836en 2017-11-17 Tooling the processing optics 5‐7

Damage to the processing optics when torn from the
NOTICE magnetic coupling!
Ø Mount the catch strap properly.
Ø Exchange damaged catch strap.
Ø Exchange damaged catch strap.
Ø Before switching off the machine, set the B and C axes to
0°.
1 Catch strap 3 Knurled screw

2 Magnetic coupling 4 Bellows
Installing processing optics Fig. 71427
1. Switch off the alignment laser.

2. Clean the pole and contact surfaces of the magnetic coupling
thoroughly.
3. Stick the processing optics on the magnetic coupling. Tighten
the 3 knurled screws by hand. Fasten the catch strap.
processing optics are docked correctly.
If the green LED does not light up, either there is no
electric contact with the magnetic coupling or the optics
are not seated properly on the flange.
Ø Shake the seating of the optics.

Ø If electrical contact can still not be established, then
remove the optics and clean the pole and contact surfa-
5‐8 Tooling the processing optics 2017-11-17 B836en

ces of the magnetic coupling thoroughly (see the "Mainte-
nance" chapter in the "Mechanics" section).
1 Beam guidance ventilation 5 Magnetic coupling

2 CAN bus 6 Sensor (option)
3 ADC additional axis 7 Cutting gas
4 unassigned
Connecting the cutting optics Fig. 71426
4. Install the media connections.
5. Acknowledge the danger zone and close the safety door.
6. Activate the tooling status:
− Press Technology, select "Tooling status management".
− Select the valid tooling status.
− Press Activate.
The optics are now registered. The additional ADC axis refer-
ences as long as the safety door is closed.
7. Record the characteristic curve for the distance regulation:
− Press Setup, "Manual functions".
− Select Distance regulation group.
− Press "Recording charac. curve".
The characteristic curve will be recorded. Afterwards, the optics
will be ready for operation.
B836en 2017-11-17 Tooling the processing optics 5‐9

3. Checking the C and B axes and
referencing manually
The drive motors of the B and C axes are motors with absolute
encoders. These motors are referenced to the absolute position
0° during start-up. If this reference point run is lost, e. g. after a
collision, the NC axes must be referenced again.
The inclined position is checked and the C and B axes are refer-
enced manually at first.
Due to the imprecision of a manual reference point run, the B
and C axes must recalibrated afterward. (see "Calibrate the B
and C axes", pg. 5‐46)
Note
Both the manual reference point run as well as the exact calibra-
tion of the C and B axes must be carried out with the reference
optics. Reference optics
The manual check and reference point run are described

below.
3.1 Checking the B and C axes
The positions of the B and C axes can be checked as needed,

e. g. after a collision.
The position is checked by positioning the B and C axes to 0°.
Any inclined position of the axes is determined by moving over a
reference surface with a dial gauge.
Conditions
■ The reference optics are installed.

■ Dial gauge and support.
5‐10 Checking the C and B axes and referencing 2017-11-17 B836en

manually
Checking the C axis 1. In MDA operation mode: Move the processing optics to
C = 0 and B = 0.
A Starting point B End point

Reference surface, C axis Fig. 71429
2. Mount the dial gauge and align the C axis with the reference
surface at starting point "A" and zero the dial gauge.
3. Move the X axis with the teach panel by approx. 50 mm
from "A" to "B". While moving over the reference surface,
check the dial gauge.
4. Either
Ø If no inclined position is determined, no other setting
work is required.
or
Ø If an inclined position is determined: Correct the position
of the axis until the dial gauge no longer shows a devia-
tion from zero when moving along the reference surface.
The axis position determined this way now corresponds to
the new absolute position of 0°. The axis will be referenced
later in this position.
B836en 2017-11-17 Checking the C and B axes and referencing 5‐11

manually
Checking the B axis
A Start position B End position

B axis reference area Fig. 71431
5. Mount the dial gauge and align the B axis with the reference
surface at starting point "A" and zero the dial gauge.
6. Move the Z axis with the teach panel by approx. 50 mm from
"A" to "B". While moving over the reference surface, check
the dial gauge.
7. Either
Ø If no inclined position is determined, no other setting
work is required.
or
Ø If an inclined position is determined: Correct the position
of the axis until the dial gauge no longer shows a devia-
tion from zero when moving along the reference surface.
The axis position determined this way now corresponds to
the new absolute position of 0°. The axis will be referenced
later in this position.
8. Afterwards, reference the B and/or C axis at the absolute
position of 0°. (see "Referencing the C and B axes man-
ually", pg. 5‐13)
5‐12 Checking the C and B axes and referencing 2017-11-17 B836en

manually
3.2 Referencing the C and B axes
manually
Referencing means: The axis position of 0° determined manually

with the dial gauge is set to the absolute value "0" in the control.
Conditions
Note
The position of the axis is exclusively corrected by the software.
Mechanical adjustment is not required.

3. Press the manual function button "Set position".
4. Press Absolute position.
5. In the dialog for "Specification position", enter 0.
6. Activate "Status position referenced" for the B and/or C axis.
7. Press Finish.
The control system sets the absolute position of the B and C
axes in the machine data to 0°.
The control system forces a warm start. After control system
start-up the set absolute positions for the axes are effective.
8. Afterwards, calibrate the B and C axes with the service pro-
gram. (see "Calibrate the B and C axes", pg. 5‐46)
B836en 2017-11-17 Checking the C and B axes and referencing 5‐13

manually
4. Test sheet holder
The setting work is usually carried out with a test sheet or a ref-
erence part. The test sheet is clamped in a holder. The holder is
mounted in the work area of the machine, preferably to the work-
piece changer.
This standard test sheet holder belongs to the scope of delivery
of the machine.
Risk of collision between processing optics and fixtures or

NOTICE assemblies in the work area!
Ø Firmly clamp the test sheet in the holder.
Ø If the small holder is mounted to a fixture, the reference part
must project over the fixture.
Ø There must be clearance of at least 500 mm available to the
left and right of the holder.
Ø Remove the holder again after completing setting work.
Installation There are 2 holders in the scope of delivery of the machine,

which can be mounted at a suitable place. Only one holder is
used at a time.
■ Large holder: installation preferably on the workpiece
changer or on the fixture holder.
■ Small holder: installation preferably on the fixture, e.g. on a
clamp.
Note
The test sheet holder must be mounted axially parallel.
5‐14 Test sheet holder 2017-11-17 B836en

A Small holder 1 Vertical test sheet 3 Sacrificial plate
B Large holder 2 Horizontal test sheet
Example: Mounting the sheets in the holder Fig. 62013
Note
Recommendation: To protect the holder, a sacrificial plate can be
clamped in: mild steel, max. 8.5 mm thick, 190 mm x 110 mm.
Installation dimensions small holder Fig. 62012
B836en 2017-11-17 Test sheet holder 5‐15

Installation dimensions large holder Fig. 62014
5‐16 Test sheet holder 2017-11-17 B836en

5. Smart Optics Setup
Smart Optics Setup is an option for the laser machine.

Setting work for the machine as well as for the processing optics
can be done using the Smart Optics Setup function and the
Smart Optics Setup station.
Basic variant scope of The scope of delivery of the Smart Optics Setup Basic option
delivery includes the following components:
■ The Smart Optics Setup station, consisting of a swivel arm
and test sheet holder, in which the test sheets for carrying
out setting work can be clamped.
■ "Measuring ball" setting device (material number 2248971)
for calibrating the sensor (option), see section "Calibrating
measuring equipment" Smart Optics Setup Station.
■ Three sets of sacrificial plates (2 sheets per set) for protect-
ing the test sheet holder from laser radiation.
Smart Optics Setup station The Smart Optics Setup station is a swivelable fixture (referred
to as the setting device in the following), which can alternatively
be used for setting work instead of the standard test sheet
holder (see "Test sheet holder", pg. 5‐14).
1 Holder with swivel arm 3 Test sheet holder

2 Measuring ball fixture 4 Sacrificial plates (2 pieces)
Smart Optics Setup station Fig. 87510
B836en 2017-11-17 Smart Optics Setup 5‐17

Setup position and parking The setting device is permanently mounted on the machine
position frame and is swiveled into the working area of the machine for
setting work.
A Setup position B Parking position

Smart Optics Setup station Fig. 86915
Risk of crushing or hitting when swiveling the

CAUTION Smart Optics Setup station!
Ø When swiveling, make sure that no parts of the body get
caught.
Ø Touch the swivel arm at the handle to swivel it.
Ø Lock the swivel arm in the set-up position and in the parking
position.
Both the setup position and the parking positions are monitored
by the machine control by touch switches.
■ The test sheet holder is swiveled into the setup position in
the working area. The swivel arm is locked into this position
with a toggle clamp.
■ In the parking position, the test sheet holder is swiveled out
of the working range and is held in the parking position with
a stop pin.
Note
If the setting device is in the setup position, rotation is not ena-
bled for the workpiece changer. The production plan or a proc-
essing program cannot be started.
Test sheets for utility For the different setting work operations, the test sheets are
programs inserted either horizontally or vertically in the test sheet holder
and screwed tight.
5‐18 Smart Optics Setup 2017-11-17 B836en

Note
A set of test sheets is part of the scope of delivery of the
machine. They can be used for Smart Optics Setup station and
also for the standard test sheet holder. They can be ordered as
consumables.

Reference position The cross-hairs on the flat, processed surface of the test sheet
holder serve as a reference position for starting the utility pro-
grams. The reference position is determined by the service engi-
neer during the commissioning of the machine.
When using the Smart Optics Setup station: At the start of the
utility program, the axes position themselves automatically from
the current axis position to the respective start position for the
laser processing.
1 Cross-hairs
Smart Optics Setup station reference position Fig. 87511
Notes
■ Approach reference position: (see "Approaching the start or
reference position", pg. 5‐24).
■ Reset reference position: (see "Resetting the reference posi-
tion", pg. 5‐25).

Contact washers for The test sheet holder is fastened to the flange plate on the
grounding the test sheet swivel arm of the Smart Optics Setup station with four screws.
holder
The two lower fastening screws on the flange plates have con-
tact washers. These two contact washers are functionally rel-
evant components. They ground the test sheet holder, thus
ensuring the functional safety of the distance regulation.
1 Contact washer
Smart Optics Setup station contact washers Fig. 86911
Risk of collision between the processing optics and the

NOTICE setting device when approaching the reference position!
Ø Do not remove the contact washers.
Ø Replace any contact washers that are lost.

5.1 Swiveling the test sheet holder into
the setup position and mounting a
test sheet
Before beginning with setting work, the Smart Optics Setup sta-
tion is swiveled out of the parking position into the working range
of the machine.
Risk of collision of the processing optics when approaching

NOTICE the reference position if the vertical test sheet is mounted
on the outer side of the test sheet holder.
Ø The vertical test sheet must always be mounted to the side
facing the working area (inside of the test sheet holder).
Risk of collision when swiveling the Smart Optics Setup

NOTICE station with the workpiece or with the fixture in the work
area!
Ø Check whether a collision between the fixture or workpiece
with the workpiece changer is possible when the
Smart Optics Setup station is swiveling.
1 Toggle clamp
Securing the swivel arm in the setup position Fig. 86914
1. Move the Z axis into the safety position (e. g. to Z = 600).

2. Unlock the swivel arm: pull the locking pin up and turn it.
3. Grasp the swivel arm at the handle and swivel it into the
work area.
4. Clamp the swivel arm in the setup position using the toggle
clamp.
5. Mount the test sheet horizontally or vertically in the test
sheet holder.
5.2 Swiveling the test sheet holder into

the parking position
After completing setting work, the Smart Optics Setup station is

swiveled back into the parking position and locked.
1 Stop pin
Locking the swivel arm in the parking position Fig. 86913
1. Move the Z axis into the safety position (e. g. to Z = 600).

2. Open the toggle clamp on the swivel arm.
3. Grasp the swivel arm at the handle and swivel it into the
parking position.
4. Lock the swivel arm in the parking position: turn the locking
pin until it engages.

5.3 Approaching the start or reference
position
The reference position is determined and set by the service engi-

neer during the commissioning of the machine.
To check, the user can approach the saved reference position as
needed or before starting a utility program.
Conditions
■ Processing optics are ready for operation.
■ The Smart Optics Setup function is applied.
■ The Smart Optics Setup station is in the set-up position.
■ Reference position is determined Reference position.
Risk of collision! NC axes move immediately to the

NOTICE reference position along a direct path!
Ø Before starting, check whether a collision is possible
between the barrel or processing optics and the fixture or
workpiece.
1 Cross-hairs

2. Select the utility program CP_HEAD_SETUP and press Exe-
cute.
The wizard starts.
3. Press the Smart Optics Setup button.
4. Press Approach position.
5. Check the collision behavior and confirm the dialog with Yes
or No.
The saved reference position is approached.
5.4 Resetting the reference position
The reference position is set by the service engineer during the

commissioning of the machine.
The user can reset and save the reference position as needed.
Conditions
■ Smart Optics Setup station is in the setup position.
1 Cross-hairs

cute.
The wizard starts.
3. Press the Smart Optics Setup button.
4. Press Set position.
5. Either
Ø If the current axis position should be saved as the new
reference position:
− Select "Current axis position".
− Position the B and C axes at B0/C0.
− Position the tool center point at approx. 10 mm above
the cross-hairs with the teach panel.
or
Ø If "Stored values" is selected, the processing optics is
immediately positioned in the stored reference position.
6. Press OK.
The newly set reference position is saved.

6. Wizard
With the help of the wizard, all setting work for the current tool-
ing status can be started and carried out menu-driven.
The Wizard is started with the service program
CP_HEAD_SETUP.LST.
Program selection and The individual setting work tasks are listed in tabular form in the
status Wizard dialog and are marked with a status. The status shows
which setting work is mandatory and which is optional.
1 Setting work 3 Wizard

2 Status
Wizard start dialog Fig. 71596
Symbol Description
This setting work must be done next.
This setting work was already carried out, but can be car-
ried out again, as needed.
This setting work must still be carried out, but the condi-
tions for this have not yet been met.
The selection is currently not possible or the setting work

has already been done.
Tab. 5-3
B836en 2017-11-17 Wizard 5‐27

Wizard Using the wizard, the program selection in the "Setting work"
table can be filtered. The Wizard filters according to the following
criteria:
■ Empty: The standard display for the activated tooling status
is shown.
■ Cleaning or replacement of the lens: In the table, only that
setting work is displayed which is required after cleaning or
replacing the lens.
■ Cutting problems: In the table, only that setting work is
shown which is to be carried out if there are cutting prob-
lems.
■ Collision: In the table, only that setting work is shown which
is required after a collision of the processing optics.
Reference optics The currently mounted optics can be defined as the reference
optics (see "Defining new reference optics", pg. 5‐33). The ref-
erence optics are the processing optics with which setting work
is carried out on the machine.
Context button Depending on the context, the following buttons will be shown:
Button Description
Reference optics Define the mounted optics as the reference optics. Dialog opens.
Smart Optics Setup (option) Approach position: Approach the stored reference position. This position
corresponds to the stored cross-hairs position on the test sheet holder.
Note: This button is only visible
when the option is applied on the Set position: Set and save a new reference position. Dialog opens.
machine.
Back Back to the previous page.
Next Continue the service program.
Finish Exit the service program.
Cancel Cancel service program.
Test sheets for utility For the different setting work operations, the test sheets are
programs inserted either horizontally or vertically in the test sheet holder
and screwed tight.
Note
A set of test sheets is part of the scope of delivery of the
machine. They can be used for Smart Optics Setup station and
also for the standard test sheet holder. They can be ordered as
consumables.
5‐28 Wizard 2017-11-17 B836en

6.1 Test sheet holder: Starting the utility
program
This section applies if the standard test sheet holder is

used which is included in the scope of delivery of the
machine (see "Test sheet holder", pg. 5‐14).
The start position for a utility program can be approached with
the teach panel.
Alternatively, the start position can also be selected on the user

interface and approached from the control panel. The following
options will be described below:
■ The actual position is the start position.
■ The start coordinates are entered absolutely in the input
fields.
■ The start position is approached incrementally (step-by-step).
■ The last stored start position can be loaded and approached.
Conditions
■ Laser device is ready for operation and assigned to the
machine.
Notes
■ To start the wizard and the following utility program, it is not
essential for the tooling status to be valid.
■ The control stores the start position automatically for the
respectively selected setting work.
■ When starting the CP_HEAD_SETUP.LST utility program, an
active processing program is ended.
B836en 2017-11-17 Wizard 5‐29

That axis position at which the laser processing of the reference
part is started is referred to as the start position.
Establish start position Fig. 71597
The start coordinates can be changed incrementally (step-by-

step) with the Plus or Minus button.
Button Description
Load position The last saved start position for this setting work is loaded automatically.
Approach position The coordinates entered in the dialog are approached as the start position.
The axes start immediately; the optics move first to the crossover position
(Z = 600) and then to the start position. Afterwards, the dialog "Approach
start position" opens again.
Next The coordinates entered in the dialog are approached as the start position.
The axes start immediately; the optics move first to the crossover position
(Z = 600) and then to the start position.
Start the Wizard 1. Press Production, select "Utility tools".

cute.
The wizard starts. The individual setting work and its status
are displayed in the table depending on the current tooling
status and the mounted processing optics.
3. In the table, select the setting work that should be started
next.
4. To start the selected setting work: Press Continue.
The utility program is started. The Start position dialog
appears.
Establish start position 5. Either

Ø If the current axis position is the start position: Press
Continue.
5‐30 Wizard 2017-11-17 B836en

or
Ø Enter the start coordinates in the input fields and press
Next.
or
Ø If the start position last saved in the control is to be
approached:
− Press Load position.
− Press Approach position or Next.
or
Ø If the new start position is to be approached incremen-
tally:
− Enter the increment in the "Increment" input field.
− Select the start position with the Plus or Minus button.
− Press Approach position or Next.
The service program is continued.
6. Follow the wizard.
6.2 Smart Optics Setup station: Starting

the utility program
This section applies if the Smart Optics Setup function is used

(option).
Instead of the standard test sheet holder, the Smart Optics
Setup station is used for setting work (see "Smart Optics Setup",
pg. 5‐17).
When the utility program is started for the respective setting
work, the axes position themselves automatically from the cur-
rent axis position to the start position of the utility program.
That axis position at which the laser processing of the reference
part is started is referred to as the start position.
B836en 2017-11-17 Wizard 5‐31

Conditions
machine.
■ The Smart Optics Setup station is in the set-up position.
■ Reference position is determined Reference position.
Notes
■ In order to start the wizard and the following utility programs,
a valid tooling status is not mandatory.
■ When starting the CP_HEAD_SETUP.LST utility program, an
active processing program is ended.
Risk of collision! The NC axes move immediately to the

NOTICE start position for laser processing along a direct path after
the utility program starts.
Ø Before starting the utility program, check whether a collision
with the fixture or workpiece is possible.
Ø Recommendation: Before starting a utility program, position
the processing optics above the cross-hairs.

cute.
The wizard starts. The individual setting work and its status
are displayed in the table depending on the current tooling
status and the mounted processing optics.
3. In the table, select the setting work that should be started
next.
4. Check the collision behavior and confirm the dialog with Yes
or No.
5. Press Continue.
The utility program is started.
5‐32 Wizard 2017-11-17 B836en

6.3 Defining new reference optics
Conditions
Note
Do not define other optics as the reference optics without a
compelling reason. All tooling statuses will become invalid
as a result. The joint offset must be redetermined for all
optics used on the machine.
1. Mount the processing optics.

2. Start the Wizard.
3. Press Reference optics.
4. Activate "Apply reference optics".
5. Press Continue.
The mounted optics are now the new reference optics.
6. Recalibrate the B and C axes. (see "Calibrate the B and C
axes", pg. 5‐46)
7. Determine the tool length for the new reference optics. (see
"Determining the Z-axis joint offset", pg. 5‐51)
8. Determine the joint offset for the X and Y axes for the new
reference optics. (see "Determining X axis and Y axis joint
offset", pg. 5‐53)
9. Afterwards, redetermine the joint offset for the X and Y axes
for all other optics used on the machine. The tool length
does not have to be determined again for the other optics.
(see "Determining the joint offset", pg. 5‐50)
B836en 2017-11-17 Wizard 5‐33

7. Cutting process setting work
Note
In order to be able to carry out the setting work described below,
the authorized user group must be logged on. If there is no
authorization, a message will be output.(see "User administra-
tion", pg. 4‐75)
7.1 Centering the beam
The beam centering must be checked:

■ after cleaning or exchanging the lens in the cutting optics.
■ after every change of the laser light cable.
■ After each basic adjustment of the beam.
The laser beam must be guided through the center of the nozzle
to achieve good cutting results, regardless of the direction. At
the same time, this ensures that the beam will not reflect on the
nozzle wall and that the flow of the cutting gas will be guided
evenly around the focus spot.
1 Nozzle orifice a Centered laser beam

2 Laser beam b,c Off-center laser beam
Centering the laser beam to the nozzle Fig. 32545
Service program The utility program is started via the Wizard. The utility program
triggers a laser pulse.
Setting device The sensor body, and therefore the nozzle, are adjusted using a
setting device.
The sensor body is fastened to a slide with a path movement in
the X and Y directions of +1.0 mm each way. The sensor body
and slide are fixed with clamping screws. The sensor body and
nozzle are joined rigidly; the beam is centered to the nozzle cen-
ter by adjusting the sensor body.
5‐34 Cutting process setting work 2017-11-17 B836en

1 Adjusting screw 4 Knurled screw 7 Sensor body
2 Dial gauge 5 Cutting insert 8 Red marking
3 Alignment pin 6 Clamping screw
Setting device Fig. 23177
B836en 2017-11-17 Cutting process setting work 5‐35

Mounting the protective cover
The protective cover is an option for the dynamic processing

optics.
The protective cover protects the cutting insert and prevents the
very fine cutting dust from being able to penetrate into the cut-
ting insert and tapping holes.
Note
The protective cover can only be used for the new cutting optics
of the TruLaser Cell 8030 (L60). The protective cover cannot be
used for cutting optics of predecessor machines due to the form
fit between the bushing and the cutting insert.
1 Notch in the cutting insert 3 Fixing screw 4 Protective cover

2 Cutting insert
Mounting the protective cover Fig. 73821
1. To mount the protective cover:

− Stick the protective cover over the cutting insert from
below; in the process, the fixing screw in the flange of
the protective cover targets the notch in the cutting insert.
− Tighten the fixing screw in the flange of the protective
cover hand-tight.
2. To remove the protective cover: Loosen the fixing screw on
the flange of the protective cover and pull the protective
cover off of the cutting insert.

Installing the setting device
The setting device is fitted on the cutting insert of the cutting

optics from below and fastened. The contact surfaces must be
clean. The device may not be tilted.

■ Setting device (mat. no. 1425940) for moving the sensor
body in X and Y direction.
■ Allen key SW 3.
1 Adjusting screw 3 Setting device

2 Knurled screw 4 Dial gauge
Installed setting device Fig. 71591
1. Move the NC axes in JOG mode into an easily accessible

position.
2. Rotate the B axis to -90°.
3. Remove the protective cover (option) from the cutting insert.
4. Rotate the anodized cover ring on the cutting insert so that
the 4 clamping screws are visible.
5. Screw the adjusting screws and the dial gauges out of the
fixture up to the red marking.
6. Fit the setting device on the cutting insert from below. Center
it with the alignment pin.
7. Tighten both knurled screws hand-tight.
8. Screw in the adjusting screws first and lightly tighten.
9. Afterwards, screw in the dial gauges hand-tight and zero.
10. Finally, tighten the adjusting screws until the dial gauges
deflect slightly.

Dismantling the setting device
After the end of nozzle centering, the adjustment device is

removed again.
1. Loosen the dial gauges and the adjusting screws until the
red marking on the screws is completely visible.
2. Loosen the knurled screws.
3. Carefully pull off the adjustment device.
4. If available, remount the protective cover for the cutting
insert.
Centering nozzle to beam
The following four working steps are required for centering the
laser beam with respect to the nozzle:
■ Perform a reference shot to check the centering and to local-
ize the beam.
■ Correct the nozzle and carry out a test shot.
■ Carry out test shot with the C axis in 4 different positions.
■ Carry out test shot with the B axis in 3 different positions.
Conditions
■ Clean, new standard nozzle, ∅ 2.3 mm.
■ Clean, new standard nozzle ∅ 1.4 mm.
machine.

■ Measuring magnifier (10 to 20 times zoom).
■ Adhesive strips (Scotch Magic transparent film).
Notes
■ For each test shot, move the adhesive strip or use a new
adhesive strip.
■ The first test shot is usually carried out with a nozzle having
a nozzle diameter of 2.3 mm.
■ Change the nozzle after adjusting the laser beam for the first
time. The smaller the nozzle diameter, the more exactly the
beam can be adjusted to the nozzle orifice.
Recommendation: For each additional test shot, use a nozzle
with a nozzle diameter of 1.4 mm or smaller.

Carrying out a reference 1. Stick an adhesive strip on to the nozzle orifice.
shot 2. Acknowledge the danger zone and close the safety door.
3. If the wizard has not been started yet: start the wizard.
4. In the table, select Centering nozzle to beam.
5. Press Continue.
6. Enter the parameters "Laser power" and "Duration" for the
laser pulse.
7. Press Trigger pulse.
The B and C axes turn to 0°. A laser pulse is triggered.
Then the B axis turns back into the initial position.
8. Do not remove the adhesive strip from the nozzle and check
the scorching in the adhesive strip with the magnifying glass.
Ø If the scorching is centered, the beam is centered. No
further centering is required.
or
Ø If the scorching is eccentric, the sensor body must be
adjusted.
Correct the nozzle and carry

out test shot
1 Clamping screws at the cutting insert (view from below)

Center the beam to the nozzle Fig. 48388
9. Mount the setting device. (see "Installing the setting device",

pg. 5‐37)
10. Only slightly loosen the four clamping screws on the
cutting insert: max. 1/2 turn.
11. Adjust the sensor body using the set screws on the fixture.
The adjustment value can be read off on the opposite dial
gauge.
12. Stick new adhesive strip on the nozzle orifice.

14. Carry out another test shot: Trigger a laser pulse and check
the scorching. If the beam is still eccentric, correct the sen-
sor body again.
The scorched hole and the scorched surrounding area on the
adhesive strip must be round and concentric to the nozzle. If
the hole and surrounding area are oval, then the beam
grazes the nozzle wall.
The test shot must deliver a satisfactory result; only
then can the test shots for the C and B axes be carried
out.
Carrying out test shot for C 15. Stick new adhesive strip on the nozzle orifice.
axis
Acknowledge the danger zone and close the safety door.
16. Press Continue.
17. Press Check C axis.
4 laser pulses are triggered at different C-axis positions.
18. Check the adhesive strip.
The rotation about the C axis is OK if the scorching is com-
pletely concentric.
Carrying out test shot for B 19. Stick new adhesive strip on the nozzle orifice.
axis 20. Acknowledge the danger zone and close the safety door.
21. Press Continue.
22. Press Check B axis.
3 laser pulses are triggered at different B-axis positions.
23. Check the adhesive strip.
The rotation about the B axis is OK if the scorching is com-
pletely concentric.
24. Once the scorching for the B and C axes is OK: Press Fin-
ish.
The centering of the nozzle is complete.
25. Tighten the clamping screws on the cutting insert hand-tight
again (max. 4 Nm).
26. Remove the adjustment device. (see "Dismantling the setting
device", pg. 5‐38)
27. If available, remount the protective sleeve.
28. Then readjust the focal position. (see "Determining and set-
ting the focal position", pg. 5‐41)

7.2 Determining and setting the focal
position
Focal position The focal position is the vertical position of the focus (also called
focus point) with respect to the sheet surface. The exact position
of the focus is essential for good cutting results.
Focus position Fig. 7461
The focal position must be redetermined:

■ after cleaning the lens or the FocusLine mirror.
■ after installing a new lens or a new FocusLine mirror.
■ after basic beam adjustment.
■ for checking for cutting problems.
Machines without FocusLine For machines without FocusLine, the exact focal position is
determined by means of cutting tests and is fixed manually
before machining. It is not possible to adjust the focal position
during machining (see: section "Setting the focal position without
FocusLine").
The parameter "FocusLine setting value" in the laser technology
table has no effect in this case.
Note
The following description for how to determine the focal
position only applies to machines with FocusLine.
FocusLine The function FocusLine is a laser processing machine option.

FocusLine compensates the focus shift and controls the focal
position during machining.
The surface of the FocusLine mirror is deformed in a targeted
way using pressure. This changes the angle of divergence of the
laser beam in such a way that the focus point can be shifted
upwards or downwards systematically during machining.
The function FocusLine is controlled via characteristic curves.
Focus search The service program is started via the Wizard. It cuts a refer-
ence part with a comb structure with 20 slats. The individual

webs are cut consecutively with a new focal position each time.
This changes the kerf between the slats continuously.
The "Increment" parameter corresponds to an increment in the
beam direction by which the focal position is changed from web
to web.
The "Increment" parameter is only changed if the focal position
offset value is outside the valid tolerance of 0.3 mm during the
focus search.
The reference sheet for the focus search is clamped in a holder
(included in the scope of delivery of the machine) and can be
mounted at a suitable place on the workpiece changer.
Start focus search
The focal position offset is determined during the focus search.

The focal position offset is the value by which the control displa-
ces the FocusLine characteristic curve in the software.
At the beginning of the service program, the operator can

choose whether the focal position should be redetermined or
whether it should be checked.
■ If the focal position is to be redetermined, the focus search is
started with the standard focal position offset value. This
might be required in the following situations:
− When starting up new optics.
− After replacing or cleaning the lens.
− After changing the LLK or after basic adjustment.
− If the focus search does not lead to a valid result.
■ If the focal position should only be checked, for example,
then the focus search is started with the current focal posi-
tion offset value.
The control corrects the FocusLine characteristic curve with the
Focus position offset parameter for the processing optics
mounted.
Conditions
machine.
■ The nozzle is centered to the beam.
■ Clean, new standard nozzle, ∅ 2.3 mm.

■ Flat sheet 190 mm x 110 mm, 1 mm thick, stainless steel
(1.4301).

■ Feeler gage (recommendation 0.3 mm to 0.5 mm).
■ Test sheet holder for reference part (included in the scope of
delivery of the machine).
or
■ Smart Optics Setup station (option).
Notes
■ When using the Smart Optics Setup station: At the start of
the utility program, the axes position themselves automati-
cally from the current axis position to the respective start
position for the laser processing.
■ The dynamic cutting optics moves 10 mm away from the
sheet surface at the time of program start.
■ If the comb structure is not cut out completely, reduce the
"Increment" parameter.
■ The focus search is carried out with a standard nozzle.
The service program cuts a reference part with this comb struc-
ture. A microjoint is set at the end of the contour.
S Starting point
Reference part Fig. 71594
Test sheet set up 1. Either

Ø Mount the test sheet holder on the workpiece changer.
or
Ø Swivel the Smart Optics Setup station into the set-up
position.
2. Clamp the test sheet horizontally in the test sheet holder.

R Reference position S Start position
Fig. 87505
3. Either
Ø If the standard test sheet holder is used: move the TCP
to the start position. Position it approx. 10 mm above the
sheet.
or
Ø When the Smart Optics Setup station is used: To avoid
collisions, the processing optics can be moved to the ref-
erence position (cross-hairs) before starting the utility pro-
gram (recommendation).
Cutting the reference part 5. If the wizard has not been started yet: start the wizard.
6. In the table, select Setting focal distance.
7. Press Continue.
8. Either
Ø If the focal position is to be checked, activate "Check
focus position and adjust".
or
Ø If the focal position is to be newly determined, activate
"Newly determine focal position and adjust".
9. Select laser technology table for engraving and cutting.
10. Press Continue.
The focus search starts. The reference part is cut. Then the
dialog opens again.

Determining the smallest Note
kerf
The smallest kerf corresponds to the focal position F=0.
12. Determine the smallest kerf in the reference part:
− With the feeler gauge, starting from the left and right,
respectively, check every individual kerf.
− Mark the kerf and the left and right where the feeler
gauge sticks.
13. In the selection list "Upper limit" and "Lower limit", select the
kerf number for each where the feeler gauge sticks.
The control calculates the number of the smallest kerf as well as

the focal position offset value and visualizes the result:
1 Lower limit selection list 3 Upper limit selection list

2 Result
Fig. 73834
14. Either
Ø Once the focal position offset value lies in the green valid
range, the focus search is completed. Press Finish.
or
Ø If the focal position offset value lies outside of the valid
tolerance, the display is red. Press Continue. Change the
Increment parameter and start the focus search again.
Tip
If the repeated focus search does not lead to a valid result,
check the lens and redetermine the focal position: Select "Newly
determine focal position and adjust" and carry out focus search.

7.3 Calibrate the B and C axes
The B and C axes are calibrated with a service program and the
reference optics. The service program is started via the Wizard.
The B and C axes must be recalibrated after each manual refer-
ence point run.
Conditions
machine.
■ The focal position is determined and set.
■ The nozzle is centered to the beam.

■ Flat sheet, 150 mm x 100 mm, 3 mm thick, mild steel
■ Micrometer or slide gauge.
or
Notes

The service program cuts a frame with a different B-axis position

(inner contour with B = -90° and outer contour with B = 90°).

This so-called frame is the reference part. A microjoint is set at
the end of the contour.
Reference part (B frame) Fig. 71592
The operator measures the 4 sides of the B frame and enters

the dimensions for Z1, Z2, Y1 and Y2 in the dialog.
The control determines the deviation from these measured val-
ues and, if required, resets the absolute position 0° for the B
and C axes.

or
position.
2. Clamp the test sheet vertically in the test sheet holder.
3. In MDA operation mode: Move the processing optics to
C = 0 and B = -90.

Fig. 86916
4. Either
sheet.
or
5. Acknowledge the safety circuit and close the safety door.
7. In the table, select Calibrate the B and C axes.
8. Press Continue.
9. Select the laser technology table for cutting.
10. Press Continue.
The reference part is cut.
Evaluating the reference part 12. Exactly measure the dimensions for Z1, Z2, Y1 and Y2
(observe engraving and chamfer) and enter in the dialog.
The measurement result is visualized immediately.
If the measured values lie within the tolerance, the display is
green. The box "Apply values" is automatically activated.
If the measurement result is invalid, the display is red. The
values will not be saved.

Measurement result Fig. 72869
13. Press Finish.
When saving values, the control forces a warm start. The
new absolute position for the B and C axes takes effect after
a warm start and the booting up of the control. The calibra-
tion is completed.
14. Subsequently, the following setting work must be carried out
in this order:
− Determine the tool length for the reference optics. (see
"Determining the Z-axis joint offset", pg. 5‐51)
− Determine the joint offset for the X and Y axes for the
reference optics: (see "Determining X axis and Y axis
joint offset", pg. 5‐53)
− Determine the joint offset of the X and Y axes for all
other optics used on the machine: (see "Determining X
axis and Y axis joint offset", pg. 5‐53)

7.4 Determining the joint offset
Joint offset The offset value for the X, Y and Z axes between the beam cen-
ter of the pivot of the B/C angular gear and the beam center of
the focus point (Tool Center Point) is referred to as the joint off-
set.
The joint offset of the Z axis is calculated from the tool length
plus 1 mm nozzle distance. The joint offset of the Z axis corre-
sponds to the swivel radius of the optics.
1 Beam center of B/C gear pivot Z Z axis joint offset

2 Beam center (TCP) L Tool length
Y Y axis joint offset
Joint offset Fig. 54164
Due to the manufacturing tolerances of the processing optics,

the joint offset on the machine must be determined during the
commissioning of the optics.
The joint offset values are saved in the control and are loaded
automatically in the machine data when the optics are selected.

Determining the Z-axis joint offset
Using the service program, the joint offset of the Z axis (same
thing as the tool length) is determined. The service program is
started via the Wizard.
A measuring point is recorded to the right and left of the sheet
surface. The control calculates the tool length from these meas-
ured values and the sheet thickness entered in the dialog.
Notice! If an incorrect value is entered in the dialog for the
sheet thickness, the calculated tool length will be incorrect!
Conditions
machine.
■ B and C axes are calibrated with the reference optics.
■ The focus position has been determined.

or
Notes
■ The optics swivel above the sheet edge by 180° during the
measurement.


or
position.
2. Clamp the test sheet vertically in the test sheet holder.
C = 0 and B = -90.

Fig. 86916
4. Either
sheet.
or
7. In the table, select Determining the tool length.
9. Press Continue.
The message will start immediately. After the end of the
measurement, a dialog will open.

10. Enter the "Sheet thickness" for the reference part.
11. Press Finish.
The newly determined tool length is saved in the machine
parameter and takes effect immediately.
12. Then, determine the joint offset for the X and Y axes for the
reference optics: (see "Determining X axis and Y axis joint
offset", pg. 5‐53)
Determining X axis and Y axis joint offset
Using the service program, the joint offset of the X and Y axes
is determined. The service program is started via the Wizard.
Conditions
■ B and C axes are calibrated with the reference optics.
■ The focus position has been determined.
machine.

or
Note
The dynamic cutting optics moves 10 mm away from the sheet
surface at the time of program start.

The service program cuts a reference part. The dimensions A, B,
C and D are the adjustment values for calculating the joint offset
values.
Reference part Fig. 71595

or
position.
2. Clamp the test sheet horizontally in the test sheet holder.
C = 0 and B = 0.

Fig. 87505
4. Approaching the start or reference position
sheet.
or
7. Select Determine joint offset XY from the table.
8. Press Continue.
9. Select the laser technology table.
10. Press Continue.
The reference part is cut. Then the dialog opens again.
Evaluating the reference part 12. Exactly measure the webs A, B, C and D and enter the
measured values in the dialog.
The measurement result is visualized immediately.
If the measured values lie within the tolerance, the display is
green. The box "Apply values" is automatically activated.

If the measurement result is invalid, the display is red. The
values will not be saved.
13. Press Finish.
When the values are saved, the determined joint offset val-
ues are saved in the machine parameters and take effect
immediately.
Tip
If no valid result is found, check the positions of the B and C
axes.

8. Calibrating the measuring equipment
Measuring equipment The following measuring equipment can be used for measure-
overview ment:
■ Offline measurement with ControlLine (standard) distance
regulation, ControlLine can measure only in the beam direc-
tion (Z direction).
■ Offline measurement with sensor (option).
Danger of collision with work piece or fixtures due to non-

NOTICE authorized measuring equipment!
Ø Only the sensor is allowed to be used on the machine.
Putting the measuring The sensor has to be activated and then calibrated each time it
equipment into service is mounted at the B/C gearbox. The selection is made via the
tooling status administration.
After the activation, the actual joint offset values are determined
by calibration. After calibration, the sensor is ready for operation.
Instead of the processing optics, the sensor is installed on the B/
C gearbox.
The following functions are automatically deactivated as soon as

the sensor is activated:
■ The beam tube ventilation is switched off.
■ The cooling water monitoring is hidden.
■ ControlLine is deactivated.
■ Alignment laser is deactivated.
■ The laser switches to the laser test mode.
Note
A NC program can be started in the test mode using the sensor.
Programming of The measurement and evaluation of the measuring data is pro-

measurement functions grammed in the NC program with the measuring cycles (NC
cycles).
Measuring ball fixture The measuring ball fixture (option) is used to calibrate the
sensor as an alternative if no Smart Optics Setup station (option)
is mounted on the machine Smart Optics Setup Station.
The measuring ball fixture is positioned in the working range on
the workpiece changer in such a way that no collision with the
fixture is possible during calibration.
B836en 2017-11-17 Calibrating the measuring equipment 5‐57

Sensor and measuring ball fixture Fig. 78074
Smart Optics Setup Station The Smart Optics Setup function is a machine option. It can be
used in combination with the "measuring ball" setting device to
calibrate the sensor.
1 Measuring ball 2 Reference position

"Measuring ball" setting device Fig. 84222
The setting device is swiveled into the working position and

locked in place for the calibration. The "measuring ball" setting
device (material no. 2248971) is inserted in the setting device
horizontally and fixed with the knurled screws.
Note
Operate the Smart Optics Setup station: (see
"Smart Optics Setup", pg. 5‐17).
5‐58 Calibrating the measuring equipment 2017-11-17 B836en

8.1 Mounting and activating the sensor
When starting up the machine, the sensor (option) is activated in

the tooling status administration.
When retrofitting the probe's sensor by the Technical Service
TRUMPF, the probe must be, for example, activated by Teleser-
vice so that the probe can be selected in the tooling status
administration.
Condition
1 Connection of the magnetic 3 Cooling water bridging

coupling 4 Magnetic coupling
2 Sensor connection
Connecting the sensor Fig. 62024
Installing the sensor 1. Remove the processing optics.

2. Install the sensor to the magnetic flange of the B-/C gearbox.
processing optics are docked correctly.
Activating the sensor 3. Press Technology, select "Tooling status management".

4. Select the valid tooling status.

1 Sensor
Tooling status administration Fig. 77375
5. Select "Sensor".
6. Select "Measuring probe".
7. Press Finish.
The sensor is activated but not yet ready for operation.
8. Then calibrate the sensor.
8.2 Calibrating the sensor
Every brand new sensor must be started up at the machine. At

the time of initial start-up, the control writes the default joint off-
set values for the sensor into the machine data. The actual joint
offset values must be determined by means of a calibration.
The sensor is calibrated with the utility program and a measuring
ball.
The utility program performs a measuring cycle and determines
the joint offset values of the sensor. The configuration in the con-
trol is immediately effective after the transfer of the geometric
data.
The sensor must be recalibrated:

■ After the initial start-up.
■ After each assembly at the magnetic flange.

Condition
■ Sensor is activated.

■ Measuring ball fixture (option).
or
■ "Measuring ball" setting device (Smart Optics Setup option).
Notes
■ The last determined geometric data is kept in case of a pro-
gram interruption.
■ If the measuring ball and the measuring probe are not cor-
rectly screwed in, the measurement can be faulty.
■ To prevent a collision, a clearance of about 50 mm around
the measuring ball has to be maintained during the calibra-
tion.
1. Positioning the measuring ball fixture

Ø Swivel the Smart Optics Setup station into the work area
and lock it in place. Mount the measuring ball setting
device.
or
Ø Position the measuring ball fixture in the work area on
the workpiece changer.
C = 0 and B = 0.
3. Position the sensor about 10 mm above the measuring ball.
4. Start the wizard:
− Press Production, select "Utility tools".
− Select the utility program CP_HEAD_SETUP and press
Execute.
− Press the START button.
5. Under "Setting work", select "Determine joint offset XYZ".
6. Press Continue.
7. Either
Ø If the sensor is already positioned: Press Finish.
or
Ø If the start position or the reference position is to be re-
approached or corrected:
− Follow the wizard.
− Press Continue.

The measuring cycle starts. After the end of the measure-
ment, the newly determined joint offset values and the previ-
ously saved values are displayed.
1 Previous values 2 Newly determined values

Joint offset values sensor Fig. 77376
8. Press Finish.
The newly determined geometric data is saved in the tooling sta-
tus administration. The sensor is ready for operation.

9. Setting up the clamping fixture
Clamping fixture A clamping fixture can be used on different machines or different

production places without having to change the NC program.
In order to compensate for the system tolerances, the fixture
position must be remeasured on the workpiece changer every
time it is remounted. The prerequisite for this is that there be
at least 3 reference elements on the fixture or workpiece, e.g.
measuring balls.
Measuring position The measuring ball positions are determined during the start-up
of the clamping fixture on the machine and remain saved in the
control until they are changed either by entering or by re-meas-
uring the ball position.
1 Measurement nozzle 2 Measuring ball

Measuring ball position Fig. 78082
The utility program CP_FIXTURE_SETUP measures the position

of the vertex as well as 2 positions on the ball circumference,
while the measuring nozzle or sensor touches the measuring ball
at these places.
Thereby, the axes carry out a compensating movement about
the Tool Center Point. The interference contour which arises due
to the cutting optics must be observed and can be tested in
advance with the teach panel.
B836en 2017-11-17 Setting up the clamping fixture 5‐63

Risk of collision during the measurement between
NOTICE processing optics and fixture parts, e.g., from the clamp.
Ø There must be a clearance of at least 30 mm in all direc-
tions between the center of the measuring ball and clamping
fixture or fixture parts.
Ø Before measurement with the teach panel, test the measur-
ing sequence, and therefore interference contour, for each
measuring ball.
Measuring nozzle The ball position is normally measured with a measuring nozzle.
Instead of the cutting nozzle, the measuring nozzle is screwed
into the sensor body of the cutting optics.
Fig. 86277
The following operations have to be performed after mounting

the measurement nozzle:
■ Recording the characteristic curve again for ControlLine.
■ Activate LASER TEST.
Notes
■ Up to the machine serial release S02, a longer measuring
nozzle (mat. no. 1821503) with a length of 11 mm was used.
■ Starting from machine serial release S03, a shorter measur-
ing nozzle (mat. no. 2086798) with a length of 5.5 mm is
used.
Sensor Alternatively, the position of the measuring balls can be meas-

ured at the fixture using the sensor.
Prerequisites:
■ The valid tooling status has been activated for the sensor.
■ The sensor has been calibrated.
5‐64 Setting up the clamping fixture 2017-11-17 B836en

Note
To calibrate the sensor, see the operator's manual for the
machine, chapter "Setting work", section "Calibrating the measur-
ing equipment".
Correction frame Each ball position is measured sequentially and offset against
the required ball position with the CP_FIXTURE_SETUP.LST util-
ity program.
The difference between the actual and required position results
in a correction frame, which is set in the NC program with a zero
point offset (SET_G54, SET_G55, SET_G56 or SET_G57) and
the NC cycle TC_FIXTURE_ACTIVATE for this fixture.
The position of the fixture, and therefore the workpiece zero

point, is corrected in the workpiece coordinate system (WCS)
through rotation and translation.
Displacement by rotation and translation Fig. 78076
The correction frame must be re-determined under the following

conditions:
■ After every remounting of the fixture on the fixture place.
■ After a deletion or change of the zero point memory G54,
G55, G56 or G57.
Determining and activating To determine the correction frame, the following operations have
the correction frame to be performed:
■ Step 1: Start the CP_FIXTURE_SETUP.LST utility program.
■ Step 2: First determine the required position for all 3 meas-
uring balls. There are two ways of doing this:
− Either measure the required position (see "Measuring the
required position", pg. 5‐71).
− Or enter the required position (see "Entering the required
position", pg. 5‐69).
■ Step 3: Afterwards, measure the actual position for all
3 measuring balls (see "Measuring the actual position",
pg. 5‐72).

■ Step 4: If the required and actual positions of the measuring
balls are known, transfer the adjustment values to the control
(see "Determining the correction frame", pg. 5‐74).
■ Step 5: Afterwards, set the zero point offset in the process-
ing program for the respective fixture and correct the zero
point memory with the NC cycle TC_FIXTURE_ACTIVATE.
Note
Activate the correction frame: see the programming manual,
chapter "Automation", section "Clamping fixture".
9.1 Starting the utility program
The fixture position is measured using the utility program

CP_FIXTURE_SETUP.LST. The utility program is started in the
main operation Production.
After starting the utility program, a dialog appears. The following

operations are started and executed one after the other:
■ "Measure nominal position": The required positions of the
three measuring balls are measured.
■ "Enter nominal position": As an alternative to measuring, the
required positions can be input in the dialog, assuming they
are known.
■ "Measure actual position": The actual positions of the three
measuring balls are measured.
■ "Transfer correction values to control": After the required and
actual positions are determined, these are transferred to the
control, the control calculates the correction frame.
Conditions
■ Laser test function is active: The LASER TEST button lights
up.
■ Cutting optics with measuring nozzle are installed.
■ Characteristic curve for ControlLine has been recorded (with
mounted measuring nozzle).
■ The distance regulation is switched on.
■ The measuring ball diameter and the fixture designation are
known.
Notes
■ First check which measuring nozzle is used: the short nozzle
(length 5.5 mm), material number 2086798, or the long noz-
zle (length 11 mm), material number 1821503.

■ The fixture must be created in the utility program. The opera-
tor can add or remove a fixture designation in the "Measure
nominal position" or "Enter nominal position" dialog.
■ Recommendation: Before a measuring sequence is started,
the interference contour should be checked for every meas-
uring ball with the teach panel in order to prevent collisions
during the measurement.

2. Select the utility program CP_FIXTURE_SETUP and press
Execute.
The utility program starts. The "Measure fixture" dialog is
opened.
1 Operation
Fig. 84221
3. After changing the measuring nozzle:

− Press Select measuring nozzle.
− Select the material number of the measuring nozzle.
− Press OK.
4. Measure the required positions of the measuring balls (see
"Measuring the required position", pg. 5‐71).
or
Ø Enter the required positions of the measuring balls (see
"Entering the required position", pg. 5‐69).

9.2 Checking the measuring sequence
(option)
To avoid collisions between the cutting optics and the fixture or

the workpiece during the subsequent measurement, the measur-
ing sequence and thus the interference contour around the
measuring ball can be tested first using the teach panel.
The test conditions must correspond to the measuring situation

later on. The following conditions must be met for this:
■ The test position of the axes corresponds to the nominal
position of the measuring balls. In particular, the position of
the B axis and of the C axis must be identical.
■ The test is carried out with the identical measuring nozzle.
■ The ball diameter must agree.
Conditions
■ The ball diameter is known and is correctly entered in the
utility program.
■ The utility program CP_FIXTURE_SETUP is started.
Notes
■ The ball diameter can only be changed in the utility program
on the control panel.
■ The function key F2 on the teach panel is preassigned with
the Check measuring sequence function.
1. Activate TEACHIN operating mode.

2. Position the measuring nozzle approx. 5 mm over the first
ball.
3. Press the F2 button.
The measuring sequence is started immediately and the
interference contour is tested.
4. Test the measuring sequence for the second ball:
− Position the measuring nozzle over the second ball.
− Press the F2 button.
The measuring sequence is started immediately.
5. Test the measuring sequence for the third ball:
− Position the measuring nozzle over the third ball.
− Press the F2 button.
The measuring sequence is started immediately.

9.3 Entering the required position
As an alternative to measuring the required positions on the

three measuring balls, the required positions can be entered in a
dialog or also just be checked.
The positions of the linear axes, X, Y and Z, correspond to the
measuring ball center. The positions for the B and C axes corre-
spond to the axis positions at the start of the measuring
sequence.
Conditions
known.
■ The ball positions are known for all linear axes.
Note
The last saved ball positions are always shown in the dialog.
1. Select "Enter required position" and press Continue.

The "Enter nominal position" dialog is opened.
1 Fixture designation 3 Ball diameter

2 Ball number 4 Required position
Fig. 86906
2. If the fixture has not yet been created in the utility program:
− Press Add designation.
− Enter the fixture designation.
− Press OK.
3. Determine the fixture and the measuring ball:

− Select the "Designation" of the fixture.
− Select "Ball roller number" 1.
− Enter "Ball diameter".
4. Enter the axis positions for ball number 1 and press Next.
5. Select "Ball roller number" 2, enter the axis positions and
press Next.
6. Select "Ball roller number" 3, enter the axis positions and
press Next.
7. Afterwards, measure the actual positions of the measuring
balls (see "Measuring the actual position", pg. 5‐72).

9.4 Measuring the required position
As an alternative to entering the required position, the required

positions of the measuring balls can be determined through
measurement.
Conditions
known.
Notes
■ The last saved ball positions are always shown in the dialog.
■ The ball positions can be approached with the teach panel,
for example, or by using the JOG buttons.
Measuring the first ball 1. Position the measuring nozzle above the first measuring ball.
position 2. Press the START button.
3. Select "Measuring required position" and press Continue.
The "Measure nominal position" dialog appears.
1 Fixture designation 3 Ball diameter

2 Ball number
Fig. 84215
4. If the fixture has not yet been created in the utility program:
− Press Add designation.
− Enter the fixture designation.
− Press OK.
5. Determine the fixture and the measuring ball:

6. Press Continue.
The measuring starts.
Measuring the second ball 7. Once the measurement has finished, position the measuring
position nozzle over the second measuring ball.
10. Select "Ball roller number" 2 and press Next.
Measuring the third ball 11. Once the measurement has finished, position the measuring
position nozzle above the third measuring ball.
15. Afterwards, measure the actual positions of the measuring
balls (see "Measuring the actual position", pg. 5‐72).
9.5 Measuring the actual position
To calculate the correction frame, the actual positions of the

three measuring balls must be determined.
Conditions
known.
■ The required positions for the three measuring balls are
determined.
Note
The ball positions can be approached with the teach panel, for
example, or by using the JOG buttons.
When the "Measure actual position" dialog opens, the last saved
ball positions for the actual and required positions are displayed.
If there are no valid position values for a ball, the display fields

of the required position are marked with this error symbol .
Here, a distinction is made between the following cases:
■ If an error symbol is displayed for the axes, there are no
saved required positions for this measuring ball. In this case,
the required position must be entered or measured first.
■ If an error symbol is displayed for the B and/or C axis, the
current position of the B axis and/or C axis deviates by more
than 3° from the saved required position. In this case, the
position of the respective axis must be corrected.
Fig. 86907
Measuring the first ball 1. Position the measuring nozzle above the first measuring ball.
position 2. Press the START button.
3. Select "Measuring actual position" and press Continue.
The "Measure actual position" dialog is opened.
1 Fixture designation 3 Ball number

2 Fixture place 4 Ball diameter
Fig. 86908

4. Determine the fixture, fixture place and measuring ball:
− Select a "Fixture place".
5. Press Continue.
Measuring the second ball 6. Once the measurement has finished, position the measuring
position nozzle over the second measuring ball.
Measuring the third ball 10. Once the measurement has finished, position the measuring
position nozzle above the third measuring ball.
14. Once the required and actual positions have been deter-
mined for all measuring balls, calculate the correction frame
(see "Determining the correction frame", pg. 5‐74).
9.6 Determining the correction frame
The control calculates a correction value for the rotary and trans-
lational offset of the fixture or workpiece position from the stored
required and actual positions.
Condition
■ The required and actual positions for all measuring balls are
determined.

2. Select "Transfer the correction values to the control".
3. Press Finish.
The determined required and actual values are transferred to
the control and the correction frame is calculated. The utility
program is ended. This completes the setup of the clamping
fixture.

4. Set the zero point offset in the processing program and acti-
vate the correction frame with the NC cycle TC_FIX-
TURE_ACTIVATE.

Chapter 6
Machine maintenance
1 General guidelines 6‐5
2 Maintenance Overview 6‐6
3 Safety device 6‐10

3.1 Overview 6‐10
Light grid 6‐12
Laser scanner 6‐13
4 Laser protection device 6‐16

4.1 Overview 6‐16
Safety cabin 6‐18
5 Lubrication 6‐24
5.1 Overview 6‐24
B836en 2017-11-17 Machine maintenance 6‐1

X axis drive 6‐25
Y axis drive 6‐31
Z axis drive 6‐37
Device panel: Low-viscosity grease reser- 6‐44
voir central lubrication
6 Mechanical elements 6‐46

6.1 Overview 6‐46
Machine and workspace 6‐47
Magnetic coupling 6‐56
Smart Optics Setup station 6‐58
Z barrel 6‐60
7 Pneumatic system 6‐61

7.1 Overview 6‐61
Device panel: Maintenance unit basic 6‐62
machine
Device panel: Maintenance unit cutting gas 6‐64
air (option)
Device panel: service unit for expanded 6‐65
(option)
Device panel: Condensation collection tank 6‐66
Cutting optics: disposable filter, pneumatic 6‐67
connection
8 Gas 6‐68
Cutting optics: disposable filter, gas connec- 6‐68
tion
9 Water 6‐69
9.1 Overview 6‐69
Cooling circuit of the machine 6‐72
Machine cooler (option), water/air chiller 6‐74
Machine cooler (option), water/water chiller 6‐81
10 Optics 6‐86
6‐2 Machine maintenance 2017-11-17 B836en

Angular gear: FocusLine mirror 6‐114
11 Electrics 6‐118
Switch cabinet: Battery/fan unit, NC CPU 6‐118
Switch cabinet: Industrial PC 6‐119
Switch cabinet: Air conditioning unit 6‐120
12 Compact dust extractor 6‐122

Compact dust extractor: dust container/fine 6‐123
dust bag
Compact dust extractor: spark arrester 6‐127
Compact dust extractor: clean gas space 6‐128
Compact dust extractor: MultiCoater 6‐130
13 Scrap conveyor 6‐133

Scrap conveyor: Sensors 6‐133
Scrap conveyor: pedestal bearing 6‐134
Scrap conveyor: lubricant container 6‐135
Scrap conveyor: conveyor belt 6‐136
Scrap conveyor: housing bottom 6‐137
14 Clamping fixture 6‐140

Clamping fixture for IHU workpieces 6‐141
15 TruDisk 6‐144
TruDisk cooling circuit 6‐145
16 Process cooler for TruDisk (chiller) 6‐146

B836en 2017-11-17 Machine maintenance 6‐3

Process cooler: chiller (water-air) 6‐147
6‐4 Machine maintenance 2017-11-17 B836en

1. General guidelines
Safety Correct maintenance and cleaning are essential for maintaining

the quality of the machine. That prevents operational malfunc-
tions and their consequences.
For maintenance work inside the safety cabin the work area
illumination must remain switched on, so do not switch the
machine's MAIN SWITCH off.
There is a risk of fatal injury during maintenance inside the

DANGER safety cabin.
Ø If not expressly described otherwise: Before starting mainte-
nance work, press the EMERGENCY STOP push-button.
Ø Strictly comply with the safety regulations.
B836en 2017-11-17 General guidelines 6‐5

2. Maintenance Overview
Interval/ Maintenance point Maintenance work Page

operating
hours
Daily Light grid Checking the protected field 6‐12
Daily Laser scanner Checking the protected field 6‐13
Daily Safety cabin Check the safety cabin 6‐18
Daily Safety cabin Checking the sealing strips and the parti- 6‐19
tion wall
Daily Safety cabin Checking the viewing window 6‐19
Daily Machine and workspace Check the air extraction pipe protective 6‐47
screen
Daily Clamping fixture for IHU workpieces Check and clean the positioner 6‐141
Daily Clamping fixture for IHU workpieces Check and replace the ball roller 6‐142
Daily Clamping fixture for IHU workpieces Clean the fixture 6‐142
Weekly Machine and workspace Clean the air extraction pipe protective 6‐47
screens
Weekly Machine and workspace Cleaning the exhaust piping 6‐48
Weekly Machine and workspace Clean the control panel and monitor 6‐49
Weekly Machine and workspace Cleaning the dirt trap and bellows 6‐49
Weekly Machine and workspace Clean the machine and working area 6‐50
Weekly Compact dust extractor: dust container/ Checking the level and replacing the con- 6‐124
fine dust bag tainer or fine dust sack
Weekly Compact dust extractor: spark arrester Cleaning the spark arrester 6‐127
Weekly Clamping fixture for hot-formed parts Cleaning the guard plates, slag channel 6‐140
and cover
Monthly X axis drive Checking the lubricating pinion 6‐25
Monthly X axis drive Clean the guide rails, stripper and rack 6‐26
Monthly Y axis drive Checking the lubricating pinion 6‐31
Monthly Y axis drive Clean the guide rails, stripper and rack 6‐32
Monthly Z axis drive Checking the lubricating pinion and the 6‐37
rack
Monthly Z axis drive Cleaning the grease collecting vessel and 6‐38
drip tray
Monthly Z axis drive Clean the guide rails and stripper 6‐39
Monthly Z barrel Checking hose connections and quick- 6‐60
release couplings
Monthly Device panel: Maintenance unit basic Checking and setting the static operating 6‐62
machine pressure
Monthly Device panel: service unit for expanded Checking and setting the static operating 6‐65
compressed air supply or vacuum pressure
ejectors (option)
Monthly Device panel: Condensation collection Check filling level 6‐66
tank
Monthly Machine cooler (option), water/water Check filling level 6‐81
chiller
Monthly Scrap conveyor: housing bottom Cleaning the housing bottom 6‐137
Every 6 X axis drive Replacing the lubricating pinion 6‐28
months
6‐6 Maintenance Overview 2017-11-17 B836en

operating
hours
Every 6 X axis drive Replacing strippers 6‐29
months
Every 6 Y axis drive Replacing the lubricating pinion 6‐34
months
Every 6 Y axis drive Replacing strippers 6‐35
months
Every 6 Z axis drive Replacing the lubricating pinion 6‐40
months
Every 6 Z axis drive Replacing strippers 6‐42
months
Every 6 Z axis drive Cleaning the rack 6‐43
months
Every 6 Device panel: Maintenance unit basic Replace the filter element 6‐63
months machine
Every 6 Device panel: Maintenance unit cutting Replace the filter element 6‐64
months gas air (option)
Every 6 Device panel: service unit for expanded Replace the filter element 6‐66
months compressed air supply or vacuum
ejectors (option)
Every 6 Cutting optics: disposable filter, pneumatic Exchange filter insert or filter 6‐67
months connection
Every 6 Cutting optics: disposable filter, gas con- Exchange filter insert or filter 6‐68
months nection
Every 6 Compact dust extractor: MultiCoater Replacing the pressure regulating valve 6‐132
months filter cartridge
Every 6 Scrap conveyor: conveyor belt Checking and setting the chain tension 6‐136
months
Annually Machine and workspace Check the door seal 6‐50
Annually Machine and workspace Clean beneath the platform 6‐51
Annually Cooling circuit of the machine Checking the flow controller 6‐72
Annually Machine cooler (option), water/air chiller Replace cooling water 6‐76
Annually Machine cooler (option), water/air chiller Replace the filter element. 6‐80
Annually Machine cooler (option), water/water Replace cooling water 6‐81
chiller
Annually Machine cooler (option), water/water Replace the filter element. 6‐85
chiller
Annually Switch cabinet: Battery/fan unit, NC CPU Replacing the buffer battery 6‐118
Annually Switch cabinet: Industrial PC Replacing the buffer battery 6‐119
Annually Switch cabinet: Air conditioning unit Cleaning the air conditioning unit 6‐120
Annually Compact dust extractor: clean gas space Check and clean 6‐128
Annually Compact dust extractor: MultiCoater Checking and replacing the seal 6‐131
Annually Scrap conveyor: pedestal bearing Lubricate the pedestal bearing 6‐134
Annually Scrap conveyor: housing bottom Cleaning the bottom of the housing in the 6‐138
area of the bend
Annually TruDisk cooling circuit Replacing cooling water and cleaning the 6‐145
tank
Annually Process cooler: chiller (water-air) Replacing the filter mat 6‐147
Annually Process cooler: chiller (water-air) Replace cooling water 6‐149
B836en 2017-11-17 Maintenance Overview 6‐7

operating
hours
Every 5 years Switch cabinet: Industrial PC UPS module, replacing the rechargeable 6‐120
battery pack
As needed Light grid Cleaning the front screen 6‐12
As needed Laser scanner Cleaning the optical window 6‐14
As needed Safety cabin Cleaning the laser protection window 6‐20
As needed Safety cabin Replacing the monitor 6‐20
As needed Safety cabin Replacing the status indicator 6‐22
As needed Machine and workspace Replace the X axis bellows 6‐52
As needed Machine and workspace Replace the Y axis bellows 6‐54
As needed Magnetic coupling Clean and check 6‐56
As needed Smart Optics Setup station Cleaning the test sheet holder 6‐58
As needed Smart Optics Setup station Replacing the test sheet holder 6‐59
As needed Cutting optics with a focal length of Clean the housing 6‐88
150 mm
As needed Cutting optics with a focal length of Checking, cleaning or replacing the lens 6‐91
150 mm
As needed Cutting optics with a focal length of Checking, cleaning or replacing the 6‐97
150 mm deflection mirror
As needed Cutting optics with a focal length of Cleaning the sensor body and the nozzle 6‐98
150 mm
As needed Cutting optics with a focal length of Replacing the sensor body 6‐99
150 mm
As needed Cutting optics with a focal length of Clean the housing 6‐101
200 mm
As needed Cutting optics with a focal length of Checking, cleaning or replacing the lens 6‐104
200 mm
As needed Cutting optics with a focal length of Checking, cleaning or replacing the 6‐110
200 mm deflection mirror
As needed Cutting optics with a focal length of Cleaning the sensor body and the nozzle 6‐111
200 mm
As needed Cutting optics with a focal length of Replacing the sensor body 6‐112
200 mm
As needed Angular gear: FocusLine mirror Checking and cleaning the deflection mir- 6‐114
ror
As needed Scrap conveyor: Sensors Cleaning sensors 6‐133
As needed Clamping fixture for hot-formed parts Replacing the wearing parts 6‐140
As needed Clamping fixture for IHU workpieces Replacing the wearing parts 6‐143
As needed Process cooler: chiller (water-air) Checking for coolant circuit leakage 6‐148
When indi- Device panel: Low-viscosity grease reser- Filling the low-viscosity grease reservoir 6‐44
cated by the voir central lubrication
control sys-
tem
When indi- Machine cooler (option), water/air chiller Checking and refilling the level 6‐74
cated by the
control sys-
tem
6‐8 Maintenance Overview 2017-11-17 B836en

operating
hours
When indi- Machine cooler (option), water/air chiller Clean the filter mat 6‐74
cated by the
control sys-
tem
When indi- Compact dust extractor: dust container/ Replacing the dust container 6‐125
cated by the fine dust bag
control sys-
tem
When indi- Compact dust extractor: MultiCoater Topping up dispensing material 6‐130
cated by the
control sys-
tem
When indi- Scrap conveyor: lubricant container Filling the lubricant container 6‐135
cated by the
control sys-
tem
When indi- TruDisk cooling circuit Cleaning or replacing the contamination 6‐145
cated by the filter
control sys-
tem
When indi- TruDisk cooling circuit Replacing the water microfilter 6‐145
cated by the
control sys-
tem
When indi- Process cooler: chiller (water-air) Checking and refilling the level 6‐148
cated by the
control sys-
tem
B836en 2017-11-17 Maintenance Overview 6‐9

3. Safety device
3.1 Overview
1 Light grid 2 Laser scanner 3 Protective wall

Safety device for rotational changer, Basic Loading variant Fig. 71173
1 Light grid 2 Mirror post/ deflection mirror 3 Laser scanner

Safety device for rotational changer, Comfort Loading variant Fig. 74485
6‐10 Safety device 2017-11-17 B836en

1 Protective wall 3 Laser scanner 4 Light grid
2 Safety strip
Safety device height, rotary indexing table, Comfort Loading variant Fig. 71174
The following devices will be used to safeguard the danger

zones:
■ Safety light curtain made by Sick, C4000 transmitter, 40 mm
resolution (TRUMPF material no. 0370953).
■ Safety light curtain made by Sick, C4000 receiver, 40 mm
resolution (TRUMPF material no. 0373297).
■ S300 Mini safety laser scanner 3 m, made by Sick (TRUMPF
material no. 1803143).
B836en 2017-11-17 Safety device 6‐11

3.2 Maintenance Instructions
Light grid
(see "Overview", pg. 6‐10)
105444: Maintenance interval: Daily

Checking the protected field
The protected field must be checked every day, preferably at the

beginning of the shift. The light grid belongs to the machine's
safety equipment.
The machine may not be put into operation unless the opera-
tional safety of the protected field is ensured.
Maintenance work on the light grid may only be performed by
specialist personnel trained in these areas.

■ Test rod (included in the scope of delivery of the light grid).
Ø Slowly move the test rod along the entire protected field,
while watching the display on the receiver.
The protected field is OK if the green or yellow operational sta-
tus indicator on the receiver does not light up while the check is
being made.
105172: Maintenance interval: As needed

Cleaning the front screen
If the operational status indicator on the receiver lights up in

orange, then the front screen must be cleaned.
Maintenance work on the light grid may only be performed by
specialist personnel trained in these areas.

■ Anti-static plastic cleaner (SICK item no. 5600006)
■ SICK lens cloth (item no. 4003353)
Notes
■ Do not use any aggressive or abrasive cleaning agents.
■ If the operational status indicator on the receiver continues to
be illuminated in orange after cleaning, then realign the light
grid.
1. Remove the dust from the front screen using a clean and
soft brush.

2. Afterwards, clean with a damp cloth and plastic cleaning
agent.
3. Check the protected field.
Laser scanner

Checking the protected field
The protected field must be checked every day, preferably at the

beginning of the shift.
The laser scanner is a safety device of the machine. The
machine may only be put into operation if the protective device
is effective.
According to the applicable national regulations, the laser scan-
ner must be checked by a skilled person within the required
period of time.
Conditions
■ The protected field is not interrupted. The "Warning field"
indicator will not light up.
1 Warning field indicator light

Laser scanner Fig. 84214

1. Enter the protected field from the front in the direction of the
laser scanner. During this, check whether the "Warning field"
indicator lights up.
2. For machines with a rotational changer and with the Com-
fort Loading safeguarding device variant.
Then access the protected field from the left and then from
the right in the direction of the laser scanner while checking
the indicator light..
3. If the indicator lights up for all three test points, when
accessing the protected field, then the laser scanner is OK
and the safety device is effective.
or
Ø If the display does not light up for at least one test point
then there is a fault. The machine may only be put back
into operation once the error has been eliminated.

Cleaning the optical window
If the indicator for the optical window flashes or lights up, then
the optical hood and window must be cleaned.
If the optical hood or the window is damaged, then the complete
optical hood can be replaced (see the operator's manual from
Sick, S300 Mini type laser scanner).

■ Anti-static plastic cleaner (SICK item no. 5600006)
■ SICK lens cloth (item no. 4003353)
Note
Do not use any aggressive or abrasive cleaning agents.

1 Optical hood 3 Optical window indicator light
2 Optical window
Checking the laser scanner Fig. 71177
1. Lift and remove the protective cover.

2. First remove the abrasive cutting dust using compressed air
or a soft brush.
3. Afterwards, clean the optical hood and window with a moist
cloth and plastic cleaner.
4. Refit the protective hood.
5. Then check the laser scanner.

4. Laser protection device
4.1 Overview

WARNING
Damage to your eyesight or even complete blindness can
be the consequence. Serious skin burns can occur.
Ø The machine may only be used with active laser safety devi-
ces.
Ø Laser safety devices must not be removed.
Ø Every day, visually inspect the safety cabin, viewing window,
partition wall and sealing strips for damage, before switching
the machine on, or before starting the shift.
Ø The machine must not be put into operation, if any of the
mentioned laser safety devices is damaged or missing.
Ø With the exception of sealing strips, laser safety devices
may only be replaced by TRUMPF service staff.
6‐16 Laser protection device 2017-11-17 B836en

1 Safety cabin sealing strips 3 Rotational changer partition wall 5 Conveyor/safety cabin interface
(green) 4 Laser protective window
2 Partition wall sealing strips (red)
Overview of the safety cabin with a rotational changer Fig. 71420
B836en 2017-11-17 Laser protection device 6‐17

1 Conveyor/safety cabin interface 3 Partition wall sealing strips (red) 5 Laser protection window
2 Safety cabin sealing strips 4 Rotary indexing table partition
(green) wall
Overview of the safety cabin with a rotary indexing table Fig. 71421
Safety cabin

Check the safety cabin
A visual inspection is carried out.
1. Check the safety cabin for damage, especially the interfaces

to the scrap conveyor, to the rotational changer or the rotary
indexing table.
2. Do not put the machine into operation if a safety device is
damaged (deep scorching, hole, crack, etc.). Replace dam-
aged parts immediately.

Checking the sealing strips
and the partition wall
The interface between the partition wall of the rotational changer
and the safety cabin as well as between the partition walls of the
rotary indexing table and the safety cabin is sealed by sealing
strips.
These sealing strips and the partition wall belong to the
machine's laser safety equipment.
Note
The rotational changer's partition wall or the rotary indexing
table's partition walls may only be replaced by TRUMPF service
engineers.
If the sealing strips are damaged or deformed, invisible,

WARNING high energy laser radiation may escape.
Ø If laser radiation escapes, do not put the machine into oper-
ation.
Ø Immediately replace the sealing strips.
Ø The sealing strips may only be replaced by qualified person-
nel who have been specially trained in the process.
1. Check the sealing strips inside and outside of the safety

cabin for damage and deformation.
2. Check whether laser radiation can be emitted. If it can,
replace the sealing strips.
3. Mount new sealing strips correctly. No light gap may develop.

Checking the viewing
window
Note
Request TRUMPF customer service to replace the viewing win-
dows.

DANGER
Severe skin burns and eye injuries may occur.
Ø Replace the viewing window if scorching is 1 mm deep or
holes are discovered during inspection.
Ø Do not put the machine back into operation until after the
defective viewing window has been replaced.
Ø Check the viewing windows for scorched areas, holes or

damage.

Cleaning the laser protection
window
The laser protection window is made of a special mineral glass
that absorbs laser radiation (plastic glass).

■ Water with mild soapy water
Note
If the window is cleaned using a dry cloth, the plastic glass will
be damaged and the protective effect may be lost.
Ø Clean the safety window with a soft cloth and lukewarm

water.

Replacing the monitor
In the front of the safety cabin, monitors for work area

monitoring (option) and/or for the remaining time display (option)
are used. If a monitor is defective, it can be replaced.
If the monitor cannot be replaced immediately, or if it is to be
removed permanently, the opening in the safety cabin must be
sealed with a cover.
Note
If this is not available, the cover (TRUMPF order number
1833736) can be ordered from TRUMPF Spare Parts Sales.
Escape of invisible, high-energy laser radiation when the

WARNING monitor is removed!
Ø Do not put the machine into operation without a monitor or
cover.

1 Monitor holder
Monitor with monitor holder Fig. 79715
1. Switch the machine off.

2. Loosen the four fastening screws for the monitor or monitor
holder on the inside wall of the safety cabin.
3. On the outside wall, pull the monitor out of the safety cabin
and disconnect from the cable.
4. Either
Ø Install a new monitor:
− Screw the existing monitor holder to the new monitor.
− Insert the monitor into the opening of the safety cabin
from the front again and connect it electrically.
or
Ø If there is no monitor available, mount the cover:
− Insert the cover into the opening of the safety cabin from
the front.

1 Fixing screws
Monitor attachment from inside Fig. 78930
5. Screw the cover or monitor firmly to the inside wall of the
safety cabin.

Replacing the status
indicator
If a light is defective, it can be replaced.
Notes
■ Instead of the missing status indicator, the opening in the
safety cabin can be sealed with a cover.
■ The cover (TRUMPF order number 1834795) can be ordered
from the TRUMPF Spare Parts Sales.
Invisible, high-energy laser radiation will escape if a status

WARNING indicator is missing!
Ø Do not put the machine into operation without a status indi-
cator or cover.

1 Fastening screws, cover
Status light Fig. 78935
Ø Either
Ø Replace the status indicator.
or
Ø If no new status indicator is to be used, seal the created
opening in the safety cabin with the cover.

5. Lubrication
5.1 Overview
Notes
■ Before starting maintenance work on the axis drives, move
the NC axes into a suitable position that is easy to access
by maintenance personnel.
■ To clean the racks and guide rails, only 2 propanol should be
used. Wear gloves and safety glasses when cleaning with
2 propanol.
The rack will not be lubricated sufficiently!

NOTICE
This results in damage to the drive.
Ø Do not install a new lubrication pinion in dry form.
Ø Replace damaged or hardened lubrication pinions at once.
1 Lubricating pinion, X axis 3 Lubricating pinion, Y axis 4 Central lubrication lubricant con-
2 Lubricating pinion, Z axis tainer
Lubrication plan for TruLaser Cell 8030 Fig. 74486
Maintenance point Volume (lit- Lubricant DIN 51502 Viscosity

ers) coding consistency
Guide rail, rack and lubricating - Low-viscosity grease, GP00 G-10 NLGI Nr. 00
pinion X, Y and Z axes KLÜBER
Microlube GB 00
Low-viscosity grease reservoir 1 Low-viscosity grease, GP00 G-10 NLGI Nr. 00
central lubrication KLÜBER
Microlube GB 00
Scrap conveyor low-viscosity 1.5 Shell Tonna oil S3 M32 - -
grease reservoir
6‐24 Lubrication 2017-11-17 B836en

Maintenance point Volume (lit- Lubricant DIN 51502 Viscosity
ers) coding consistency
Scrap conveyor pedestal bear- - Roller bearing grease - -
ing Mobiltemp SHC100
Lubricant table Tab. 6-1
X axis drive
100658: Maintenance interval: Monthly

Checking the lubricating
pinion
The driving pinion of the axis is lubricated by a pinion made
of felt. The lubricating pinion is supplied from the central
lubrication system.
1 Cover plate 3 Lubricating pinion 5 Fixing screws, lubricating pinion

2 Fixing screws 4 Connection central lubrication
Lubricating pinion for the X axis drive Fig. 59611
1. Move the extension arm to an easily accessible position.

Lower the Z axis to the Z = 0 position.
3. On the extension arm, remove the covering sheet (posn. 1).
4. Check the lubricating pinion:
− Is the lubricating pinion damaged, worn, hardened or
clogged with cutting dust?
− Is the driving pinion or the rack supplied with sufficient
low-viscosity grease?
B836en 2017-11-17 Lubrication 6‐25

5. Immediately replace damaged lubricating pinions (e. g. miss-
ing teeth).
6. Install the covering sheet again.

Clean the guide rails,
stripper and rack
The guide carriage of the axis is protected by a pair of strippers.
Grease and dirt must be removed at regular intervals. After
2000 hours of operation, the outer plastic stripper must be
replaced. Damaged strippers must be replaced immediately.
The bellows protects the guide rails and the drive from con-
tamination and thus from damage. Damaged bellows, e.g. by
holes or cracks, must be replaced.

■ Torque screwdriver, material no. 1851934.
■ Clean, lint-free cloth.
■ Industrial vacuum cleaner.
■ Brush
■ 2-propanol.
■ Low-viscosity grease, e.g. KLÜBER Microlube GB 00.
Notes
■ Do not use any solvents for cleaning the guide rails.
■ The inner stripper must not be removed.
■ It is not necessary to clean the upper guide rail of the X
drive.

1 Dirt trap 4 Retaining nuts (2x)
2 Bellows guide plate 5 Guide rail
3 Stripper
Lower stripper guide carriage Fig. 68258
1. First move the extension arm to the end of the working

range in the X direction: either to X = 0 or X = 3000.
2. Lower the Z axis to the Z = 0 position.
3. Press the FEED HOLD button.
4. Clean the bellows, remove the cutting slugs. Extract dust
from the bellows and check for damage.
5. Only on the lower guide rail, undo the bellows on the exten-
sion arm and slide it outwards, so that the drive guide is
open for its full length.
6. Clean the dirt trap and the deflector plate as well as the gap
between them with an industrial vacuum cleaner.
7. Clean the outermost stripper on the guide carriage:
− Remove the hexagonal nuts from the stripper.
− Remove the external stripper from the guide, tilt the strip-
per slightly to do so.
− Thoroughly clean the stripper and check for damage. If it
is damaged, replace the stripper immediately.
8. Refit the stripper. Tighten the retaining nuts to a torque of
0.4 Nm. If the retaining nuts are over-tightened, the
molded part in the stripper package will be deformed too
much.
9. Put some 2 propanol on a cloth and clean the guide rail as
well as the guide plates for the bellows over the entire
length.
10. Clean the rack with a brush and 2 propanol.

11. After the cleaning: lightly grease the rack and guide rail with
low-viscosity grease.
12. Then move the extension arm to the other end of the work-
ing range.
14. Clean the bellows and then undo the bellows on the exten-
sion arm.
15. Clean the drive guide in the same way as the other side.
16. Finally, remount the bellows. Take care that the contour of
the bellows is aligned with the contour of the holder.
100660: Maintenance interval: Every 6 months

Replacing the lubricating
pinion
24 hours before being installed, the new lubricating pinion
must be placed in low-viscosity grease, Klüber Microlube
GB 00.

Note
The lubricating pinion is secured with a locking washer. The lock-
ing washer is under tension, it can be removed with a screw-
driver.
The washer securing the lubricating pinion is under

CAUTION tension!
Ø While replacing the lubricating pinion, wear safety glasses.

1 Cover plate 3 Lubricating pinion 5 Fixing screws, lubricating pinion
2 Fixing screws 4 Connection central lubrication
Lubricating pinion for the X axis drive Fig. 59611

3. On the extension arm, remove the covering sheet (posn. 1).
4. Remove the lubricant line at the lubricating pinion.
5. Release the fastening screws (pos. 5). Take out the lubricat-
ing pinion.
6. Assembling a new lubricating pinion:
− Loosen the securing washer, remove the disk and pull
the lubricating pinion off upward.
− Insert the new, lubricating pinion, soaked in low-vis-
cosity grease.
− Place the securing washer on the lubricating pinion,
lightly press it down and secure.
7. Reinsert the lubricating pinion and fasten.
8. Re-install the lubricant line and the cover sheet.

Replacing strippers
The stripper kit consists of an inner and an outer stripper. Only

the outer plastic stripper is replaced.

■ Brush
■ 2-propanol.

Notes
1 Dirt trap 4 Retaining nuts (2x)

2 Bellows guide plate 5 Guide rail
3 Stripper
Lower stripper guide carriage Fig. 68258
1. First move the extension arm to the end of the working

range in the X direction: either to X = 0 or X = 3000.
5. Only on the lower guide rail, undo the bellows on the exten-
sion arm and slide it outwards, so that the drive guide is
open for its full length.
7. Replace the outer plastic stripper on the guide carriage:
− Refit the stripper. Tighten the retaining nuts to a torque of
molded part in the stripper package will be deformed
too much.

length.
11. Then move the extension arm to the other end of the work-
ing range.
13. Clean the bellows and then undo the bellows on the exten-
sion arm.
Y axis drive

pinion
lubrication system.
1 Holder 2 Fixing screw 3 Lubricating pinion

Lubricating pinion, Y axis Fig. 59615

3. Remove the hood from the Y drive. Undo the 3 fixing screws
(one screw at the bottom, the top and at the side).
4. Undo the fixing screws (posn. 2) on the holder for the lubri-
cating pinion. Pull out the lubricating pinion.
5. Check the lubricating pinion:
− Is the lubricating pinion damaged, worn, hardened or
clogged with cutting dust?
− Is the driving pinion or the rack supplied with sufficient
low-viscosity grease?
6. Immediately replace damaged lubricating pinions (e. g. miss-
ing teeth).
7. Insert a lubricating pinion and screw on holder.
8. Reinstall the hood.

Clean the guide rails,
stripper and rack

■ Brush
■ 2-propanol.
Notes

1 Fixing screws 4 Grease drip tray
2 Stripper 5 Bellows guide plate
3 Guide rail
Stripper guide carriage Fig. 72855
1. Move the Y slide to the Y = 0 position.

5. On the guide carriage, undo the bellows for the upper and
lower guide rails on the holder.
6. Unscrew and clean the grease drip tray.
much.
length.

13. Reinstall the grease drip tray.
14. Then move the Y slide to the other end of the working range.
16. Clean the bellows and then undo the bellows from the Y
slide.

pinion
GB 00.

Note
driver.

CAUTION tension!

1 Holder 2 Fixing screw 3 Lubricating pinion
Lubricating pinion, Y axis Fig. 59615

3. Remove the hood from the Y drive. Undo the 3 fixing screws
(one screw at the bottom, the top and at the side).
4. Undo the fixing screws (posn. 2) on the holder for the lubri-
cating pinion. Pull out the lubricating pinion.
cosity grease.
6. Insert the lubricating pinion and screw the holder in place.
7. Reinstall the hood.

Replacing strippers



■ Brush
■ 2-propanol.
Notes
1 Fixing screws 4 Grease drip tray

2 Stripper 5 Bellows guide plate
3 Guide rail
1. Move the Y slide to the Y = 0 position.

5. On the guide carriage, undo the bellows for the upper and
lower guide rails on the holder.
6. Unscrew and clean the grease drip tray.
8. Replace the outer plastic stripper on the guide carriage:

− Refit the stripper. Tighten the retaining nuts to a torque of
molded part in the stripper package will be deformed
too much.
length.
12. Reinstall the grease drip tray.
13. Then move the Y slide to the other end of the working range.
15. Clean the bellows and then undo the bellows from the Y
slide.
Z axis drive

pinion and the rack
lubrication system.

1 Cover plate 2 Lubricating pinion
Z axis drive Fig. 74929

3. Remove the cover plate (posn. 1).
4. Check the lubricating pinion: Is the lubricating pinion dam-
aged, worn, hardened or clogged with cutting dust?
Immediately replace damaged lubricating pinions (e. g. miss-
ing teeth).
5. Check whether the rack is supplied with sufficient low-viscos-
ity grease. If the rack is damaged or heavily soiled, request
assistance from TRUMPF Technical Service.
6. After the check, install the covering sheet again.

Cleaning the grease
collecting vessel and drip
tray Excess grease will collect in the grease collecting vessel and in
the drip tray.

■ 2-propanol.

1 Drop-in sheet 3 Grease drip tray 4 Belt
2 Grease collecting vessel
The grease collecting vessel and drip tray Fig. 72859

3. Unscrew the grease collecting vessel and pull out the drop-in
sheet.
4. Clean the grease collecting vessel and drop-in sheet.
5. Reinstall the grease collecting vessel:
− Fit the grease collecting vessel with the tab in the lower
fixing screw, align and then slide it straight up as far as it
goes.
− Tighten the top and bottom fixing screws hand-tight.
6. Clean the grease drip tray with a clean cloth.

Clean the guide rails and
stripper

■ 2-propanol.

Notes
1 Stripper 3 Guide rail

2 Retaining nut

4. Put some 2 propanol onto a clothe an clean the guide rail.
5. After the cleaning: lightly grease the guide rail with low-vis-
cosity grease.
much.
7. Remove the excess grease in the drip pan.

pinion
GB 00.

Note
driver.

CAUTION tension!
1 Befestigungsschrauben 2 Cover plate 3 Lubricating pinion


4. Remove the lubricant line at the lubricating pinion.
5. Undo the fixing screws on the holder for the lubricating pin-
ion, tilt the holder to the back and pull out the lubricating pin-
ion.
cosity grease.
7. Reinstall the lubricating pinion and align it so that the lubri-
cating pinion is aligned to the rack.

8. Firmly screw the holder for the lubricating pinion in place.
Install cover plate.

Replacing strippers


■ 2-propanol.
Notes
1 Stripper 3 Guide rail

2 Retaining nut

3. Replace the outermost stripper on the guide carriage:
4. Put some 2 propanol onto a clothe an clean the guide rail.
5. After the cleaning: lightly grease the guide rail with low-vis-
cosity grease.

6. Mount a new stripper. Tighten the retaining nuts with a tor-
que of 0.4 Nm. If the retaining nuts are over-tightened,
the molded part in the stripper package will be deformed
too much.
7. Remove the excess grease in the drip pan.

Cleaning the rack
The belt protects the toothed rack from dirt. If the belt is dam-
aged, or if the rack is too heavily soiled, ask for a service call.
Conditions
■ The Z axis is lowered to position Z = 0.
■ The machine's drives are switched on: The
MACHINE ON/OFF button lights up.

■ Brush
■ 2-propanol.
1 Cover plate 2 Rack


2. Move the Z axis step by step upwards, cleaning each acces-
sible area with a brush and 2 propanol. Then apply a thin
layer of grease.
3. Once the complete rack has been cleaned, remount the
cover plate.
4. Then clean the grease collecting vessel and the drip tray.

Device panel: Low-viscosity grease
reservoir central lubrication
100672: Maintenance interval: When indicated by the control system

Filling the low-viscosity
grease reservoir
The control system monitors the filling level in the low-viscosity
grease reservoir. As soon as the minimum filling level is
reached, the control system displays a message.
Note
The lubrication pressure must be at least 50 mbar. The lubrica-
tion cycle stops if the pressure is too low. An error message is
issued.
Causes of error could include: Air in the line, a broken hose or
the low-viscosity grease reservoir is empty.
Air in central lubrication!

NOTICE
The axis drives are not lubricated. Machine downtime.
Ø Top up the low-viscosity grease reservoir when the message
appears.
1 Level sensor 2 Low-viscosity grease reservoir

Lubricant container lubricant pump Fig. 74468

1. If a message appears or if the yellow LED display on the
low-viscosity grease reservoir is not illuminated, fill the reser-
voir.
− Remove the cover, pour the low-viscosity grease in
slowly to avoid bubbles.
− Close the cover.
2. Reset the lubrication counter:
− Press Maintenance, select "Manual functions".
− Select the Maintenance group.
− Press "Reset lubricat. count."

6. Mechanical elements
6.1 Overview
1 Bellows for X and Y axis 3 Air extraction pipe protective 5 Magnetic coupling
2 Dirt trap screen 6 Cable connections, barrel
4 Air deflecting plate on the body
of the machine
Overview of the mechanics Fig. 74471
6‐46 Mechanical elements 2017-11-17 B836en

Machine and workspace

Check the air extraction pipe
protective screen
The scrap conveyor is connected to the air extraction piping on
both sides. The interface where the air is sucked in is protected
by a screen. This prevents waste parts or other objects lying on
the scrap conveyor from being sucked up and thus getting into
the compact dust extractor.
1 Protective screen
Connection of the air extraction piping to the scrap conveyor Fig. 74631
Ø Check the protective screen to the left and right of the con-
veyor belt's feed area and remove coarse dirt and any waste
parts stuck there.
106861: Maintenance interval: Weekly

Clean the air extraction pipe
protective screens
■ Steel brush.
B836en 2017-11-17 Mechanical elements 6‐47

1 Protective screen
Connection of the air extraction piping to the scrap conveyor Fig. 74631
Ø Thoroughly clean the protective screens to the left and right

of the conveyor belt's feed area:
− Use an industrial vacuum cleaner to remove coarse dirt.
− Clean the protective screen with a brush.

Cleaning the exhaust piping
Dust may accumulate in the pipeline between the machine and
the compact dust extractor.

Cleaning opening of exhaust piping Fig. 84223
1. Remove the cover of the cleaning opening.

2. Clean the pipeline with an industrial vacuum cleaner.
3. After cleaning, seal the pipeline opening again with the cover.

Clean the control panel and
monitor
Ø Clean the monitor, control panel and keyboard with a moist
cloth.

Cleaning the dirt trap and
bellows
The bellows protect the guide rails on the X and Y axes from
dirt. The bellows must be regularly cleaned of dust.
A dirt trap is installed behind the lower bellows on the X axis.
The purpose of the dirt trap is to collect dirt and protect the
guide rails and bellows.

Notes
■ Do not remove the bellows.
■ The "air deflecting plates" on the body of the machine and
on the side of the scrap conveyor are bent functional sheets
which ensure that air is effectively extracted from the work
area.
1 Dirt trap 3 Air guiding plate

2 Air guiding plate
Fig. 74943
1. Vacuum clean the dirt trap and the bellows.

2. Check that the bellows are properly seated. The guides on
the bellows must easily run in the stainless steel guide.

Clean the machine and
working area
The machine and the working area must be thoroughly cleaned
at regular intervals:
■ The machine frame, air guiding plate on the machine frame
and the bellows.
■ Rotational changer or rotary indexing table (option).
■ For machines with a rotary indexing table: hinged guide plate
and platform.
■ Devices (option).
■ Scrap conveyor and exhaust piping.
■ Safety cabin, inside and out.

■ Soft brush.
■ Universal cleaner.
Note
Do not use any solvents for cleaning.
Very fine or oily cutting dust can be deposited on the

NOTICE components inside the safety cabin.
Destruction of the axis drives.
Ø Regularly clean the work area and the machine's compo-
nents.
1. For machines with a rotary indexing table: hinge up the

deflector plate along the body of the machine.
2. Remove coarse dirt and waste parts from the work area or
from the platform.
3. Use an industrial vacuum cleaner to vacuum up dust.
4. Remove slag with a soft brush.
5. Clean components with a moist, soft cloth.
106859: Maintenance interval: Annually

Check the door seal
The service door is sealed all around with a sponge rubber seal,
so that the reduced pressure necessary for effective air extrac-
tion can be achieved inside the safety cabin.

The door seal is important for the proper functioning of the sys-
tem. If it gets damaged or comes loose, then it must be
replaced.
Ø Check the door seal and replace if necessary.

Clean beneath the platform
Note:
This is only valid for machines with a rotary indexing table
(option).
The scrap conveyor is open near its lower bend, beneath the
platform. Waste parts and dust can collect in this area.

1 Flap
Platform, open flap Fig. 86909
1. Open the flap on the platform.

1 Cover, exhaust piping 2 Collecting pan
Clean beneath the platform Fig. 86910
2. Pull out the collecting pan under the platform, remove the
large waste parts and clean the collecting pan with an indus-
trial vacuum cleaner.
3. Afterwards, push the collecting pan back under the deflection
of the scrap conveyor.
4. Remove the cover from the exhaust piping and clean the
tube with an industrial vacuum cleaner.
5. After cleaning, seal the exhaust piping again with the cover.

Replace the X axis bellows
Each bellows has a velcro fastener on the side which moves.
When replacing the bellows, the holder with the velcro fastener
is also replaced. On the other, fixed, side the bellows is firmly
screwed to the holder
Notes
■ The guiding parts can deform or jump out when engaging
them into the guide. Make sure that they are properly seated
and move easily.
■ The upper bellows on the X axis does not generally have to
be replaced.

The X axis bellows are different on the left and on the right.
Inside each bellows on the extension arm side, there is a pull-
out stop on and a velcro fastener.
1 Pull-out lock
X axis bellows guide rail Fig. 59996
1. Unscrew the bellows holder on the extension arm side.
1 Holder crewed in place 3 Fixing screws, holder 4 Velcro fastened holder

2 Bellows
X axis bellows Fig. 68761
2. Remove the left bellows:

− Unscrew the bellows from the outer holder at the other
end.
− Unscrew the holder (posn. 1) and remove the bellows.
3. Remove the right hand bellows:
end and remove the bellows.

4. Before installing the new bellows: Clean the dirt trap and the
deflector plate as well as the gap between them with an
industrial vacuum cleaner.
5. Mount the new velcro fastened holder on the extension arm
side.
6. Install the left bellows:
− Introduce the correct bellows for the side into the guide
plates from the outside.
− Remount the outer holder again.
− Screw the bellows holder onto the outer holder.
7. Install the right hand bellows:
− First hook in the bellows from above into the upper guide
plate. Then engage the guide parts into the lower guide
plate, while slightly tilting them to the side.
8. Check whether the bellows moves easily in the guide.
9. Close the bellows onto the velcro fastener. Take care that
the bellows' shape is aligned with the shape of the holder.

Replace the Y axis bellows
Each bellows has a velcro fastener on the side which moves.
When replacing the bellows, the holder with the velcro fastener
is also replaced. On the other, fixed, side the bellows is firmly
screwed to the holder
Note
The guiding parts can deform or jump out when engaging them
into the guide. Make sure that they are properly seated and
move easily.

1 Bellows, lower guide rail 2 Bellows, upper guide rail 3 Bellows, upper and lower guide
rail
Y axis bellows Fig. 72856
1. Unscrew the Y slide bellows holder.

2. Remove the left bellows:
end and remove the bellows.
3. Remove the right hand bellows:
end.
− Unscrew the outer holder and remove the bellows.
4. Before installing the new bellows, clean the guide plates.
5. Mount the new velcro fastened holder onto the Y slide.
6. Install the left hand bellows:
− First hook in the bellows from above into the upper guide
plate. Then engage the guide parts into the lower guide
plate, while slightly tilting them to the side.
7. Install the right hand bellows:
− Introduce the correct bellows for the side into the guide
plates from the outside.
− Remount the outer holder again.
8. Check whether the bellows moves easily in the guide.
9. Close the bellows onto the velcro fastener. Take care that
the bellows' shape is aligned with the shape of the holder.

Magnetic coupling
1 Catch strap 4 Foam rubber

2 Bellows 5 Plastic screws
3 Metal cable ties 6 Impact protection
Magnetic coupling with bellows Fig. 60959

Clean and check
With each replacement of the processing optics and in the event
of a malfunction (missing electrical contact), the contact surfaces
on the flange and on the plate must be thoroughly cleaned.
In order to ensure proper functioning, the gap between the
flange and the plate must not exceed 0.1 mm. The pole and
contact surfaces must be absolutely clean. Dust, chips or weld-
ing beads can cause malfunctions.
The following components are functional elements and must be

exchanged when they are damaged:
■ Impact protection, including plastic screws.
■ Catch strap.
■ Foam rubber.
■ Bellows, including both metal cable ties.
■ Banjo screws.

■ Bar magnet
■ Cotton buds
■ Acetone or propanol

Note
Do not use compressed air to clean, because then there would
be a danger of chips and dirt getting into the beam guidance,
onto the mirrors or into the processing optics.
The electromagnetic of the magnetic coupling at the Z

DANGER barrel presents a danger of life for persons with
pacemakers!
from the magnetic coupling on the Z barrel.
maintenance or setting work on the Z barrel or on the proc-
Ferromagnetic attractive force (1000 N) due to the

CAUTION permanent magnets!
Ø Do not hold any metal objects or watches near the perma-
nent magnets.
If there is a collision, the processing optics is separated

NOTICE from the flange.
Ø Replace damaged plastic strap.
Ø Do not start processing without a properly mounted catch
strap.
1. Use a non-metal tool to remove slag or other impurities.

2. Clean the contact surfaces on the flange and on the plate
thoroughly with a rag.
3. Remove chips in the pole surfaces thoroughly using a bar
magnet.
4. Afterwards, subsequently clean the pole surfaces with cotton
swabs and acetone or propanol.
5. Check the catch strap for damage.
6. Exchange damaged components.


Cleaning the test sheet
holder
Notes
■ The sacrificial plates can be ordered in pairs as consuma-
bles.
■ Do not use the test sheet holder without sacrificial plates.
1 Sacrificial plates
Cleaning the test sheet holder Fig. 87509
1. Swivel the setting device into the parking position and lock it
in place.
2. Remove the test sheets and sacrificial plates from the test
sheet holder.
3. Clean the test sheet holder thoroughly with a cloth.
4. Replace used sacrificial plates.

Replacing the test sheet
holder
If the test sheet holder is damaged, it can be ordered as a spare
part and replaced.

■ Allen key SW 4.
Note
The two lower fastening screws on the flange plates have con-
tact washers.
These two contact washers are functionally relevant compo-
nents. They ground the test sheet holder, thus ensuring the
functional safety of the distance regulation.
Risk of collision between the processing optics and the

NOTICE setting device when approaching the reference position!
Ø Do not remove the contact washers.
Ø Replace any contact washers that are lost.
1 Fixing screws 3 Contact washers

2 Flanged plate 4 Test sheet holder
Replacing the test sheet holder Fig. 86912

1. Swivel the setting device into the parking position and lock it
in place.
2. Loosen the fastening screws and remove the test sheet
holder from the flange plate on the swivel arm. Observe the
contact washers!
3. Attach a new test sheet holder from above to the flange
plate and align it.
4. Tighten the fixing screws hand-tight. Observe the contact
washers!
5. Insert sacrificial plates.
Z barrel

Checking hose connections
and quick-release couplings
Ø Check that there are no leaks in the air and gas connections.

7. Pneumatic system
7.1 Overview
The device panel is integrated into the front of machine's body.

To get to the device plate, the door must be opened.
1 Maintenance unit, extended 3 Maintenance unit cutting gas air

compressed air supply (option) 4 Condensate precipitation col-
2 Maintenance unit machine lecting tank
Instrument panel Fig. 73835
B836en 2017-11-17 Pneumatic system 6‐61

Device panel: Maintenance unit basic

machine

Checking and setting the
static operating pressure
The required pressure is 5+1 bar.
Condition
■ MAIN SWITCH Basic machine is switched on.
Note
Set the pressure: Turn the knob while pulling it up.
1 Turning knob 2 Pressure gauge

Compressed air gauge for the operating pressure Fig. 74478
Ø Check the operating pressure on the pressure gauge. If the

gauge is in the green area, the operating pressure is OK.
or
Ø If the gauge is in the red area then correct the operating
pressure: Press the FEED STOP button. Set the required
pressure of 5 bar.
6‐62 Pneumatic system 2017-11-17 B836en

Replace the filter element
Condition
■ The MAIN SWITCH is switched off.
1 Prefilter 5 Slide
2 Main filter 6 Housing
3 Microfilter 7 Condensation screw
4 Activated carbon filter
Filter maintenance unit basic machine Fig. 74479
1. Unlock the filter housing: Pull the slide downward while at

the same time rotating the housing counter-clockwise by 45°
and pulling it off from below.
2. Screw out the filter element.
3. Clean the housing with a lint-free cloth.
4. Screw in the new filter element.
5. Reinstall the housing.

Device panel: Maintenance unit cutting gas
air (option)

Condition
1 Main filter 5 Slide

2 Microfilter 6 Housing
3 Activated carbon filter 7 Condensation screw
4 Activated carbon filter
Filter maintenance unit cutting gas air Fig. 74480


Device panel: service unit for expanded
(option)

static operating pressure
The required pressure is 5+1 bar.
Condition
Note
Set the pressure: Turn the knob while pulling it up.
1 Turning knob 2 Pressure gauge

Compressed air gauge for extended compressed air supply Fig. 74481
Ø Check the operating pressure on the pressure gauge. If the

gauge is in the green area, the operating pressure is OK.
or
Ø If the gauge is in the red area then correct the operating
pressure: Press the FEED STOP button. Set the required
pressure of 5 bar.

Condition
1 Main filter
Extended compressed air supply maintenance unit Fig. 74482

Device panel: Condensation collection tank

Check filling level
Note
If a large quantity of condensate is precipitated, then the com-
pressed air quality supplied is not OK.
Ø Check the level in the tank and empty it if necessary.

Cutting optics: disposable filter, pneumatic
connection

Exchange filter insert or
filter
The complete filter or just the filter insert can be exchanged.
Notes
■ Do not touch the filter element with your hand.
■ Only exchange the filter element under clean conditions so
that no dirt can get into the optics.
1 Disposable filter
Disposable filter, pneumatic connection Fig. 74618
1. Release the quick-release coupling from the media adapter.

2. Disconnect the connection hose from the filter.
3. Exchange the complete filter.
or
Ø Replace the filter insert:
− Screw out the quick-release coupling connection.
− Remove the blue filter insert and insert a new one.
− Close the filter housing.
4. Reconnect the filter.

8. Gas
Cutting optics: disposable filter, gas

connection

Exchange filter insert or
filter
The complete filter or just the filter insert can be exchanged.
Notes
■ Do not touch the filter element with your hand.
■ Only exchange the filter element under clean conditions so
that no dirt can get into the optics.
1 Disposable filter
Disposable filter, gas connection Fig. 74619
1. Release the quick-release coupling from the media adapter.

2. Disconnect the connection hose from the filter.
3. Exchange the complete filter.
or
Ø Replace the filter insert:
− Screw out the quick-release coupling connection.
− Remove the blue filter insert and insert a new one.
− Close the filter housing.
4. Reconnect the filter.
6‐68 Gas 2017-11-17 B836en

9. Water
9.1 Overview
The following two variants are available for cooling the optical
components of the LLK machine, collimator and cutting optics,
as well as for cooling the switch cabinet:
■ Cooling by machine cooler (optional): The machine has
an internal machine cooler which cools the optical compo-
nents of the machine as well as the switch cabinet.
■ Cooling by external laser cooling circuit (chiller): In the
standard variant, the cooling circuit of the machine is con-
nected to the external cooling circuit of the laser device. In
this case, the water stopcocks in the laser device as well as
beneath the instrument panel on the machine, must be open
while the machine is operating. In the event of an error, the
status of the shut-off valve must be checked.
In the following sections, the maintenance work for the cooling
circuit of the machine (machine cooler) will be described.
Laser device maintenance work: see section "TruDisk".
Maintenance of the external cooling circuit of the laser device:
see section "Process cooler for TruDisk".
Notes
■ No antifreeze agent is required.
■ Replace all of the water filters which are part of the cleaned
cooling circuit after each replacement of the cooling water.
■ Always seal the water container tightly to ensure that no soil-
ing gets into the water tank and that the water does not
evaporate.
■ If oil or coolant is leaking, request a service call.
Cooling water specification The cooling system may only be filled with demineralized or
deionized water that meets the following requirements.
Specific conductivity prior to filling the proc- max. 10 μS/cm

ess cooler tank
Carbonate content max. 100 mg/l
Cooling water data Tab. 6-2
Water can also be used as cooling water if it complies with the

following standards:
■ DIN ISO 3696, Quality Level 3 (and better).
■ ASTM D 1193-91, Type IV (and better).
B836en 2017-11-17 Water 6‐69

Ensuring the cooling water To ensure that the required water quality specifications are
quality always complied with, the cooling water may only be treated
according to the following rules:
■ Reduce storage time to a minimum, at best only a few days.
■ Only store it in suitable, clean plastic containers.
■ Cooling water should not be used under any circumstances if
it is discolored, cloudy or if it smells.
■ Only use pumps, hoses and other additional equipment that
are suitable for cooling water and intended solely for this pur-
pose. Do not use these parts in any other way.
■ No other devices may be connected to the cooling circuits.
Conductivity limit values The following limit values apply:
Conductivity of freshly filled cooling water Max. 20 μS/cm

after 10 minutes of circulation
Copper circuit conductivity limit. Max. 200 μS/cm
Tab. 6-3
Note
The cooling water must be replaced when the conductivity limits
have been exceeded.
Dispose of cooling water Note

The cooling water must be disposed of in coordination with
regional government authorities responsible for such matters.
6‐70 Water 2017-11-17 B836en

Cooling water additives The cooling water additives are supplied in bottles (Easy Kit).
The apportionment per bottle corresponds to the amount of cool-
ing water of respective cooling circuit. One Easy Kit is required
for each water change. Each Easy Kit contains one bottle with
anticorrosive agent (yellow) and one bottle with cleaning biocide
(red).
Application Cooling water addi- Bottle top color code

tive
Corrosion protection Water Care-Copper Yellow
Cleaning cycle Cleaning biocide Red
Cooling water additives Tab. 6-4
Cooling water and cooling water additives are aggressive!

WARNING
Irritation to eyes and skin possible!
Ø Avoid direct contact with cooling water and cooling water
additives.
Ø Wear safety goggles and gloves.
Ø Follow the safety instructions on the products and safety
datasheets.
Note
Refer to the machine's spare parts catalog for the Easy Kit mate-
rial numbers (country-specific).
Cooling water requirements The following Easy Kits and the following water volumes are
for the machine's cooling required for cooling water replacement, depending on the config-
circuit uration of the machine and the laser power:
Process cooler Easy Ki Volumetric Water require-

t capacity of cool- ment for cooling
ing circuit in l water replace-
ment in l
Type L 4/0 TR2 CU3 48 160
Type P 4/0 TR2
Cooling water requirement and Easy Kit for machine cooling Tab. 6-5
circuit
Note
Cooling water requirement and Easy Kit for the cooling circuits of
the laser and chiller: see the section "TruDisk and process
cooler for TruDisk" .
B836en 2017-11-17 Water 6‐71

Cooling circuit of the machine

Checking the flow controller
Note:
This maintenance work is only relevant, if the machine's compo-
nents are cooled via the laser cooler: In this case, the machine
will not have its own cooler.
After replacing the cooling water in the laser device as well as in
its process cooler, the system checks whether the flow controller
in the machine's cooling circuit is still properly set.
Condition
machine.
1 Supply/return stopcock
The water supply on the device panel Fig. 74630
1. Open the door to the device panel and close both water
stopcocks.
2. Then check whether an error message is displayed on the
machine's control panel. If an error message is issued, then
the flow controller is properly set.
6‐72 Water 2017-11-17 B836en

or
Ø If no error message is issued, then the flow controller is
faulty and must be replaced when the next service work
is carried out.
B836en 2017-11-17 Water 6‐73

Machine cooler (option), water/air chiller

Checking and refilling the
level
■ Demineralized water.
Note
Generally, little water is lost from the closed cooling circuit, as
long as the water tank has been closed properly. If the cooling
circuit loses water within a short period of time, then the cause
must be found.
1 Level indicator
Level in the machine cooler Fig. 74624
Ø Check the filling level. When the minimum level is reached,

top up with water.

Clean the filter mat
The degree of contamination of the filter mat depends on the
respective manufacturing conditions.
if the LED "E4" flashes on the display of the cooling unit, this
means the filter mat must be cleaned.
Note
The filter mat protects the condenser from dirt.
6‐74 Water 2017-11-17 B836en

1 Fixing screw 3 Filter mat
2 Grid sheet
The machine cooler filter mat Fig. 74623
1. Screw out the grid sheet.

2. Remove filter mat.
3. Clean the metal filter mats with a high-pressure cleaner and
re-insert. Replace damaged filter mats.
4. Reinstall the grid plate.
B836en 2017-11-17 Water 6‐75

Replace cooling water
cleaning biocide is added to the cooling circuit 2 hours before
changing the cooling water. During the cleaning cycle, the
machine is ready for operation.
After the cleaning cycle, the water tank is cleaned and the cool-
ing circuit is flushed with fresh water at least 3x.
After replacing the cooling water, replace the cartridge in the
water filter.
Conditions
machine.

■ 160 l demineralized water.
■ Easy Kit CU-3.
■ Conductivity measuring device.
■ Protective gloves.
■ Safety glasses.
■ Flat blade screwdriver
Notes
■ For each rinse cycle, the tank is filled up to 60% with fresh
water.
■ The water in the cooling circuit will only be circulated if the
drives are switched on.
■ Switch off each of the drives before draining off the water
and switch back on again after filling up.
Corrosion and microbial contamination of the cooling

NOTICE circuit!
Material damage to the cooling circuit of the machine.
Ø Only use fresh and clean de-ionized water.
Ø Thoroughly rinse the cooling circuit after the cleaning run.
Ø Do not operate the cleaning circuit without corrosion protec-
tion.
Ø Only use cleaning biocide when cleaning.
6‐76 Water 2017-11-17 B836en

1 Central cover plate 2 Lower cover plate
Machine cooling unit cover plate Fig. 74621
1 Condenser 3 Water container

2 Cover
Replacing the water in the machine's cooling unit Fig. 74625
B836en 2017-11-17 Water 6‐77

Starting the cleaning cycle 1. Remove the cover plate from the rear side of the machine's
body, positions 1 and 2 (fig. 74621).
2. Open the water container and add cleaning biocide to the
water. Close the water container
3. Switch the drives on again: Press the MACHINE ON/OFF
button.
4. Production can continue while the cleaning biocide takes
effect.
Draining water 5. After 2 hours end the cleaning cycle: Press the MACHINE
ON/OFF button.
1 Water outlet
Machine cooling unit water drain Fig. 74626
6. If not yet done, remove the lower cover sheet, pos. 2
(Fig. 74621). Open the shut-off valve and drain the water
completely.
7. Close shut-off valve once again.
Flushing the cooling circuit 8. Fill the tank up to about 60% with fresh, demineralized water.
9. Close the water container
button.
11. Wait for approx. 10 minutes.
12. Switch off the drives: Press the MACHINE ON/OFF button.
13. Drain the water completely.
14. Carry out the second and third flushing processes, each with
fresh water.
6‐78 Water 2017-11-17 B836en

Measure conductivity 15. Fill the tank up to about 60% with fresh, demineralized water.
16. Wait for approx. 10 minutes. Drives must be switched on.
17. Measure the conductivity of the water.
18. If the conductivity of the water is less than or equal to 20 µS/
cm, completely fill the tank and add an anticorrosive agent
Water Care-Copper.
or
Ø If the conductivity of the water is greater than 20 µS/cm:
rinse the cooling circuit. Afterwards, fill with fresh water,
flush for approx. 10 minutes and measure the conductiv-
ity again.
19. After adding the anticorrosive agent wait for about 10
minutes.
20. Afterwards, measure the conductivity of the water again. If
the conductivity is still more than 200 µS/cm, the cooling
water must be completely replaced again.
The cooling water replacement is completed when the con-
ductivity of the water does not exceed 200 µS/cm.
21. On completing the replacement of the cooling water, top up
the water container and close it.
22. On completing the replacement of the cooling water, clean
the condenser with compressed air and replace the insert in
the water filter.
23. After completion of the all of the maintenance work, reinstall
the cover plate.
B836en 2017-11-17 Water 6‐79

Replace the filter element.
Replace the filter element in the water filter each time the cool-
ing water is replaced.
1 Stop cocks (2x) 2 Water filter

Machine cooling unit water filter Fig. 74620
1. Close the stop cocks on the water filter.

2. Screw out the filter container and clean it.
3. Replace the filter insert.
4. Screw the filter container back in.
5. Open the stop valves.
6‐80 Water 2017-11-17 B836en

Machine cooler (option), water/water chiller

Check filling level
Note
must be found.
Ø Check the filling level. When the minimum filling level is

reached: Top up with water.

After replacing the cooling water, replace all water filters for the
cooling circuit.
Conditions
machine.

■ 160 l demineralized water.
■ Easy Kit CU-3.
■ Safety glasses.
■ Flat blade screwdriver
B836en 2017-11-17 Water 6‐81

Notes
water.
■ The water in the cooling circuit will only be circulated if the
drives are switched on.
■ Switch off each of the drives before draining off the water
and switch back on again after filling up.

NOTICE circuit!
tion.
Preparing the cooling water 1. Remove the lower cover sheet of the machine cooler from
replacement the rear side of the machine frame.
Starting the cleaning cycle 2. Open the water container and add cleaning biocide to the
water. Close the water container
button.
Draining water 4. After 2 hours end the cleaning cycle: Press the MACHINE
ON/OFF button.
6‐82 Water 2017-11-17 B836en

1 Water outlet
Machine cooling unit water drain Fig. 74626
5. If not yet done, remove the lower cover sheet, pos. 2
(Fig. 74621). Open the shut-off valve and drain the water
completely.
6. Close shut-off valve once again.
8. Close the water container
button.
fresh water.
Measure conductivity 14. Fill the tank up to about 60% with fresh, demineralized water.
15. Wait for approx. 10 minutes. Drives must be switched on.
16. Measure the conductivity of the water.
Water Care-Copper.
or
ity again.
minutes.
B836en 2017-11-17 Water 6‐83

the conductivity is still more than 200 µS/cm, the cooling
water must be completely replaced again.
20. On completing cooling water replacement, top up the water
container and close it tightly.
21. On completing the replacement of the cooling water, clean
the condenser with compressed air and replace the insert in
the water filter.
22. After completion of the all of the maintenance work, reinstall
the cover plate.
6‐84 Water 2017-11-17 B836en

Replace the filter element.
Replace the filter element in the water filter each time the cool-
ing water is replaced.
1 Stop cocks (2x) 2 Water filter

Machine cooling unit water filter Fig. 74620
1. Close the stop cocks on the water filter.

2. Screw out the filter container and clean it.
3. Replace the filter insert.
4. Screw the filter container back in.
5. Open the stop valves.
B836en 2017-11-17 Water 6‐85

10. Optics
10.1 Overview
General guidelines Utmost cleanliness and the greatest care must be ensured when
handling optical components. A clean environment, a clean work
station, and clean additional equipment are absolutely essential.
■ All work involving the removal, installation and cleaning of
optical components, as well as the adjustment of the laser
beam after cleaning, if necessary, may only be carried out by
trained personnel.
■ Optical components should be cleaned in clean rooms and
not in the vicinity of the machine itself.
■ Cover all exposed maintenance points on the machine's
beam guidance or its optics with optical adhesive tape.
■ Only the auxiliary tools included in the cleaning set may be
used.
■ Only touch the lenses and mirror wearing disposable gloves;
use cushioned tweezers if necessary.
■ Touch the lenses only on their circumference! Do not touch
the surface of the lens.
■ The optical surfaces must remain free of oil, grease and
dust.
■ Do not clean the optics with compressed air. This will con-
taminate the optical components with dirt particles.
■ Do not adjust the marked reference screws.
Safety notes Note

The optical components (lens, deflection mirror and protective
glass) of the processing optics for processing with the solid-state
laser are made of silica glass. They are cleaned exclusively with
methanol.
Damage to the optical components!

NOTICE
Ø Use only methanol to clean the optical components made of
silica glass.
Ø Do not use acetone , Topol or Optics Cleaner for cleaning.
Fire hazard due to methanol!

NOTICE
Ø Keep methanol away from ignition sources.
Ø Do not smoke.
6‐86 Optics 2017-11-17 B836en

Danger of poisoning due to methanol!
WARNING
Ø Do not breathe in or ingest methanol fumes.
Ø Make sure there is plenty of fresh air.
Ø Wash your hands after the cleaning process.
Additional equipment, tools, ■ Allen keys sizes 2.5, 3, 4, and 5 mm.

materials ■ Face wrench.
■ Screwdriver.
■ Suction cups.
■ Bellows.
■ For cleaning all machine optical components: complete clean-
ing kit (TRUMPF order number 1675885).
■ LED lamp with white light.
■ Lens adapter device (TRUMPF order number 1652982).
■ Finger cots (TRUMPF order number 0145843) or Nietriel dis-
posable gloves (TRUMPF order number 0352197).
■ Cleaning cloths (TRUMPF order number 0359506).
■ Optical adhesive tape (TRUMPF order number 1317829).
Tool for the sensor body This tool is included in the scope of delivery of the cutting optics.
and lens It is used to replace the lens and the sensor body.
Tool A Tool B
Tool for sensor body/lens Fig. 73822
Focal Material no. Tool A Tool B

length
f = 150 mm 1846903 To replace To replace the sensor body.
the lens.
f = 200 mm - ■ To replace the lens.
■ To replace the sensor
body.
Application Tab. 6-6
B836en 2017-11-17 Optics 6‐87

Cutting optics with a focal length of

150 mm

Clean the housing
Particularly when processing high-tensile steels (hot-forming

parts), a very fine, oily cutting dust is produced, which gets stuck
in the housing of the dynamic processing optics. If the dust is
not cleaned from the housing, this leads to malfunction of
the additional axis.
The level of contamination of the optics depends on which mate-
rials are being processed.
The housing is cleaned with a spatula that has been dipped in
methanol and with cleaning cloths.
Recommendation: always clean the housing before cleaning the
lens.

■ Spatula.
■ Methanol.
■ Allen key size 2.
■ Allen key SW 3.
Notes
■ Only service the processing optics in a clean room area.
■ If the cutting insert and the deflection mirror are removed
before cleaning the spaces, cutting dust falls on the lens and
deflection mirror.
Damage to the optical components due to improper

NOTICE maintenance.
Ø Do not clean processing optics and optical components with
compressed air.
6‐88 Optics 2017-11-17 B836en

Clean the outer surface 1. Remove processing optics from the machine and close the
beam aperture in the optics using the protective cover.
2. Clean optics thoroughly from outside.
3. Remove the protective cover from the cutting insert.
4. Pull cutting insert forcefully in order to remove the mobile
section of the optics from the fixed housing section.
5. Undo the screws on the covering and pull it toward the cut-
ting insert.
1 Guard 2 Cutting insert

Fig. 68902
6. Clean the spaces, edges and spindles
Fig. 68900
Clean internal surfaces 7. If the optics need to be cleaned more thoroughly, remove the
deflection mirror and cutting insert.
8. Pull the bellows holder out of the housing and pull the bel-
lows off of its holder.
9. Clean interior and exterior bellows thoroughly.
B836en 2017-11-17 Optics 6‐89

A Narrow lip B Wide lip
Fig. 74634
10. Either
Ø Put the cleaned bellows back onto the bellows holder,
make sure that it is the right way around: Pull the narrow
lip onto the bellows holder. The wide lip points upwards.
or
Ø Clean the lens.
11. Clean internal surfaces of the optics.
Fig. 68903
12. Clean the deflection mirror and insert it back into the optics.
13. Mount the cutting insert.
14. Screw the guard back on tightly.
6‐90 Optics 2017-11-17 B836en

Checking, cleaning or
replacing the lens
All optical components must be absolutely clean. Streaks, grains
of dust or scorching could influence the focus shift or the focal
position and thus lead to cutting problems.
In the event of cutting problems, first check the focal position
and then, if necessary, re-determine it. If this does not lead to an
improvement, clean the lens.
The lens must be cleaned even if it is contaminated only slightly.
The lens must be replaced immediately if damaged.

■ Torque wrench.
■ AF 1.5 Allen key
■ Allen key SW 4.
■ Tool for sensor body and lens (belongs to the scope of deliv-
ery of the machine).
■ Complete solid state laser cleaning set (TRUMPF order num-
ber 1675885).
■ The following additional equipment will be needed from the
cleaning set:
− LED lamp (TRUMPF order number 1632115).
− Lens adapter fixture (TRUMPF order number 1652982).
− Methanol (TRUMPF order number 0764334).
− Bellows (TRUMPF order number 0779473).
− Spatula (TRUMPF order number 1222024).
Notes
■ Each time, before opening the optical system, the spaces as
well as the outside of the housing must be cleaned, to pre-
vent cutting dust from getting onto the lens or the mirror.
■ When the lens is cleaned, the bellows in the optical housing
should also be cleaned.
■ The sealing ring in the cutting optics seals the housing gas
tight. Make sure that the new sealing ring is properly seated.
Replace if damaged.
B836en 2017-11-17 Optics 6‐91

Removing the lens 1. Remove processing optics from the machine and close the
1 Mounting screws (2x) 3 Fixing screw

2 Protective cover 4 Cutting insert
Fig. 73673
2. Remove the protective cover from the cutting insert:
− Undo the two fixing screws (posn. 1 and diagonally
opposing) on the flange of the protective cover.
− Pull off the protective cover (posn. 2).
3. Undo the cutting insert:
− Undo four fixing screws (posn. 3) on the cutting insert.
− Pull the cutting insert off from the housing.
4. Remove the lens cartridge (fig. 73674):
− Undo the union nut (posn. 1).
− Pull the lens cartridge (posn. 2) out (don't unscrew
it).
6‐92 Optics 2017-11-17 B836en

1 Union nut 2 Lens cartridge
Fig. 73674
5. Remove lens (see "Fig. 73675", pg. 6‐93):

− Put tool B (see "Fig. 73822", pg. 6‐87) on the lens
adapter (pos. 4) and rotate until both pins engage.
− Only undo the lens holder in the lens cartridge
(posn. 1), do not completely unscrew it.
− Put the tool on a flat surface and carefully remove the
lens cartridge so that the lens is not damaged.
Caution! The lens lies loosely on its holder.
1 Lens cartridge 3 Lens 4 Lens adapter

2 Tool
Fig. 73675
B836en 2017-11-17 Optics 6‐93

Cleaning the lens Notes
■ Clean the convex side first and the flat side afterward.
■ Use the spatula only once.
■ Do not look into the intensive, white light emitted by the
lamp.
■ Avoid streaking.
6. Switch on the LED lamp and place on the lens support. Blow
off the lens holder using the bellows.
Fig. 60299
7. First place the lens with the convex side facing up on the
lens holder and blow it clean using bellows.
8. Moisten the spatula with methanol.
9. Slowly and carefully, clean the lens with the spatula with cir-
cular movements.
10. Turn the lens over and clean the other side in the same way.
11. Check the lens using the white LED lamp, and while doing
this, gently rotate the lens on its support.
Installing the lens Note

If the support ring is inserted with the wrong side facing
upward, the inside edge of the support ring will press against
the lens and damage it.
12. Blow off single parts with bellows.
6‐94 Optics 2017-11-17 B836en

1 Lens adapter 3 Support ring
2 Spring ring 4 Lens
Fig. 73676
13. Fit the lens (fig. 73676):
− Place the spring lock washer (posn. 2) into the lens
adapter (posn. 1).
− Place the support ring (posn. 3) into the lens holder with
the bevel facing upwards.
− Place the lens (posn. 4) in the lens holder with the con-
vex side upwards (so that the labelling is legible) into the
lens holder.
14. Carefully screw the lens cartridge onto the lens holder and
tighten, hand-tight.
Cleaning the bellows

(option)
1 Bellows holder
Fig. 72874
B836en 2017-11-17 Optics 6‐95

15. Pull the bellows holder out of the optical housing and then
pull the bellows off.
16. Thoroughly clean the bellows and bellows holder with clean-
ing cloths inside and out.
17. Thoroughly clean the inner housing of the optics.
18. Pull the thin lip of the bellows over the bellows holder. The
bellows must lie fully on the shoulder of the bellows holder.

Fig. 73678
19. Put the bellows and the bellows holder back into the hous-
ing.
Installing the cutting insert The contacts and the flat surfaces must be absolutely clean.
1 Cylindrical pin/Mating hole 3 Lens cartridge 5 Union nut

2 Sealing ring 4 Sealing ring
Fig. 73677
20. Fit the lens cartridge (posn. 3) in the correct orientation into
the cutting insert and press down as far as it goes.
6‐96 Optics 2017-11-17 B836en

Make sure that the sealing rings (posn. 2 and 4) are properly
seated.
21. Screw the union nut (posn. 5) hand-tight to the cutting insert.
22. Mount the cutting insert back into the optical housing:
− Place the cutting insert in the housing and align it to the
cylindrical pin.
− Tighten the four fixing screws on the cutting insert with a
torque of 4 Nm.
− Remount the protective cover.
23. After the lens has been cleaned or replaced:
− Re-center the nozzle to the beam.
− Check and set the focal position.

replacing the deflection
mirror If there are still cutting problems, despite cleaning the lens, this
can be because the mirror in the cutting optics (or the FocusLine
mirror in the angular gear) is dirty (particles or coating) or dam-
aged.
The deflection mirror in the processing optics is a permanently
installed mirror. It is not necessary to adjust the beam after
cleaning the mirror or after replacing the entire mirror block.
The deflection mirror must be replaced if it is scratched or dam-
aged. It is completely replaced with the mirror holder. The mirror
must be absolutely clean.

■ Allen key SW 3.
■ Torque wrench.
ber 1675885).
cleaning set:
− Green optical adhesive tape (TRUMPF order number
1317829).
Notes
■ Do not open or remove the cap (posn. 2, fig. 73672).
B836en 2017-11-17 Optics 6‐97

1 Befestigungsschrauben 2 Sealing cap 3 Silica mirror
Fig. 73672
Checking the deflection 1. Remove processing optics from the machine and close the
mirror beam aperture in the optics using the protective cover.
2. Undo the fixing screws (posn. 1) for the mirror holder.
3. Pull out the mirror holder carefully. Clean the mirror if it is
contaminated.
Cleaning the mirror 4. Use bellows to blast off the mirror.

5. Carefully clean the mirror surface with the spatula and meth-
anol with circular movements.
6. Check the cleanliness with a white LED lamp.
7. Blow the mirror support area clean using bellows.
8. Carefully put the mirror back into the optical housing.
9. Tighten the four fixing screws on the mirror holder with a tor-
que of 2.5 Nm.

Cleaning the sensor body
and the nozzle
The sensor body is a component important for the functioning of
the distance regulation. The sensor body, the nozzle and the
cover ring must be clean so that distance regulation functions
reliably. A damaged nozzle or a damaged sensor body must be
replaced.
Ø Remove the slag spatter using a flange; do not use any

sharp objects.
6‐98 Optics 2017-11-17 B836en

Replacing the sensor body
The sensor body is only replaced in the event of a malfunction.

■ Allen key SW 4.
■ Bellows.
Notes
■ Damaged sealing rings must be replaced.
■ Hold the sensor body firmly while releasing it. It could fall off
as soon as it is released.
The anodized (brown) components on the sensor body are func-

tional components which help with insulation. Check and clean
the anodized components before installing the new sensor body.
All mating surface must be clean and correctly seated. Damaged
components must be replaced.
1 Bushing 4 Insulation ring

2 Cutting insert 5 Sensor body
3 Cover ring
Replace the sensor body Fig. 48939
B836en 2017-11-17 Optics 6‐99

Removing the sensor body 1. Remove processing optics from the machine (see chapter
"Setting work").
3. Undo the cutting insert from the housing and remove the
lens cartridge.
4. Unscrew the sleeve from the cutting insert:
− Place tool B into the sleeve so that all four pins are
engaged in the sleeve's slots.
− Rotate the tool to the left till the sleeve is loosened.
1 Bushing 2 Tool for sensor body 3 Cutting insert

Fig. 51636
Installing a new sensor body 5. Fit the cover ring, sensor body and insulation ring onto the
cutting insert. Turn the cover ring so that the four screws in
the cutting insert are covered.
6. Fit the sleeve into the cutting insert and screw, hand-tight, to
the body of the sensor.
7. Fit the lens cartridge into the cutting insert and screw into
place.
8. Return the cutting insert to the optical housing and tighten
the four fixing screws on the flange with a torque of 4 Nm.
9. If there is one, reinstall the protective cover from the cutting
insert.
6‐100 Optics 2017-11-17 B836en

Cutting optics with a focal length of
200 mm

Clean the housing
Particularly when processing high-tensile steels (hot-forming
parts), a very fine, oily cutting dust is produced, which gets stuck
in the housing of the dynamic processing optics. If the dust is
not cleaned from the housing, this leads to malfunction of
the additional axis.
The level of contamination of the optics depends on which mate-
rials are being processed.
The housing is cleaned with a spatula that has been dipped in
methanol and with cleaning cloths.
Recommendation: always clean the housing before cleaning the
lens.

■ Spatula.
■ Methanol.
■ Allen key size 2.
■ Allen key SW 3.
Notes
■ If the cutting insert and the deflection mirror are removed
before cleaning the spaces, cutting dust falls on the lens and
deflection mirror.
Damage to the optical components due to improper

NOTICE maintenance.
Ø Do not clean processing optics and optical components with
compressed air.
B836en 2017-11-17 Optics 6‐101

Clean the outer surface 1. Remove processing optics from the machine and close the
2. Clean optics thoroughly from outside.
4. Pull cutting insert forcefully in order to remove the mobile
section of the optics from the fixed housing section.
5. Undo the screws on the covering and pull it toward the cut-
ting insert.
1 Guard 2 Cutting insert

Fig. 68902
6. Clean the spaces, edges and spindles
Fig. 68900
Clean internal surfaces 7. If the optics need to be cleaned more thoroughly, remove the
deflection mirror and cutting insert.
8. Pull the bellows holder out of the housing and pull the bel-
lows off of its holder.
9. Clean interior and exterior bellows thoroughly.
6‐102 Optics 2017-11-17 B836en

Fig. 74634
10. Either
Ø Put the cleaned bellows back onto the bellows holder,
make sure that it is the right way around: Pull the narrow
lip onto the bellows holder. The wide lip points upwards.
or
Ø Clean the lens.
11. Clean internal surfaces of the optics.
Fig. 68903
12. Clean the deflection mirror and insert it back into the optics.
13. Mount the cutting insert.
14. Screw the guard back on tightly.
B836en 2017-11-17 Optics 6‐103

replacing the lens
All optical components must be absolutely clean. Streaks, grains
of dust or scorching could influence the focus shift or the focal
position and thus lead to cutting problems.
If cutting problems arise first of all check the focal position. If
necessary, re-determine it. If this does not lead to an improve-
ment: clean the lens.
The lens must be cleaned even if it is contaminated only slightly.
The lens must be replaced immediately if damaged.

■ Torque wrench.
■ AF 1.5 Allen key
■ Allen key SW 4.
ber 1675885).
cleaning set:
− Lens adapter fixture (TRUMPF order number 1652982).
Notes
■ Each time, before opening the optical system, the spaces as
well as the outside of the housing must be cleaned, to pre-
vent cutting dust from getting onto the lens or the mirror.
■ When the lens is cleaned, the bellows in the optical housing
should also be cleaned.
■ The sealing ring in the cutting optics seals the housing gas
tight. Make sure that the new sealing ring is properly seated.
Replace if damaged.
6‐104 Optics 2017-11-17 B836en

Removing the lens 1. Remove processing optics from the machine and close the
1 Mounting screws (2x) 3 Fixing screw

2 Protective cover 4 Cutting insert
Fig. 73666
2. Remove the protective cover from the cutting insert:

− Undo the two fixing screws (posn. 1 and diagonally
opposing) on the flange of the protective cover.
− Pull off the protective cover (posn. 2).
3. Undo the cutting insert:
− Undo four fixing screws (posn. 3) on the cutting insert.
− Pull the cutting insert off from the housing.
4. Undo the union nut on the cutting insert (fig. 73837).
B836en 2017-11-17 Optics 6‐105

1 Lens cartridge 2 Union nut
Fig. 73837
5. Pull the lens cartridge out (don't unscrew it).
Note
Caution! The lens lies loosely on its holder.
6. Remove the lens (fig. 73667):
− Put tool "B" onto the lens holder and turn it until all of the
pins engage.
− Only undo the lens holder in the lens cartridge, don't
completely unscrew it.
− Put the lens holder on a flat surface and carefully remove
the lens cartridge so that the lens is not damaged.
6‐106 Optics 2017-11-17 B836en

1 Lens cartridge 3 Lens adapter
2 Lens 4 Tool
Fig. 73667
Cleaning the lens Notes

■ Clean the convex side first and the flat side afterward.
■ Use the spatula only once.
■ Do not look into the intensive, white light emitted by the
lamp.
■ Avoid streaking.
7. Switch on the LED lamp and place on the lens support. Blow
off the lens holder using the bellows.
Fig. 60299
8. First place the lens with the convex side facing up on the
lens holder and blow it clean using bellows.
9. Moisten the spatula with methanol.
B836en 2017-11-17 Optics 6‐107

10. Slowly and carefully, clean the lens with the spatula with cir-
cular movements.
11. Turn the lens over and clean the other side in the same way.
12. Check the lens using the white LED lamp, and while doing
this, gently rotate the lens on its support.
Installing the lens 13. Blow off single parts with bellows.
Note
If the support ring is inserted with the wrong side facing
upward, the inside edge of the support ring will press against
the lens and damage it.
14. Fit the lens (fig. 73668):
− Place the spring lock washer (posn. 2) into the lens
adapter (posn. 1).
− Place the support ring (posn. 3) into the lens holder with
the bevel facing upwards.
− Place the lens (posn. 4) in the lens holder with the con-
vex side upwards (so that the labelling is legible) into the
lens holder.
1 Lens adapter 3 Support ring

2 Spring ring 4 Lens
Fig. 73668
15. Carefully screw the lens cartridge onto the lens holder and
tighten, hand-tight.
Cleaning the bellows 16. Pull the bellows holder out of the optical housing and then
(option) pull the bellows off.
17. Thoroughly clean the bellows and bellows holder with clean-
ing cloths inside and out.
6‐108 Optics 2017-11-17 B836en

1 Bellows holder 2 Bellows
Fig. 73670
18. Thoroughly clean the inner housing of the optics.

19. Pull the thin lip of the bellows over the bellows holder. The
bellows must lie fully on the shoulder of the bellows holder.
20. Put the bellows and the bellows holder back into the hous-
ing.
Installing the cutting insert The contacts and the flat surfaces must be absolutely clean.
1 Cylindrical pin/Mating hole 2 Union nut

Fig. 73669
21. Fit the lens cartridge in the correct orientation into the cutting
insert and press down as far as it goes.
22. Screw the union nut (posn. 2) hand-tight to the cutting insert.
23. Mount the cutting insert back into the optical housing:
B836en 2017-11-17 Optics 6‐109

− Place the cutting insert in the housing and align it to the
cylindrical pin.
− Tighten the four fixing screws on the cutting insert with a
torque of 4 Nm.
− Remount the protective cover.
24. After the lens has been cleaned or replaced:
− Re-center the nozzle to the beam.
− Check and set the focal position.

replacing the deflection
mirror If there are still cutting problems, despite cleaning the lens, this
can be because the mirror in the cutting optics (or the FocusLine
mirror in the angular gear) is dirty (particles or coating) or dam-
aged.
The deflection mirror in the processing optics is a permanently
installed mirror. It is not necessary to adjust the beam after
cleaning the mirror or after replacing the entire mirror block.
The deflection mirror must be replaced if it is scratched or dam-
aged. It is completely replaced with the mirror holder. The mirror
must be absolutely clean.

■ Allen key SW 3.
■ Torque wrench.
ber 1675885).
cleaning set:
− Green optical adhesive tape (TRUMPF order number
1317829).
Notes
■ Do not open or remove the cap (posn. 2, fig. 73672).
6‐110 Optics 2017-11-17 B836en

1 Befestigungsschrauben 2 Sealing cap 3 Silica mirror
Fig. 73672
Checking the deflection 1. Remove processing optics from the machine and close the
mirror beam aperture in the optics using the protective cover.
2. Undo the fixing screws (posn. 1) for the mirror holder.
3. Pull out the mirror holder carefully. Clean the mirror if it is
contaminated.
Cleaning the mirror 4. Use bellows to blast off the mirror.

5. Carefully clean the mirror surface with the spatula and meth-
anol with circular movements.
6. Check the cleanliness with a white LED lamp.
7. Blow the mirror support area clean using bellows.
8. Carefully put the mirror back into the optical housing.
9. Tighten the four fixing screws on the mirror holder with a tor-
que of 2.5 Nm.

Cleaning the sensor body
and the nozzle
The sensor body is a component important for the functioning of
the distance regulation. The sensor body, the nozzle and the
cover ring must be clean so that distance regulation functions
reliably. A damaged nozzle or a damaged sensor body must be
replaced.
Ø Remove the slag spatter using a flange; do not use any

sharp objects.
B836en 2017-11-17 Optics 6‐111

Replacing the sensor body
The sensor body is only replaced in the event of a malfunction.

■ Allen key SW 4.
■ Bellows.
Notes
■ Damaged sealing rings must be replaced.
■ Hold the sensor body firmly while releasing it. It could fall off
as soon as it is released.
The anodized (brown) components on the sensor body are func-

tional components which help with insulation. Check and clean
the anodized components before installing the new sensor body.
All mating surface must be clean and correctly seated. Damaged
components must be replaced.
1 Bushing 4 Insulation ring

2 Cutting insert 5 Sensor body
3 Cover ring
Replace the sensor body Fig. 48939
6‐112 Optics 2017-11-17 B836en

Removing the sensor body 1. Remove processing optics from the machine (see chapter
"Setting work").
3. Undo the cutting insert from the housing and remove the
lens cartridge.
4. Unscrew the sleeve from the cutting insert:
− Place tool B into the sleeve so that all four pins are
engaged in the sleeve's slots.
− Rotate the tool to the left till the sleeve is loosened.
1 Bushing 2 Tool for sensor body 3 Cutting insert

Fig. 51636
Installing a new sensor body 5. Fit the cover ring, sensor body and insulation ring onto the
cutting insert. Turn the cover ring so that the four screws in
the cutting insert are covered.
6. Fit the sleeve into the cutting insert and screw, hand-tight, to
the body of the sensor.
7. Fit the lens cartridge into the cutting insert and screw into
place.
8. Return the cutting insert to the optical housing and tighten
the four fixing screws on the flange with a torque of 4 Nm.
9. If there is one, reinstall the protective cover from the cutting
insert.
B836en 2017-11-17 Optics 6‐113

Angular gear: FocusLine mirror

Checking and cleaning the
deflection mirror
If there are cutting problems, apart from checking the lens in the
processing optics, the FocusLine mirror in the B/C angular gears
should also be checked.
If the mirror is soiled, then it needs to be cleaned. A damaged
mirror must be replaced.
The adaptive FocusLine mirror is air-cooled. Before removing the
mirror holder, the compressed air supply must be shut off.

■ Flat-bladed screwdriver
■ Allen key SW 4.
■ 1-propanol.
■ Finger cots (TRUMPF order number 0145843) or Nietriel dis-
posable gloves (TRUMPF order number 0352197).
■ Lens cleaning paper (Kodak) (TRUMPF order number
1687226).
Notes
■ Use optical adhesive tape to close the opening in the
angular gear while the mirror is being cleaned.
■ There is a loose spring lock washer in the mirror housing.
6‐114 Optics 2017-11-17 B836en

Checking mirrors 1. Remove the processing optics and check the mirror through
the opening in the angular gear with a pocket lamp. If there
are dirt particles or a coating on the surface of the mirror,
then remove the mirror and clean it.
Removing and cleaning the 2. Turn the C axis so that you have easy access to the angular
mirror gear.
3. Shut off the compressed air supply: Press the MACHINE ON/
OFF button.
1 Mirror holder fixing screws 2 Mirror fixing screw

Removing the mirror Fig. 71430
4. Remove the four fixing screws on the mirror holder and care-
fully pull it out.
5. Undo the central slotted screw and carefully remove the mir-
ror from the housing. Do not touch the surface of the mirror.
6. On the back of the mirror, remove the supply connections
and put the mirror with its back down onto something
clean and flat.
7. Blow off mirror surface with bellows.
B836en 2017-11-17 Optics 6‐115

Pre-cleaning the mirror Fig. 72870
8. Preclean the mirror surface with propanol and a spatula. The
propanol removes particles, as well as grease and oil resi-
dues.
− Moisten the spatula generously with propanol.
− Clean the surface of the mirror with the spatula, while
holding the spatula at a slight angle. With slow, circular
movements, clean the surface of the mirror from the cen-
ter outwards, until there are no more particles to be seen
on the surface.
− Then with the spatula, run once around the outer flat
edge of the mirror.
− Then go once around the circumference of the mirror
with the spatula.
− With the white LED lamp check whether the mirror sur-
face is completely clean.
Finally cleaning the mirror Fig. 72872

9. The final cleaning will be done with methanol and lens clean-
ing paper.
− Apply methanol to the cleaned mirror surface and place
lens cleaning paper on it.
− With the moist lens cleaning paper, wipe several times
backwards and forwards over the surface of the mirror.
− Finally, pull the lens cleaning paper off from the mirror
surface in one direction.
− Repeat the final cleaning as required.
The cleaning is finished when there are no more particles or
smears on the mirror surface.
10. Re-attach the supply connections to the back of the mirror.
6‐116 Optics 2017-11-17 B836en

11. Put the mirror body back into the mirror holder.
− Clean the mirror housing with a cleaning cloth.
− Insert the spring lock washer.
− Carefully put the mirror, correctly oriented (supply and
return), the hole for the pin at the bottom, into the mirror
holder.
12. Hand tighten the central slotted screw.
13. Remove the adhesive optical tape and put the mirror holder
into the opening on the angular gear. Hand tighten the four
fixing screws.
14. Switch the supply of compressed air back on: Press the
MACHINE ON/OFF button.
15. Then check the focal position and adjust. (see "Start focus
search", pg. 5‐42)
B836en 2017-11-17 Optics 6‐117

11. Electrics
11.1 Overview
All components in the switch cabinet that have not been

DANGER de-energized are still live and dangerous for four minutes
after turning off the MAIN SWITCH!
Risk of fatal injury!
Ø Maintenance work on the electrical system may only be per-
formed once the machinery has been switched off and de-
energized.
Ø Do not touch components marked with warning signs.
Ø Maintenance work on the electrical system may only be per-
formed by qualified electricians.
Note
Batteries must not be charged or opened by force. Do not throw
batteries into fires!
Switch cabinet: Battery/fan unit, NC CPU

Replacing the buffer battery
Notes
■ Three years beginning with the delivery date of the Siemens
control.
■ Acknowledge the danger zone and close the access door.
■ The complete fan unit is replaced.
Loss of data!
NOTICE
Ø Replace battery within 15 minutes.
6‐118 Electrics 2017-11-17 B836en

1 Fan unit 2 Buffer battery
Fan unit buffer battery Fig. 74622

2. Open the left switch cabinet.
3. Pull the fan unit off downwards.
4. Fit a new fan unit.
5. Close the switch cabinet.
Switch cabinet: Industrial PC

Replacing the buffer battery
The buffer battery on the Motherboard must be replaced after no
more than 5 years. It must be replaced when the system is pow-
ered down.
If it takes longer than 5 seconds to replace, then the time date
and basic settings will have to be set in the basic input/output
system (BIOS). Only the technical service can make these set-
tings.
Notes
■ Five years from the delivery date of the control system by its
manufacturer, Beckhoff. If this time is exceeded, there is a
risk of data loss.
■ For machines with a maintenance contract, the battery will
be replaced during routine maintenance by the technical
service team.
Ø Have the buffer battery replaced by the technical service staff

during a maintenance or service call.
B836en 2017-11-17 Electrics 6‐119

107302: Maintenance interval: Every 5 years
UPS module, replacing the
rechargeable battery pack
The Beckhoff IPC is equipped with an uninterruptible power sup-
ply (UPS) that temporarily supplies the industrial PC with power
in the event of a power failure in order to save data and shut
down the operating system correctly.
The UPS module is maintenance-free. The rechargeable battery
pack for the module should be replaced as a precautionary
measure.
Notes
■ Recommendation: Five years from the delivery date of the
control system by its manufacturer, Beckhoff. If this time is
exceeded, there is a risk of data loss.
■ For machines with a maintenance contract, the rechargeable
battery pack is replaced during routine maintenance by Tech-
nical Service.
Ø Have the rechargeable battery pack replaced by Technical

Service during a maintenance or service operation.
Switch cabinet: Air conditioning unit

Cleaning the air conditioning
unit
The air conditioning units in both electrical cabinets are water-air
heat exchangers, which are connected to the cooling circuit of
the machine.
The condensate water is fed into the condensate tank via a
house at the device sheet.
Note
The cooling temperature is factory set and may not be
changed.
6‐120 Electrics 2017-11-17 B836en

1 Fixing screws 3 Display plug
2 fan plate
Air conditioning unit electrical cabinet Fig. 68764

2. Open the electrical cabinet doors.
3. Remove the display connector.
4. Release the fan plate and remove it carefully.
5. Blow out fan with compressed air.
6. Re-insert the fan plate and screw it firmly in place.
7. Re-insert the display plug.
8. Close the electrical cabinet.
B836en 2017-11-17 Electrics 6‐121

12. Compact dust extractor
12.1 Overview
The following maintenance may only be carried out by service

engineers from the manufacturer or other authorized and accord-
ingly trained personnel.
■ Maintenance work on the extinguisher system (option).
■ Replacing valves, seals and filter inserts.
■ Checking the purging.
Residual dust If the machine is used as intended, the filtered dust can be sup-
plied for metal recycling. It does not have to be disposed of as
special waste. The relevant national and local regulations must
be observed.
Health hazard from inhalation of the residual dust.

WARNING
Ø Wear a filter class P3 breathing mask.
Ø Do not empty the dust container or fine dust bag.
Ø Only transport the dust container or fine dust bag when
closed.
Ø Before switching the machine off, wait for the lag time of the
exhaust system.
Dust identification According to German national legal provisions, the dust container
or fine dust bag must be marked as follows for disposal:
Identification
Dust from steel machining LAGA key 35101 (ferrous dust without harmful impurities)
or
EAK code 120102 (particles containing iron); EAK group: waste from
mechanical shaping (including welding and cutting)
Dust from aluminum machining LAGA code 35304 (aluminum waste)
or
EAK code 120103 (chips and cuttings containing metals other than iron);
EAK group: waste from mechanical shaping (welding, cutting, among oth-
ers)
Dust identification Tab. 6-7
6‐122 Compact dust extractor 2017-11-17 B836en

Extinguisher system The extinguisher system (CO2 or argon) is optional for the com-
pact dust extractor. It is connected before the machine's main
switch.
The extinguisher system must be serviced and checked by its
manufacturer, every year. A record of the test must be produced.
The extinguisher system is only ready for use if the follow-

ing conditions are met:
■ The extinguishing gas cylinder is open and has been filled
with gas.
Compact dust extractor: dust container/fine

dust bag
A fine dust bag that can be closed can be inserted in the dust
container. The dust that accumulates is collected in this special
fine dust bag (TRUMPF material number 1831493) and disposed
of. The sack for fine dust has a maximum capacity of 30 kg.
Dust container with fine dust bag Fig. 68763
B836en 2017-11-17 Compact dust extractor 6‐123

Checking the level and
replacing the container or
fine dust sack Note:
This maintenance work is valid for the compact dust extrac-
tor without a level sensor.
The dust container is located below the dust discharge unit. The
fine dust sack or dust container can be replaced with the com-
pact dust extractor switched on.
The amount of dust produced depends heavily on the
component and on the process. If a lot of dust is produced, it
may be necessary to check and empty the dust container on a
daily basis. The operator must adjust the maintenance interval at
regular intervals.

■ Breathing mask 8833 FFP3 (mat. no. 0374270).
Notes
■ Between the fine dust sack and the dust container, there is a
minimal gap to equalize the pressure. It is possible that small
amounts of dust fall through this gap into the container. If
there is dust in the container, empty it.
■ Misshapen dust containers must be replaced. The container
must be close to the dust discharge.
There is a high fire risk in the dust container with

WARNING flammable, potentially explosive dust.
Ø Check the dust level in the container on a weekly or daily
basis.
Fire hazard in the dust container if an unsuitable fine dust

WARNING bag is used!
Ø Only the original fine dust bag (TRUMPF material number
1831493) may be used to collect the dust.

A Clamp container 1 Hand grip
B Unscrewing the container 2 Dust container
Dust container (disposable container) Fig. 74615
1. Unlock and remove the dust container.

2. Check the level and replace the fine dust bag if necessary.
3. Seal the fine dust bag tightly with a lid and dispose of it.
4. Put a new fine dust bag in the container. Clamp the con-
tainer under the dust discharge.

Replacing the dust container
Note:
This maintenance work is valid for the compact dust extrac-
tor with a level sensor (option).
The compact dust extractor is equipped with a level sensor at its
closing flap. In this case the control system will report when the
dust container has reached the maximum level and has to be
emptied.
The dust container is located below the dust discharge unit. The
fine dust sack or dust container can be replaced with the com-
pact dust extractor switched on.

Notes
■ Between the fine dust sack and the dust container, there is a
minimal gap to equalize the pressure. It is possible that small

amounts of dust fall through this gap into the container. If
there is dust in the container, empty it.
■ Misshapen dust containers must be replaced. The container
must be close to the dust discharge.
There is a high fire risk in the dust container with

WARNING flammable, potentially explosive dust.
Ø Check the dust level in the container on a weekly or daily
basis.
Fire hazard in the dust container if an unsuitable fine dust

WARNING bag is used!
Ø Only the original fine dust bag (TRUMPF material number
1831493) may be used to collect the dust.
A Clamp container 1 Hand grip

B Unscrewing the container 2 Dust container
Dust container (disposable container) Fig. 74615
1. Unlock and remove the dust container.

2. Check the level and replace the fine dust bag if necessary.
3. Seal the fine dust bag tightly with a lid and dispose of it.
4. Put a new fine dust bag in the container. Clamp the con-
tainer under the dust discharge.

Compact dust extractor: spark arrester
1 Inspection door 2 Tool cartridge

Spark arrester Fig. 74617

Cleaning the spark arrester
The spark arrester is a safety-relevant component. It consists of

a cartridge with porcelain balls. The balls prevent sparks or
smoldering or burning particles from being able to get into the fil-
ter elements with the raw gas flow.
During operation, fibers, dust and particles collect in the car-
tridge. If the cartridge is not regularly and thoroughly cleaned, a
fire can develop in the compact dust extractor.

■ Steel brush.
Note
The cartridge weighs 15 kg.
Fire hazard in the compact dust extractor due to deficient

WARNING maintenance of the spark arrester.
Ø Thoroughly clean the spark arrester every week.

Insufficient fire protection due to missing or damaged
WARNING porcelain balls in the cartridge.
Ø Do not hit or knock the cartridge.
Ø If any porcelain balls are damaged, replace the cartridge.

2. Open the inspection door of the compact dust extractor and
remove the cartridge.
3. Using a steel brush, loosen fiber residues on the lower and
upper sides of the cartridge.
4. Thoroughly vacuum off fiber residues and impurities.
5. Remove deposits from the plug-in unit and clean the decom-
pression chamber.
6. Push the cartridge back in.
7. Close the inspection door.
Compact dust extractor: clean gas space

Check and clean
A thick layer of dust or caking on the filter elements are a sign
that the dust discharge or purging effect is insufficient.
The accumulation of dust in the clean gas space or a trail of
dust on the clean gas outlet is a sign of damaged filter elements
or damaged seals. In this case, request a service call.

The extinguisher system can be triggered unintentionally.

NOTICE
Ø For a compact dust extractor with a fire extinguisher, before
opening the door, the extinguisher must first be switched off.

2. If there is an extinguisher, switch it off. Set the toggle switch
on the control panel to "Anlage Aus"/"Off System".
3. Open the door to the clean gas space.
4. Clean the clean gas space with an industrial vacuum cleaner.

5. Check that the filter inserts and seals are undamaged. Have
damaged components replaced by their manufacturer, Herd-
ing.
6. After finishing all work: close the door. If present, switch the
extinguisher system back on again.

Compact dust extractor: MultiCoater
1 Knurled screw 2 Signal light 3 Mesh insert

Topping up dispensing material for the MultiCoater Fig. 68263

Topping up dispensing
material
A capacitive level sensor measures the level of the dispensing
material in the storage container. If the switching value for the
lower limit has been reached, a message is output.
Conditions
■ The pre-coating procedure is not active; the signal light is not
lit.

■ Dispensing material: Calcium carbonate, CaCO3 or trass
powder.
Notes
■ The maximum permissible filling height for the dispens-
ing material is the lower edge of the grid insert.
■ A leaky cover seal must be replaced:

1 Knurled screw 2 Signal light 3 Mesh insert
Topping up dispensing material for the MultiCoater Fig. 68263
Name Calcium carbonate Trass powder

(CaCo3)
Grain size range ≥0 µm and ≤90 µm ≥0 µm and ≤150 µm
Average grain size ≥5 µm and ≤15 µm ≥20 µm and ≤40 µm
Purity level 99.1 % -
Filling volume of stor- 55 liters 55 liters
age container
Specification of dispensing material for MultiCoater Tab. 6-8
1. Open the MultiCoater cover and lock it into place.

2. Fill dispensing material into the storage container up to the
lower edge of the grid insert.
3. Close the cover again.

Checking and replacing the
seal
Condition

Note
Dust accumulation on the cover or inside the MultiCoater is an
indication that the parameterization of the pre-coating procedure
is not correct. In this case, inform the manufacturer.
1. Open the MultiCoater cover and lock it into place.

2. Check the cover seal and replace it if it is leaky or torn.
3. Check the interior space and the cover for dust accumula-
tion.
4. Close the cover again.

Replacing the pressure
regulating valve filter
cartridge 1. Switch off the MAIN SWITCH Machine.
2. Remove left side panel at the MultiCoater.
3. Turn the condensation water plug counter-clockwise and
drain the condensation water. Then reclose the condensation
water plug.
4. Replace the filter cartridge.
5. Reclose the side part of the MultiCoater.

13. Scrap conveyor
Scrap conveyor: Sensors
1 Discharge hopper sensor/ 2 Scrap container sensor

receiver
Scrap conveyor sensors Fig. 74474

Cleaning sensors
The scrap conveyor's rising and ejection areas are monitored by
sensors. The sensors are on the left side when looking in the
direction of transport. Each sensor consists of a transmitter and
a receiver (single beam light barrier). A reflector is fitted on the
opposing side.
If the sensor detects waste parts which could lead to a fault, an
error message will be issued and a FEED STOP will be trig-
gered.
The sensors prevent waste parts, which get stuck on the con-
veyor belt or which are pulled out of the container by the belt,
from getting into the lower part of the conveyor or into its hous-
ing.
A sensor is also monitored in the scrap container under the con-
veyor's outlet. If the sensor doesn't detect a container, an error
message will be issued and a FEED STOP will be triggered.
Notes
■ The scrap container is not supplied as part of the machine.
■ Empty the scrap container regularly.
B836en 2017-11-17 Scrap conveyor 6‐133

1. Remove the scrap container.
2. If necessary, clean the area behind the scrap container.
3. Clean the sensor with a soft, clean cloth.
Scrap conveyor: pedestal bearing
1 Grease nipples
Scrap conveyor pedestal bearing Fig. 74476

Lubricate the pedestal
bearing
■ Anti-friction bearing grease, e.g. Mobiltemp SHC100
■ Manual grease gun.
Ø Use a grease gun to fill the grease nipple until grease oozes
out.
6‐134 Scrap conveyor 2017-11-17 B836en

Scrap conveyor: lubricant container
1 Lubricant container
Scrap conveyor lubricant container Fig. 74472

Filling the lubricant
container
The conveyor belt lubrication is automatically initiated by the
machine control via the central lubrication.
The lubricant container on the scrap conveyor has a level sen-
sor. The control system will report when oil has to be topped up.

■ 1500 ml oil: Tonna S3 M32.
Notes
■ Always use the same oil.
■ After approx. 4 weeks, depending on the operating hours,
the lubricant container should be empty. Should this not be
the case, it can be an indication that the conveyor belt is not
being adequately lubricated.
1. Remove the cover from the lubricant container.

2. Pour the oil in slowly to avoid bubbles.
3. Close the lubricant container with the cover.

Scrap conveyor: conveyor belt

chain tension
If the chain tension is not set correctly, it will result in faster wear
of the mechanical components.
Signs that the chain tension is not correctly adjusted could

include:
■ Wear of the side boards. The chain is not evenly tensioned.
■ Severe wear of side chains. The tension is too high.
■ Wear in track roller guides in the curved sections. The ten-
sion is too high.
■ Compression of the belt/chain without blockage. The tension
is too low.

■ Torque wrench.
■ Bar or ruler.
Note
Two people are needed to remove the hood.
1 Cover 2 Bar 3 Conveyor belt

Scrap conveyor belt Fig. 74473
Checking the chain tension 1. Switch off the electrical supply to the scrap conveyor by turn-
ing the key switch on the device box to its central position.
2. Undo the fixing screws on the hood. Lift off the hood working
together with someone else.
3. Check the sag of the chain with a bar or ruler.

4. If necessary, readjust the chain tension.
Setting the chain tension
1 Befestigungsschrauben 3 Lock nut

2 Clamping screw
Setting chain tension Fig. 74477
5. Slightly undo the fixing screws (posn. 1) on the bearing.
6. Loosen the lock nut and turn it approx. 15 mm toward the
screw head.
7. Adjust the clamping screw evenly on both sides with max.
27 Nm.
Ø To increase the tension, increase the X dimension.
or
Ø To reduce the tension, reduce the X dimension.
8. Once the tension is correctly adjusted:
− Check the X dimension on both sides.
− If the X dimension is the same, tighten the lock nut.
9. Tighten the fixing screws hand-tight.
10. After the work is complete, put the hood back on and screw
it in place.
Scrap conveyor: housing bottom

Cleaning the housing bottom
Small parts and cutting dust collects in the housing bottom.
Using a cleaning carrier, dirt and waste can be removed from
the housing bottom.

Conditions
■ Scrap conveyor is ready for operation.

■ Vulkollan cleaning carrier.
Notes
■ Make sure that no dust is stirred up. Use an industrial vac-
uum cleaner with activated carbon filter.
■ The cleaning pusher dog belongs to the accessories for the
scrap conveyor.
■ If the cleaning pusher dog is not removed after cleaning, this
will lead to the polyester urethane strip wearing very quickly.
Waste parts in the housing bottom block and damage the

NOTICE conveyer belt!
Ø Use the cleaning carrier to clean the housing bottom at reg-
ular intervals.
Ø Dismantle the sheet skeleton into small parts.
Installing the cleaning 1. Acknowledge the danger zone and close the access door.
carrier 2. Start and stop the waste conveyor belt in setup mode, as
soon as the plate marked in red on the conveyor belt's upper
run is visible in the conveyor's feed area.
3. Remove the fixing screws in the area marked in red.
4. Screw the cleaning carrier between the red and black bars.
Starting the cleaning cycle 5. Acknowledge the danger zone and close the access door.
6. Start the waste conveyor belt in setup mode.
Waste parts and dust in the lower run are ejected via the
discharge hopper.
7. After 2 to 3 loops, stop the conveyor belt so that the
cleaning pusher dog can be removed again.
8. Disassemble the cleaning carrier.
9. Screw the black bar back onto the conveyor belt.
10. Empty the scrap container and clean it.

Cleaning the bottom of the
housing in the area of the
bend Note:
Only valid for machines with a rotational changer.

Waste parts and dust can collect in the vicinity of the lower bend
in the waste conveyor belt.

1 Befestigungsschrauben 2 Cover
The base of the housing and the scrap conveyor's lower Fig. 74945
bend
1. Undo the screws on the cover and remove it.

2. Remove the large pieces of waste.
3. Clean the bottom of the housing with an industrial vacuum
cleaner.
4. After cleaning, reinstall the cover.

14. Clamping fixture
Clamping fixture for hot-formed parts

Cleaning the guard plates,
slag channel and cover
1. If the clamping fixture is maintained while mounted:
− Switch off the MAIN SWITCH.
− Disconnect the fixture from the fixture interface
electrically and pneumatically.
2. Remove slag spatter from all parts of the fixture using a soft
copper brush. Do not use sharp objects to clean the fixture.
3. Reconnect the clamping fixture.

Replacing the wearing parts
All copper parts on the fixture are wear parts. They protect the
fixture against slag and damage by the laser beam.
1. If the wear parts are exchanged while mounted:

− Rotate the clamping fixture into the loading position.
2. Replace any worn components.
4. Unlock the EMERGENCY STOP push-button.
6‐140 Clamping fixture 2017-11-17 B836en

Clamping fixture for IHU workpieces

Check and clean the
positioner
The fork as well as the positioning bolt on the positioner are
functionally relevant components that significantly influence the
manufacturing accuracy.
The stop surfaces on the fork as well as the bolts must be regu-
larly cleaned and tested for wear.

■ Steel or brass brush.
Notes
■ Do not damage the protective plates when cleaning. Grooves
promote slag build-up.
■ A geometry deviation > 1 mm on the finished part can be an
indication of wear on the functional surfaces on the fork.
1 Positioning bolt 2 Fork stop surfaces

Fig. 86282
1. Thoroughly clean the fork surfaces (especially the support

areas) pads with a brush.
2. Thoroughly clean the positioning bolts. In the event of dam-
age (notch), the bolt can at first be rotated by 180°. If, how-
ever, a notch is formed circumferentially, the bolt must be
replaced.
B836en 2017-11-17 Clamping fixture 6‐141

3. Clean the protective plate.

Check and replace the ball
roller
The ball roller (TRUMPF material number 2238916) is a function-
relevant component, a mobile load ball.
1 Ball roller
Fig. 86283
1. Check whether the ball is still present, if it can be moved

and if it reacts to pressure.
2. Replace damaged ball roller.

Clean the fixture

■ Steel or brass brush.
1. If the clamping fixture is maintained while mounted:

− Switch off the MAIN SWITCH.
2. Remove slag spatter from all parts of the fixture using a soft
copper brush. Do not use sharp objects to clean the fixture.
6‐142 Clamping fixture 2017-11-17 B836en

Replacing the wearing parts
All copper parts on the fixture are wear parts. They protect the
fixture against slag and damage by the laser beam.
1. If the wear parts are exchanged while mounted:

− Rotate the clamping fixture into the loading position.
4. Unlock the EMERGENCY STOP push-button.
B836en 2017-11-17 Clamping fixture 6‐143

15. TruDisk
15.1 Overview
Pending maintenance work on the TruDisk is displayed on the

user interface of the machine in the maintenance wizard of the
laser control system.
Contamination of the water filter depends on the water quality.
(red).

tive

WARNING
additives.
datasheets.
Cooling water requirement Laser device Easy Kit Volumetric capacity

of internal laser device of cooling circuit in l
cooling circuit TruDisk 2000 CU2 approx. 30
TruDisk 3001 CU3 approx. 70
TruDisk 4001
Internal cooling circuit of the laser device Tab. 6-10
6‐144 TruDisk 2017-11-17 B836en

TruDisk cooling circuit

Replacing cooling water and
cleaning the tank
Ø See Operator's manual TruDisk, Chapter "Maintenance".

Cleaning or replacing the
contamination filter
Note
After each cooling water replacement and if the message is dis-
played: "Temperature in the laser device too high".

Replacing the water
microfilter
Note
After each cooling water replacement and if the message is dis-
played: "Pump has reached its capacity limit".
B836en 2017-11-17 TruDisk 6‐145

16. Process cooler for TruDisk (chiller)
16.1 Overview
This section applies to external process coolers of type RLxx/0

SR/TR and type RWxx/0 SR/TR from Riedel.
(red).

tive

WARNING
additives.
datasheets.
Cooling water requirement Process cooler Easy Ki Volumetric Water require-

of external laser device t capacity of cool- ment for cooling
ing circuit in l water replace-
cooling circuit
ment in l
Type RL10/0 CU3 80 260
Type RL13/0
Type RL17/0 CU4 150 500
Type RL20/0
Type RW13/0 CU3 80 260
Type RW17/0 CU4 150 500
Type RW20/0
External laser device cooling circuit (chiller) Tab. 6-12
6‐146 Process cooler for TruDisk (chiller) 2017-11-17 B836en

Process cooler: chiller (water-air)
1 Level indicator 2 Filter mat

Process cooler type RLxx/0 SR/TR (water-air) Fig. 74218

Replacing the filter mat
■ Filter mat, cut to size.
or
■ Filter mat in roll form.
Notes
■ The degree of contamination of the filter mat(s) depends on
the ambient conditions. The filter mat might have to be
replaced at shorter intervals.
■ If the laser device and/or process cooler have their own main
switches, these main switches must be additionally switched
on and off.
B836en 2017-11-17 Process cooler for TruDisk (chiller) 6‐147

2. Remove the filter mat and replace with a new one.

Checking and refilling the
level
Note
must be found.
Ø Check the filling level. When the minimum level is reached,

top up with water.

Checking for coolant circuit
leakage
It can be checked on the level indicator whether the coolant cir-
cuit is leaking, as needed or if coolant is escaping.
In the event of coolant leakage, a service mission must be
requested.
Note
If the laser device and/or process cooler have their own main
switches, these main switches must be additionally switched on
and off.

1 Inspection glass
Checking for leaks Fig. 87508

2. Open the longitudinal side of the process cooler.
3. Check on the level indicator whether there is air in the cool-
ant circuit.


Condition
machine.

■ Safety glasses.
■ Water collecting container.
■ Clean cleaning cloth.
■ Easy Kit.

Notes
water.
■ If the laser device and/or process cooler have their own main
switches, these main switches must be additionally switched
on and off.

NOTICE circuit!
tion.
1 Compressor 4 Water tank

2 Evaporator 5 Pump
3 Condenser
Cooling circuit for external laser device cooler Fig. 87506

Starting the cleaning cycle 1. Switch off the MAIN SWITCH Machine.
2. Open the process cooler on a longitudinal side.
3. Open the water container and add cleaning biocide (red bot-
tle lid) to the water. Close the water tank and process cooler
again.
Note
Cooling water must circulate during the cleaning cycle.
4. Switch the machine and drives back on. Production can con-
tinue during the cleaning cycle.
Draining water 5. End the cleaning cycle after 2 hours.

7. Open the longitudinal side on the process cooler again.
Note
The water container, pump and pipelines must be drained.
1 Drain, water tank 3 Drain, pipeline

2 Drain, pump
Emptying the tank Fig. 87507
8. Open all 3 sealing caps and drain the water.
9. When the water tank is empty, mount the sealing caps again
and thoroughly clean the inside of the water tank.
11. Close the water tank.
12. Switch the machine back on again.

13. Switch the drives back on: Press the MACHINE ON/OFF but-
ton.
fresh water.
Measure conductivity 18. After the third rinse cycle, measure the conductivity of the
water.
Water Care-Copper.
or
ity again.
minutes.
the conductivity is still more than 20 µS/cm, the complete
cooling water replacement must be repeated.
22. After completing the cooling water replacement, close the
water tank with the tank cap.
23. After completing the cooling water replacement, clean the
condenser with an industrial vacuum cleaner.
Attention: No dirt may fall into the tank in the process!
24. Clean the interior space of the process cooler with a cloth.
25. Check the water pressure at the pressure gauge. The set
pressure is 4 bar.
If the pressure is greater than 4 bar, check the water micro-
filter in the laser device for contamination.
26. After completing all maintenance work, close the process
cooler again.
27. Document the cooling water replacement on the process
cooler.

Chapter 7
Noise level test certificate
1 Test report 7‐3
2 Measurement result 7‐4
3 Measuring point arrangement 7‐5
B836en 2017-11-17 Noise level test certificate 7‐1

Output 2014-10-01
Drawing number 93964-7-82
Tab. 7-1
Note
The noise measurement record contains two measurements:
The noise measurement was carried out once with and once
without the soundproofing cover for the compact dust
extractor.
The "Noise level" test report contains the results for the compo-
nent with the highest noise levels - the basic machine. The max-
imum values determined also apply for all variants of automated
machines. On average, the contribution of the automation parts
to the noise level for the loudest and the typical operating mode
can be neglected.
7‐2 Noise level test certificate 2017-11-17 B836en

1. Test report
Noise measurement to DIN EN Location and Measurement with soundproofing:

ISO 11553-3 with DIN EN date of the Ditzingen, April 11, 2014
ISO 3746 also applicable measurement
Measurement without soundproofing:
Ditzingen, January 16, 2015
Accuracy class 3
Responsible Eike Cillis
Machine investigated Manufacturer TRUMPF Laser- and Systemtechnik
Type 3D laser processing machine with solid-state laser
TruDisk 2000
Type TruLaser Cell 8030 (L60)
Serial number S1631C0002
Year of manufacture 2013
Process cooler Type PC 161.1L4-D13L, made by Riedel
for laser device
Compact dust DELTA Comp 1500-14/9 SB, made by Herding
extractor
Measurement ■ Length: 7.36 m
surface, basic ■ Width: 4.45 m
machine ■ Height: 3.70 m
Measurement conditions Installation site In lightweight shed in Ditzingen
Installation According to installation plan 93964-5-11
Operating status Loudest operating mode:
■ High-pressure cutting
■ Material: mild steel, 2 mm thick
■ Nozzle diameter: 2.3 mm
■ Cutting gas pressure: 15 bar
Sound sources ■ Basic machine drives
active during ■ Cutting unit
measurement ■ Integral switch cabinets
■ TruDisk chiller
■ Compact dust extractor
Acoustic measurement environ- Description Size of the shed:
ment ■ Length: 60 m
■ Width: 25 m
■ Height: 8 m
The machine is standing in a corner of the lightweight
shed.
Suitability Ambience correction: K2A= 2.8 dB
Measuring device Sound level Brüel & Kjaer, type 2250
meter Serial number 2645064
Calibration date: 19.4.2013
Microphone Brüel & Kjaer, type 4189
Serial number 2631420
Calibration date: 19.4.2013
Test certificate Tab. 7-2
B836en 2017-11-17 Test report 7‐3

2. Measurement result
Acoustical data Sound pressure level L'pi [dB] with and without soundproofing:
Acoustic data Basic machine Process cooler

with soundproofing without soundproof-
ing
Measuring distance 1.0 m 1.0 m 1.0 m
Number of measuring points 16 16 6
Position of the measuring points See Fig. 73827 See Fig. 73828
Extraneous noise adjustment K1A = 0 dB K1A = 0 dB K1A = 0 dB
Environmental adjustment K2A= 2.8 dB K2A= 2.8 dB K2A= 2.8 dB
Sound pressure level L'pi see table "measurement result" see table "measure-
ment result"
Maximum sound pressure level LPA = 73 dB LPA = 76 dB LpA = 75 dB
Sound pressure level at control 69 dB 72 dB -
panel (MP 16)
Uncertainty KpA = 4 dB KpA = 4 dB KpA = 4 dB
Acoustic data Tab. 7-3
Measurement result Sound pressure level L'pi [dB] at the measurement points:
Measuring Basic machine Process cooler

point
Compact dust Compact dust
extractor with extractor with-
soundproofing out sound-
proofing
1 72.3 75.2 69.7
2 74.3 76.6 69.2
3 75.8 77.7 68.4
4 72.0 76.2 71.1
5 70.3 75.9 77.8
6 70.9 77.7 71.5
7 74.2 78.9 -
8 70.7 78.2 -
9 70.6 77.5 -
10 72.3 77.5 -
11 71.4 77.2 -
12 70.7 75.7 -
13 70.7 76.0 -
14 71.5 76.7 -
15 71.0 74.6 -
16 71.5 74.9 -
Sound pressure level Tab. 7-4
7‐4 Measurement result 2017-11-17 B836en

3. Measuring point arrangement
Measuring point arrangement base machine Fig. 73827
B836en 2017-11-17 Measuring point arrangement 7‐5

Arrangement of the measuring points for process cooler (heat exchanger) Fig. 73828
7‐6 Measuring point arrangement 2017-11-17 B836en

Index
3D working range ......................................3‐7
Core range ............................................ 3‐7
6D mouse .............................................. 4‐199
Axis group ......................................... 4‐199 C
Cable rack ............................................... 2‐24
Calibrating the sensor ............................. 5‐60
A CE marking ................................................1‐5
Ceiling plate .............................................2‐10
Access Control Key System 4‐29, 4‐31–4‐33 Change of application ............................. 4‐15
Identification .........................................4‐31 Change of sign ........................................4‐15
Reading device ....................................4‐33 Characteristic curve ....................... 2‐20, 2‐22
User groups .........................................4‐32 Cooling water requirement ..................2‐20
User management ...............................4‐29 Differential pressure ............................ 2‐22
Accessories ............................................. 1‐53 Clamping device ............................ 3‐35, 3‐39
Acknowledging feed stop ........................ 4‐17 Emergency triggering ................ 3‐35, 3‐39
Actuation ..................................................3‐30 Clamping error .........................................4‐61
Additional axis ....................................... 4‐133 Clamping fixture ....3‐29, 3‐34, 3‐37, 5‐63,
Advanced shop floor programming ...... 4‐165 6‐140
Air cutting gas ........................................... 6‐7 Hot-formed parts ................................. 3‐34
Ambient conditions .................................. 2‐12 IHU .......................................................3‐37
Ambient temperature ...............................2‐12 Clamping unit .................................3‐35, 3‐39
Assemblies .....................................3‐34, 3‐37 Hot-forming .......................................... 3‐35
IHU .......................................................3‐37 IHU .......................................................3‐39
WUF .....................................................3‐34 Collimation ............................................... 3‐13
Automation ...............................................4‐99 Cooling .................................................3‐13
Axes ........................................... 4‐126, 4‐135 Compact dust extractor ....2‐15, 3‐23, 4‐40,
Move continuously .............................4‐126 6‐9, 6‐125
Move incrementally ........................... 4‐126 Controls ............................................... 4‐40
Moving manually ............................... 4‐126 Exhaust air system ............................. 2‐15
Park ................................................... 4‐135 Installation ............................................2‐15
Axis group ............................................. 4‐198 Level sensor .............................. 6‐9, 6‐125
Axis position .......................................... 4‐117 Compressed-air cutting ........................... 2‐44
Switching over ................................... 4‐117 Compressed air consumption ................. 2‐43
Basic machine ..................................... 2‐43
Compressed air supply ........................... 2‐43
Configurable control interface ................. 1‐22
B Configuration ......................................... 4‐139
Automation interface ......................... 4‐140
Backspace ............................................... 4‐15 Workpiece change .............................4‐139
Base plate ............................................... 2‐10 Container transport ..................................2‐52
Beam guidance ....................................... 3‐12 Context-sensitive help ........................... 4‐191
Bookmarks .............................................4‐190 Start ................................................... 4‐191
Edit .....................................................4‐190 ControlLine ............................................ 4‐134
Buffer battery ................................. 6‐7, 6‐118 Record characteristic curve .............. 4‐134
Siemens fan unit ........................6‐7, 6‐118 Cooling circuit ............................................6‐7
Buttons .....................................................4‐79 Machine ................................................. 6‐7
Production plan ................................... 4‐79 Cooling water .................................2‐46, 2‐48
Requirements ...................................... 2‐48
Cooling water additives ... 6‐71, 6‐144, 6‐146
Easy Kit ........................6‐71, 6‐144, 6‐146
Cooling water requirement ........ 6‐144, 6‐146
B836en 2017-11-17 Index 8‐1

Cooling circuit, external laser device 6‐146
Cooling circuit, internal laser device 6‐144
Coordinate system .................................... 3‐4
Current program .................................... 4‐115 F
Edit .....................................................4‐115
Cutting gas .............................................. 2‐29 F keys ....................................................4‐208
Consumption ........................................2‐29 F1 key ....................................................4‐209
Cutting gases .......................................... 2‐29 Fault current circuit breaker ....................2‐36
Purity ....................................................2‐29 FEED HOLD .................................. 1‐41, 4‐16
Cutting parameters ................................4‐167 Feedrate potentiometer ........................... 4‐17
Cutting problems ..................................... 5‐41 File manager ......................................... 4‐178
Filtering installation ..................................3‐21
Fine dust bag .....................................6‐6, 6‐9
Fire safety ................................................1‐53
D Firewall .................................................. 4‐145
Fixture ............... 5‐65, 5‐69, 5‐71, 5‐72, 5‐74
Danger zone Actual position ..................................... 5‐72
Safeguarding device ........................... 1‐34 Correction frame ........................ 5‐65, 5‐74
Date ......................................................... 4‐71 Required position .......................5‐69, 5‐71
Day shift plan, create ............................4‐109 Fixture port .............................................. 3‐29
Day shift plan, deleting ..........................4‐111 Fixtures .................................................... 3‐23
Day shift plan, editing ........................... 4‐109 Arrangement ........................................ 3‐23
Deflection mirror Flatness ..................................................... 2‐9
B/C gearbox ........................................ 3‐13 Floor requirements .................................... 2‐9
Deflection mirror, B/C gearbox ............... 3‐13 Focal position ...............................4‐136, 5‐41
Dew point ................................................ 2‐13 Without FocusLine .............................4‐136
Dew point diagram .................................. 2‐13 Focus search ...........................................5‐41
Differential pressure ................................ 2‐22 Focus shift ............................................... 5‐41
Display area ............................................ 4‐67 FocusLine .......................................3‐13, 5‐41
Distance regulation ................................4‐133 Characteristic curve .............................5‐41
Activating ........................................... 4‐133 Frame .................................................... 4‐162
Door seal ......................................... 6‐7, 6‐50 Free span base plate ..............................2‐10
Dusts ........................................................1‐32
Dynamic cutting optics ................ 3‐13, 4‐132
Dynamic distance regulation .................4‐132
G
Geometry deviation ............................... 4‐206
E
Embedded Help .....................................4‐166
EMERGENCY STOP push-button 1‐40, 4‐18 H
Enable key .............................................4‐199
Enter ........................................................ 4‐15 Hazardous materials ............................... 1‐67
Escape .....................................................4‐15 Hydroforming package ............................ 3‐11
Escape door ............................................ 1‐38
EU Declaration of Conformity ................... 1‐5
Exhaust air .............................................. 1‐32
Exhaust system ....................................... 3‐21
I
Extended compressed air supply ......6‐6, 6‐7 I/O monitor .............................................4‐181
External cooling circuit ............................ 2‐18 Display ............................................... 4‐181
Extinguisher system . 1‐53, 3‐24, 4‐40, 6‐123 Identification .............................................3‐33
Annual test .......................................... 1‐53 Clamping fixture .................................. 3‐33
Controls ............................................... 4‐40 Industrial PC .................................. 6‐7, 6‐119
Buffer battery ............................. 6‐7, 6‐119
Installation site ...........................................2‐9
8‐2 Index 2017-11-17 B836en

Installation surface .................................... 2‐9 Machine ON/OFF .................................... 4‐16
Intended use ..............................................1‐8 Magnetic coupling .........1‐20, 1‐43, 3‐16, 6‐8
Internal management ................. 4‐118, 4‐145 Ferromagnetic attractive force ............ 1‐20
magnetic flux density .......................... 1‐20
Magnifying glass ......................................4‐15
Main activities ..........................................4‐66
J Main operation .........................................4‐43
PRODUCTION .....................................4‐43
Job ........................................................... 4‐84 Main switch .................................... 1‐40, 4‐11
Disable .................................................4‐84 Machine ............................................... 4‐11
Job data Manual functions 4‐120, 4‐122, 4‐127, 4‐130,
Edit .......................................................4‐84 4‐177
Jobs Call ......................................... 4‐122, 4‐130
Program sequence .............................. 4‐90 Maintenance ...................................... 4‐177
Joint offset ....................................... 3‐5, 5‐50 Production ..........................................4‐120
Setup ................................................. 4‐127
Manual loading ........................................ 4‐99
Marking test mode ................................ 4‐123
K Activating ........................................... 4‐123
Key-operated switch ................................1‐42 Master file .................................. 4‐118, 4‐145
TEACHIN ............................................. 1‐42 Import .................................................4‐118
Key switch ............................................... 4‐12 MDA .......................................................4‐138
Under Voltage Trip .............................. 4‐12 Block-by-block ................................... 4‐138
Kinematic transformation ... 3‐5, 4‐134, 4‐161 Single block ....................................... 4‐138
KSS ..........................................................1‐22 Measuring ball fixture ..............................5‐57
KSS configuration ..................................4‐163 Measuring equipment ..............................5‐57
KSS modules .........................................4‐146 Measuring nozzle .................................... 5‐64
Import .................................................4‐146 Measuring position .................................. 5‐63
Measuring system ........................4‐71, 4‐205
Imperial .............................................. 4‐205
Mechanics ................................................6‐46
L Maintenance ........................................ 6‐46
Media adapter ........................................... 5‐6
Language .................................................4‐71 Message details .................................... 4‐180
Laser ......................................................4‐131 Message history .................................... 4‐180
Enabling .............................................4‐131 Message line ........................................... 4‐65
Requesting .........................................4‐131 Message types ...................................... 4‐180
Laser cutting ..........................................4‐167 Messages .............................................. 4‐180
Laser network .................................. 1‐9, 3‐44 Display ............................................... 4‐180
Laser ON/OFF .........................................4‐16 MobileControl ................................. 4‐19, 4‐20
Laser scanner .................................... 6‐6, 6‐8 Wireless Operating Point .................... 4‐20
Laser status lamp ....................................1‐43 WLAN .................................................. 4‐20
laser technology tables ......................... 4‐166 WPA key ..............................................4‐20
Laser Test ................................................4‐16 MobileControl App ......................... 1‐43, 4‐20
Liability disclaimer ................................... 1‐53 MobileControl software ............................4‐20
List selection ............................................4‐67 Motion unit ............................................... 3‐11
Loading place .......................................... 4‐57 Mounting and activating the sensor ....... 5‐59
Loading status ............................... 4‐94, 4‐96 MultiCoater ........ 1‐17, 1‐18, 2‐16, 2‐49, 3‐24
Log-in status ............................................4‐65 Dispensing material .............................2‐49
Inertization ........................................... 3‐24
Precoating ............................................3‐24
M
Machine body .......................................... 3‐11
Machine cooler ...................................6‐6–6‐9
B836en 2017-11-17 Index 8‐3

Process cooler ............................... 2‐17, 2‐18
Laser device ........................................ 2‐18
Outdoor installation ............................. 2‐18
N Production place ......................................4‐57
Production plan . 4‐43, 4‐78, 4‐79, 4‐81, 4‐85
Nameplate ................................................. 3‐9 Automation interface ........................... 4‐87
Naming convention ................................4‐167 Cell status ............................................4‐79
LTT .....................................................4‐167 Clamping fixtures .................................4‐87
NC program Create ........................................ 4‐81, 4‐82
Start ................................................... 4‐115 Deleting ................................................4‐85
NC simulation ........................................ 4‐117 Job ....................................................... 4‐81
TruTops Cell Basic ............................ 4‐117 Loading acknowledgment ................... 4‐86
Network directory .................................. 4‐145 Loading place ...................................... 4‐86
Number pad .............................................4‐15 Order ....................................................4‐78
Production ............................................4‐86
Production place ..................................4‐81
Production plan ................................... 4‐78
O Program details ................................... 4‐78
On-screen keyboard ................................4‐72 Program sequence .............................. 4‐80
Activate ................................................ 4‐72 Run empty ........................................... 4‐93
Online help ................. I, 4‐189, 4‐190, 4‐204 Start ............................................4‐87, 4‐89
Start ........................................4‐190, 4‐204 Program ....4‐85, 4‐115, 4‐116, 4‐119, 4‐146,
Operating materials ................................. 2‐46 4‐147, 4‐150, 4‐151, 4‐219
Operating mode .......................................4‐43 Cancel ................................................4‐116
AUTOMATIC ........................................ 4‐43 Copy .................................................. 4‐147
JOG ..................................................... 4‐43 Create .................................... 4‐146, 4‐219
MDA .....................................................4‐43 Delete .......................................4‐85, 4‐151
Operating modes .....................................4‐43 Exporting ............................................4‐150
Operation mode, changing ....................4‐112 Importing ............................................4‐151
Optical laser cable .................................. 3‐43 Load ................................................... 4‐119
Order .............................................. 4‐84, 4‐93 Number .............................................. 4‐150
Delete .................................................. 4‐84 Pausing .............................................. 4‐116
Exporting ..............................................4‐93 Prepare .............................................. 4‐119
Order status .............................................4‐80 Select .................................................4‐146
Text editor ..........................................4‐147
Program header .................................... 4‐219
Program status ........................................ 4‐69
P Programming instructions ......................4‐189
Context sensitive help .......................4‐189
Page down .............................................. 4‐15 Programming system ............................ 4‐165
Page up ................................................... 4‐15 Programs ............................................... 4‐144
Partial backup ........................................4‐177 Management ......................................4‐144
Parts backup ......................................... 4‐177 Prepare .............................................. 4‐118
Password ................................................. 4‐75
User group ...........................................4‐75
Path ......................................................... 4‐67
Piece rate .............................................. 4‐102 R
Pilot laser .................................................3‐44
Planning aid ...............................................2‐5 Ramp cycles ..........................................4‐170
Pneumatics .............................................. 6‐61 Programming ..................................... 4‐170
Positioning unit ........................................ 3‐41 Rechargeable battery pack ........... 6‐8, 6‐120
IHU .......................................................3‐41 UPS module .............................. 6‐8, 6‐120
Power supply ........................2‐34, 2‐37, 2‐38 Reference optics ..............................5‐4, 5‐33
Central ........................................2‐34, 2‐37 Reference point run ................................ 3‐31
decentralized ..............................2‐34, 2‐38 Clamping fixture .................................. 3‐31
8‐4 Index 2017-11-17 B836en

Remaining time ..........................4‐102, 4‐103 Edit .....................................................4‐174
Basic .................................................. 4‐103 Shift change .......................................... 4‐106
Remaining time display .. 4‐101, 4‐103–4‐106 Shift goal ............................................... 4‐104
Basic .................................................. 4‐103 Shift plan, create ................................... 4‐106
Comfort .............................................. 4‐104 Shift plan, editing .................................. 4‐108
Day shift plan .................................... 4‐106 Shift, extending ......................................4‐113
Operation mode .................................4‐106 Shift, manually beginning and ending .. 4‐113
Piece rate .......................................... 4‐105 Single job .................................................4‐43
Screen ............................................... 4‐101 Smart Optics Setup ............. 5‐17, 5‐18, 5‐20
Shift plan ........................................... 4‐106 Basic .................................................... 5‐17
Required cooling water ........................... 2‐47 Parking position ...................................5‐18
Requirements, space ................................ 2‐9 Reference position .............................. 5‐20
Reset ....................................................... 4‐16 Setup position ......................................5‐18
Residual dust .........................................6‐122 Smart Optics Setup Station .................... 5‐58
Residual risks .......................................... 1‐55 Measuring ball ..................................... 5‐58
Rotary indexing table ..................... 4‐58–4‐60 Software ...................................................1‐53
Automatic mode .................................. 4‐60 Software version ....................................4‐181
Loading place ...................................... 4‐58 Solid-state lasers ............................. 3‐3, 3‐43
Rotational direction ..............................4‐58 Sound pressure level .........................7‐3, 7‐4
Setup mode ......................................... 4‐59 Test report ............................................. 7‐3
Rotational changer ......................... 4‐58–4‐60 Spare parts ..............................................1‐53
Automatic mode .................................. 4‐60 Spark arrester ............................................6‐6
Rotational direction ..............................4‐58 SPM ....................................................... 4‐154
Setup mode ......................................... 4‐59 Start ......................................................... 4‐17
Status bar ...................................... 4‐68, 4‐69
Status display ........................................ 4‐172
Setup state ........................................ 4‐172
S Status indicators ......................................4‐37
Step-by-step ............................................ 4‐94
Safety cabin .............................................3‐19 Start ..................................................... 4‐94
Safety Integrated ........................... 1‐42, 4‐52 Stop after cycle end ................................4‐92
Safety position .........................................4‐58 STOP push-button ...................................1‐41
Station change .................................... 4‐58 Teach panel ......................................... 1‐41
Safety test ............................................... 4‐53 Sub-operations ........................................ 4‐67
Start ..................................................... 4‐53 Sub program ..........................................4‐148
Scrap conveyor .............3‐28, 4‐38, 4‐62, 6‐8 Program name ...................................4‐148
Controls ............................................... 4‐38 Subroutine
Production ............................................4‐62 Create ................................................ 4‐148
Reverse mode ..................................... 4‐62 Subroutine macro .......................4‐153–4‐156
Sensors ..................................................6‐8 Inserting ............................................. 4‐156
Set up .................................................. 4‐62 Macro editor ...................................... 4‐155
Scrap conveyors ......................................4‐62 Programming ..................................... 4‐154
Screen holder .......................................... 2‐25 Support unit ................................... 3‐36, 3‐40
Screen view ........................................... 4‐116 Hot-forming .......................................... 3‐36
Switch ................................................ 4‐116 IHU .......................................................3‐40
Sensor ..................................................... 5‐64 Switch cabinet cooling ............................ 2‐14
Sensor system .........................................3‐15 Swivel unit ............................................... 3‐38
Operating status .................................. 3‐15 IHU .......................................................3‐38
Set of drawings ....................................... 3‐29 System settings ....................................... 4‐71
Setting device ..........................................5‐34
Setup plan ............................................. 4‐146
Setup state ................................. 4‐172–4‐175
Activate .............................................. 4‐172
Create ................................................ 4‐173
T
Delete ................................................ 4‐175 Tab ........................................................... 4‐15
B836en 2017-11-17 Index 8‐5

Teach panel ......................1‐51, 4‐194, 4‐195 User interface .......................................... 4‐73
Function key ...................................... 4‐195 Close ....................................................4‐73
Safety ...................................................1‐51 User responsibility ................................... 1‐22
Teach points .......................................... 4‐211 Utility tools ............................................. 4‐125
Teaching ...4‐201, 4‐203, 4‐211–4‐215, 4‐217
Arc ..................................................... 4‐212
Button ................................................ 4‐203
Circle ..................................................4‐214 V
Macro center ..................................... 4‐213
Macro help point ............................... 4‐213 Vacuum ejectors ................................ 6‐6, 6‐7
Oblong hole ....................................... 4‐217 Video monitoring ....................................... 3‐9
Rectangle ...........................................4‐215 Visual Online Support ........................... 4‐184
Square ............................................... 4‐215 VOS App ............................................... 4‐184
Straight line ........................................4‐211
User interface .................................... 4‐201
Teachpanel ............................................ 4‐195
Display ............................................... 4‐195
W
Technical data ......................................... 3‐45 Warm start ............................................. 4‐136
Cutting optics ............................. 3‐14, 3‐15 Run .................................................... 4‐136
Teleservice .............................................4‐182 Warning signs ..........................................1‐44
............................................................ 4‐182 Water protection ...................................... 1‐52
Modem ...............................................4‐182 Weight load ..............................................2‐11
Test sheet ...................................... 5‐18, 5‐28 Wireless Operating Point ...................... 4‐184
Test sheet holder .....................................5‐14 Wizard ............................................ 5‐27, 5‐28
Time ......................................................... 4‐71 Reference optics ................................. 5‐28
Titanium ................................................... 1‐17 Status ...................................................5‐27
Tool changer ............................................4‐61 Wizard ..................................................5‐28
Malfunction, acknowledging ................ 4‐61 Workpiece ................................................ 1‐18
Tool length ............................................... 5‐51 Oil residue ........................................... 1‐18
Tooling setup ......................................... 4‐171 Workpiece changer ...3‐25, 4‐57, 4‐59, 4‐141
Tooling status ........................................ 4‐171 Loading and unloading place ........... 4‐141
TOS ..........................................................4‐73 Manual functions ................................. 4‐59
TRUMPF Operating System ............... 4‐73 Setup mode ......................................... 4‐59
Touchscreen ............................................ 4‐15 Workpiece counter .....................4‐124, 4‐135
Transformation .......................................4‐159 Display ............................................... 4‐124
Transformation accumulator ..................4‐160 Reset ................................................. 4‐124
Transport ..................................................2‐50 Workpiece recognition .............................3‐30
Transport regulation ................................ 2‐50 Workpiece status ........ 4‐94, 4‐96, 4‐98, 4‐99
Tropical version ....................................... 2‐14
TruControl ................................................ 4‐74
Switching ............................................. 4‐74
TruDisk emergency stop push-button .....1‐40
TruTops Cell Basic ................................ 4‐165
U
Uninterruptable power supply ................. 2‐36
User administration ................................. 4‐75
User consent ........................................... 4‐54
Issue .................................................... 4‐54
User event logfile .................................... 4‐70
User group ..................................... 4‐75, 4‐76
Log on ................................................. 4‐76
8‐6 Index 2017-11-17 B836en

Operator's Manual 11-17-17 PDF

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Operator's manual

TruLaser Cell 8030 (L60)

TruLaser Cell 8030 (L60)

Original operator's manual

TRUMPF GmbH + Co. KG

For "partly completed machinery" in accordance with the EC

© TRUMPF GmbH + Co. KG

The machine documentation ■ TruLaser Cell 8030 Operator's manual

B836en 2017-11-17 Before you proceed ... I

Delivery variants 1‐4

1 For your safety 1‐5

3 Operational safety 1‐8

B836en 2017-11-17 Table of contents 0‐1

5 Measures to be taken by the manufacturer 1‐34

6 Organizational measures to be taken by the 1‐48

0‐2 Table of contents 2017-11-17 B836en

7 Overview of residual risks 1‐55

8 Machines without complete safety equip- 1‐59

9 Disassembly and disposal 1‐67

Chapter 2 Installation conditions TruLaser Cell

To what does this apply? 2‐4

1 Planning aid 2‐5

2 Installation site 2‐9

3 Gas supply 2‐28

B836en 2017-11-17 Table of contents 0‐3

4 Electric power supply 2‐34

5 Compressed air supply 2‐43

6 Operating materials 2‐46

0‐4 Table of contents 2017-11-17 B836en

1 Machine concept 3‐3

2 Coordinate system and working range 3‐4

3 Machine components 3‐8

4 Technical data 3‐45

1 Description of the controls and indicators 4‐8

B836en 2017-11-17 Table of contents 0‐5

2 Operating modes of the machine 4‐43

3 Operating the machine 4‐44

0‐6 Table of contents 2017-11-17 B836en

4 Description of the user interface 4‐65

5 System settings 4‐71

6 User administration 4‐75

7 Production plan 4‐78

B836en 2017-11-17 Table of contents 0‐7

0‐8 Table of contents 2017-11-17 B836en

B836en 2017-11-17 Table of contents 0‐9

0‐10 Table of contents 2017-11-17 B836en

B836en 2017-11-17 Table of contents 0‐11

Chapter 5 Setting work

Safety notes 5‐3

1 Overview of setting work 5‐4

2 Tooling the processing optics 5‐6

3 Checking the C and B axes and referencing 5‐10

4 Test sheet holder 5‐14

5 Smart Optics Setup 5‐17

0‐12 Table of contents 2017-11-17 B836en

8 Calibrating the measuring equipment 5‐57

9 Setting up the clamping fixture 5‐63

Chapter 6 Machine maintenance

1 General guidelines 6‐5

2 Maintenance Overview 6‐6

3 Safety device 6‐10

B836en 2017-11-17 Table of contents 0‐13

6 Mechanical elements 6‐46