Operator's manual

TruLaser 3030 (L49)

TruLaser 3040 (L50)

TruDisk
Operator's manual

TruLaser 3030 (L49)

TruLaser 3040 (L50)

TruDisk

Original operator's manual

Edition 2019-02-01
 Order Information Please specify when ordering this document:
Operator's manual
TruLaser 3030 (L49) TruLaser 3040 (L50)
Edition 2019-02-01
Document number B813en

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 ...

Operator's manual for This operator's manual documents the TruLaser 3030 and
TruLaser 3030 (L49), TruLaser 3040 laser cutting machines with TRUMPF CNC path
TruLaser 3040 (L50) control system on the basis of SIEMENS SINUMERIK 840Dsl.
The operator's manual is intended not only for the user (owner)
and the operator of the machine, but also for the maintenance
personnel. It should be made accessible to all of these people.

The entire machine documentation contains important safety

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

Documentation for further The Programming manual like the spare parts catalogue, control
reference system documentation and procurement documents is a
separate part of the complete system documentation. The docu-
mentation must be accessible to all persons involved with opera-
tion, programming, and maintenance.
The regulations and instructions of the documentation must be
observed to prevent unnecessary downtime and as a condition
for the recognition of warranty claims. The safety instructions
should be strictly adhered to in order to avoid accidents.

B813en 2019-02-01 Before you proceed ... I

II Before you proceed ... 2019-02-01 B813en
 Table of contents

Chapter 1 Safety

1 For your safety 1‐4

2 Terms 1‐6

3 Operational safety 1‐7

3.1 Intended use 1‐7
3.2 Authorized personnel 1‐8

4 Hazards 1‐9
4.1 Overview of laser classes 1‐9
Laser classes of the machine 1‐10
Laser classes of laser device and compo- 1‐10
nents
4.2 Hazards due to laser radiation 1‐10
4.3 Danger due to bright light 1‐12
4.4 Fire hazard 1‐12
Extinguishing a fire in the compact dust 1‐14
extractor (Camfil) with the CO2 extinguisher
system
Manually extinguishing the fire in the 1‐14
compact dust extractor (Camfil)
4.5 Danger due to hot surfaces 1‐15
4.6 Dangers from magnetic fields 1‐15
Linear drives 1‐15
4.7 Dangers due to the open electrical cabinet 1‐16
4.8 Dangers due to live parts 1‐17
4.9 Dangers due to travel motions in enabling 1‐18
mode
4.10 Dangers handling workpieces 1‐18
Risk of injury when removing a workpiece 1‐18
Hot workpieces 1‐18
4.11 Dangers due to accessing the pallet 1‐19
4.12 Hazards due to escaping coolant or cooling 1‐19
water

B813en 2019-02-01 Table of contents 0‐1

 4.13 Risks due to remote support 1‐19
4.14 Dangers when using the MobileControl app 1‐20
4.15 Hazardous materials 1‐20
Dusts, exhaust air 1‐21
Hazardous materials due to cutting oils 1‐22
Hazardous substances derived from poly- 1‐22
ethylene films

5 Measures to be taken by the manufacturer 1‐23

5.1 Danger zones and safeguarding device 1‐23
5.2 Warning signs at the machine 1‐28

6 Organizational measures to be taken by the 1‐31

user
6.1 Observe warnings and warning signs 1‐31
6.2 Training and instructing operators 1‐31
Measures applicable worldwide 1‐31
Protection against laser radiation: Additional 1‐32
information for Germany
Protection against laser radiation: Additional 1‐33
information for the USA
6.3 Duty of care when handling the machine 1‐33
6.4 Pay attention to water protection 1‐35
6.5 Using spare parts, accessories, software and 1‐35
operating materials
6.6 Safety data sheet on hazardous materials 1‐36

7 Overview of residual risks 1‐37

8 Disassembly and disposal 1‐40

Chapter 2 Installation conditions TruLaser 3030

(L49), TruLaser 3040 (L50)

To what does this apply? 2‐3

1 Planning aid 2‐4

2 Installation site 2‐6

2.1 Space requirements 2‐6

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 2.2 Floor requirements 2‐6
Surface 2‐6
Floor quality 2‐8
2.3 Weight load 2‐9
2.4 Stress due to vibration 2‐10
2.5 Ambient conditions 2‐10
2.6 Exhaust air system of the compact dust extrac- 2‐12
tor
2.7 Cable racks for laser light cables 2‐12
2.8 Installation of the process cooler 2‐13

3 Gas supply 2‐16

3.1 Cutting gases 2‐17
Purity 2‐17
Cutting gas consumption 2‐17
Supply lines for cutting gas supply 2‐19
Requirements on the connection point of 2‐22
the machine
Cutting gas supply with cylinders or bundles 2‐22
Cutting gas supply with gas tank 2‐23
3.2 Nitrogen for cutting unit ventilation 2‐24

4 Compressed air supply 2‐25

5 Electrics 2‐27
5.1 Power supply 2‐27
Connected loads 2‐27
Startup power 2‐28
Connecting cables 2‐29
5.2 Power supply 2‐30
Uninterruptible Power Supply (UPS) 2‐30
Residual current device (RCD) 2‐30
Power supply configurations 2‐31
Isolating transformer 2‐32
5.3 Remote support 2‐34
5.4 Cloud connection 2‐34
5.5 Network link 2‐34

6 Operating materials 2‐36

6.1 Gases 2‐36
6.2 Cooling water 2‐36

B813en 2019-02-01 Table of contents 0‐3

 7 Transportation of the machine 2‐40
7.1 Measures to be taken by the customer 2‐41
Transport TruDisk laser device 2‐42
7.2 Service work by Technical Service 2‐44

Chapter 3 Description

1 The most important assemblies 3‐4

1.1 Nameplate 3‐5
1.2 Closed machine frame 3‐6
1.3 Closed safety cabin with sliding roof 3‐6
1.4 Motion unit 3‐7
1.5 TruDisk Laser 3‐8
1.6 TRUMPF laser light cable 3‐10
1.7 Cutting unit 3‐11
1.8 Exhaust system 3‐12
1.9 Compact dust extractor 3‐13
1.10 Longitudinal conveyor belt 3‐13
1.11 Storage container 3‐13
1.12 Automatic pallet changer 3‐14
1.13 Spraying equipment 3‐15
1.14 Pilot laser 3‐15

2 Control system 3‐17

2.1 Operator panel with touchscreen 3‐18
2.2 Order List 3‐18
2.3 Shop floor programming 3‐19

3 The most important functions 3‐20

3.1 High-speed technology package 3‐20
3.2 Multi-sheet processing 3‐20
3.3 FocusLine 3‐21
3.4 FastLine 3‐21
3.5 FlyLine 3‐22
3.6 AdjustLine 3‐22
3.7 PierceLine 3‐23
3.8 Laser power control 3‐23

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 3.9 NitroLine 3‐24
3.10 ControlLine 3‐24
3.11 Cutting flaw detection with PlasmaLine 3‐25
3.12 ContourLine 3‐25
3.13 Microweld 3‐26
3.14 Auto-shutdown 3‐26
3.15 Drive-based collision detection 3‐27

4 The most important options 3‐28

4.1 BrightLine fiber (option) 3‐28
4.2 TruTops Boost 3‐29
4.3 Drop&Cut image-based post-production 3‐30
(option)
4.4 Smart Collision Prevention (option) 3‐30
How does Smart Collision Prevention work? 3‐32
4.5 Technology package Highspeed Eco (option) 3‐33
4.6 Compressed-air cutting (option) 3‐34
4.7 DetectLine (option) 3‐34
4.8 Automatic nozzle changer (option) 3‐35
4.9 Pipe cutting with RotoLas (option) 3‐36
4.10 CoolLine (option) 3‐37
4.11 Cleaning brush (option) 3‐38
4.12 Reconditioning cooling water with Easy Filter 3‐39
(option)
4.13 Clamps (option) 3‐40
4.14 Camera for process monitoring (option) 3‐41

5 Industry 4.0 with TruConnect 3‐42

5.1 What is Industry 4.0 at TRUMPF? 3‐42
5.2 Production overview 3‐43
5.3 Production control 3‐45
5.4 Connectivity 3‐46
5.5 Remote support 3‐48
5.6 Digital enhancement of the TRUMPF machines 3‐48

6 Safety 3‐50
6.1 CE marking 3‐50

7 Automation components and their functions 3‐51

7.1 Example 3‐53

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 8 Technical data 3‐54

Chapter 4 Operation

1 Description of the operating elements 4‐8

1.1 Operating elements outside the control panel 4‐8
1.2 Operating elements on the start post 4‐8
1.3 Operating part at the control panel 4‐11
1.4 USB port 4‐15
1.5 Keyboard 4‐15
1.6 User interface 4‐16
Status line 4‐16
Message bar 4‐17
Login status 4‐18
TRUMPF logo 4‐18
Main menus 4‐19

2 User administration 4‐22

2.1 Log on user group 4‐23
2.2 Change password 4‐24
2.3 Deleting the password 4‐24

3 Switch the machine on and off 4‐25

3.1 Unlock EMERGENCY STOP push-button 4‐25
3.2 Switching on the machine 4‐25
3.3 Switching off the machine 4‐26
3.4 Automatic switch on and shutdown 4‐26
Activating/deactivating auto-shutdown 4‐26
Activating/deactivating auto-switch on 4‐27

4 Activating the energy-saving mode 4‐28

4.1 Activating the energy-saving mode via "Laser 4‐29
energy-saving mode"
4.2 Activate energy-saving mode via "Automatic 4‐30
shutdown, machine+laser"

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 5 Water temperature monitoring 4‐31

6 Basic settings 4‐32

6.1 Calibrate the touchscreen 4‐32
6.2 Set language, measuring system, date and 4‐33
time
6.3 Activate the on-screen keyboard 4‐33
6.4 Open TRUMPF Operating System (TOS) 4‐34
6.5 Online Update Manager 4‐34
Call up Online Update Manager (on 4‐34
machines with TOS)
Switch off Online Update function 4‐36
6.6 To show the installed options 4‐36
6.7 Close user interface 4‐37
6.8 Switching to the TruControl interface 4‐38

7 Production 4‐40
7.1 Prepare program 4‐40
7.2 Execute program 4‐41
7.3 Switching the view for programs 4‐42
7.4 Pause program 4‐43
7.5 Aborting a program 4‐43
7.6 Carry out post-production 4‐44
7.7 Show status 4‐44
Machine 4‐44
Automation 4‐45
7.8 Triggering the manual transport procedure 4‐47
(automation)
7.9 Viewing active travel to storage (automation) 4‐48

8 Working with the production plan 4‐49

8.1 Creating a single job 4‐51
8.2 Create job for automatic systems 4‐53
For systems without connection to storage 4‐53
For systems with connection to storage 4‐54
For systems with SortMaster 4‐56
8.3 Modifying jobs 4‐57
8.4 Creating production packages 4‐58
8.5 Modifying the sequence of the jobs in the pro- 4‐58
duction plan
8.6 Preparing production plan/tool setup check 4‐59

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 Starting tool setup check during non-pro- 4‐60
ductive time
8.7 Starting a production plan 4‐60
8.8 Pause (stop) production plan 4‐60
8.9 Resuming production plan after a malfunction 4‐62
Correct error in the inventory management 4‐62
Correct malfunction at a component 4‐63
8.10 Disabling job in the production plan 4‐63
8.11 Deleting a job from the production plan 4‐63
8.12 Stocks 4‐64
Creating inventory 4‐65
Modifying inventory 4‐66
8.13 Manual handling (option) 4‐66
Manually loading the sheet 4‐67
8.14 Manual sorting (option) 4‐67
Manually sort parts 4‐67
8.15 Displaying the status in currently running pro- 4‐67
duction plan
8.16 Production options 4‐68
Manual loading of raw sheet 4‐68
Manually unloading the sheet 4‐69
Manually remove the small part. 4‐69
Single pallet mode 4‐69
8.17 Execution with intermediate storage (option) 4‐70
Creating a job with intermediate layer 4‐70
8.18 Preparatory loading (option) 4‐70
Activating preparatory loading 4‐70

9 Flexible entry into the program 4‐71

9.1 Restarting the program after an interruption 4‐72
Entry at the point of interruption 4‐72
Entry at a piercing 4‐74
Entering at a specific part 4‐75

10 Manually adjust technology parameters 4‐77

10.1 Select technology 4‐77
10.2 Loading 4‐78
10.3 Program properties 4‐79
10.4 Sheet technology 4‐79
10.5 Measuring sheet position 4‐80
10.6 Laser technology 4‐81

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 10.7 Microjoint 4‐82
10.8 Tube technology (RotoLas) 4‐83
10.9 Load tube (RotoLas) 4‐85
10.10 Part technology (RotoLas) 4‐85
10.11 Edge technology (RotoLas) 4‐86
10.12 Loading sheet (automation) 4‐88
10.13 Removal (automation) 4‐89
Small part removal - receiver 4‐90
Small part removal - palletizing 4‐91
Maxi part removal - receiver 4‐92
10.14 Skeleton separation (automation) 4‐93
10.15 Unload scrap skeleton (automation) 4‐93

11 Manual functions 4‐95

11.1 Using manual functions 4‐95
11.2 Engraving 4‐95

12 Move the zero point of the NC program 4‐97

12.1 Defining the new zero point 4‐97
12.2 Deleting "Offset zero point" 4‐97

13 Setup 4‐98
13.1 Moving the axes manually 4‐98
13.2 Releasing brakes for the Z axis drive 4‐99
13.3 MDA 4‐99
Creating NC programs block-by-block 4‐99
13.4 Activating or deactivating cleaning brush 4‐100

14 Multiple-machine operation with TruTops 4‐101

FMC
14.1 Master/Slave operation 4‐101
Execute an Master/Slave switch 4‐101
Switching off the LiftMaster 4‐102

15 Managing NC programs 4‐104

15.1 Load master file (NC program) in the internal 4‐105
management system
15.2 Editing NC programs 4‐105
Enter NC program in the editor 4‐106
Create NC sub program 4‐106
Modifying tests in the NC program 4‐108

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 Modifying technology tables in the NC pro- 4‐108
gram
Searching and replacing in the NC program 4‐109
Renumbering program blocks 4‐110
15.3 Output (export) NC program as master file 4‐110
15.4 Deleting NC program 4‐111
15.5 Copying a NC program 4‐112

16 Creating programs 4‐113

16.1 Process part 4‐113
Add a part to the partlist 4‐113
Process part 4‐113
16.2 Generate program 4‐115
16.3 Managing parts 4‐116
Manage files 4‐116
Delete files or clear folder 4‐116

17 Multi-sheet processing 4‐117

17.1 Edit several sheets 4‐117

18 Drop&Cut image-based post-production 4‐119

(option)
18.1 Start image-based post-production 4‐119

19 MobileControl app (option) 4‐121

19.1 Safety: MobileControl App 4‐122
19.2 Operating procedure 4‐122
19.3 Making settings 4‐124
19.4 Activating or deactivating the MobileControl 4‐125
app
19.5 Backup during service work 4‐125
19.6 Name for identification of the machine 4‐126
19.7 Setting up and connecting WLAN 4‐126
19.8 Wireless operation point – WLAN network of 4‐127
the machine
Changing the settings on the wireless oper- 4‐128
ation point

20 Wireless operation point 4‐129

20.1 Changing the settings on the wireless opera- 4‐129
tion point

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 21 Operating CoolLine 4‐130
21.1 Select technology table 4‐130

22 Smart Collision Prevention 4‐131

22.1 Use in TruTops 4‐131
Activation in TruTops Boost HERE2 4‐131
Activation in TruTops Laser 4‐132
22.2 Configuring Smart Collision Prevention 4‐132
22.3 Notes on use on the machine 4‐133
Restrictions 4‐134

23 Operation of automatic nozzle changers 4‐135

(option)
23.1 The replacement procedure 4‐135
23.2 Translating axes 4‐135
23.3 Manual functions 4‐136
23.4 Nozzle management 4‐137
Nozzle holder allocation 4‐138
23.5 Tooling dialog in the production plan 4‐140
23.6 Defining the service life of the nozzles 4‐141
23.7 Loading nozzle changers 4‐142
23.8 Canceling an automatic nozzle change 4‐143
23.9 Minimizing and/or preventing malfunctions and 4‐144
failures
Examples of damaged nozzles and ceramic 4‐145
bodies
Example of a damaged nozzle holder 4‐145

24 Diagnostics 4‐147
24.1 Pending messages 4‐147
Displaying alarm and warning messages 4‐147
24.2 History of messages 4‐147
Displaying message history 4‐147
24.3 Condition Guide 4‐148
Showing signal lamps for monitored proper- 4‐148
ties
24.4 Displaying software versions 4‐148

25 Help when problems arise 4‐149

25.1 Switch off the machine if malfunctions occur 4‐149
25.2 Activating remote support 4‐149

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 25.3 Start Visual Online Support (option) 4‐150
25.4 Measures after a collision detection 4‐152
25.5 Conversion software 4‐153
25.6 Performing spot image 4‐153
Recording a spot image 4‐153

Chapter 5 Setting work

1 Safety notes 5‐3

2 Luminous displays on the cutting unit 5‐4

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

3 State of the protective glass 5‐6

3.1 Checking the state of the protective glass 5‐6

4 Center the beam to the nozzle 5‐10

4.1 Procedure with adhesive strips 5‐10

5 Determining the focal position 5‐13

5.1 Procedure 5‐13
5.2 CP_FOCUS_COMB focus search program 5‐13

6 Working with DetectLine 5‐14

6.1 Sheet position detection with DetectLine 5‐14
6.2 Calibrating DetectLine 5‐15
Calibrating DetectLine 5‐15

7 Calibrating the camera for the image-based 5‐16

post-production (option)
7.1 Calibrating the camera with a laser diode 5‐16
7.2 Calibrating the camera without a laser diode 5‐18

8 Setting work for the Highspeed Eco cutting 5‐21

process
8.1 Set cutting parametersHighspeed Eco 5‐21
8.2 Cut interruption with Highspeed Eco nozzle 5‐21

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 9 Setting work on the pallet conveyor 5‐22
9.1 Replace pallet conveyor chain 5‐22
Replace pallet conveyor chain 5‐22

10 Further utility programs and files 5‐25

10.1 CP_TRIM_OFF parting cut program 5‐25
Image-based separating cut with 5‐25
CP_TRIM_OFF
10.2 Cutting workpiece support consumables 5‐25
Loading files for tool cartridge slats 5‐26

Chapter 6 Maintenance

1 General guidelines 6‐8

2 Maintenance Overview 6‐10

3 Lubrication 6‐15
3.1 Overview 6‐15
3.2 Central lubrication 6‐17
Checking and refilling the lubricant level 6‐17
[101]
Checking lubrication lines for air pockets 6‐20
and bleeding them if necessary
3.3 Guide rails on the pallet 6‐21
Lubricating the guide rail [41] 6‐21
3.4 Longitudinal and transverse conveyor belt 6‐22
brush lubrication
Refilling lubricant [46] 6‐22
Check brush lubrication and brushes and 6‐23
replace if necessary
3.5 Chain and cam assembly of pallet transport 6‐24
unitChain, cam and guide rail of pallet trans-
port unit
Cleaning and lubricating the chain and cam 6‐24
assembly of the pallet transport unit

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 4 Hydraulics 6‐25
4.1 Overview 6‐25
4.2 Hydraulic unit 6‐25
Check oil level, top up as required [85] 6‐25
Change the oil and oil filter 6‐25
4.3 Hydraulic hoses 6‐27
Check the hydraulic hoses 6‐27

5 Mechanics 6‐29
5.1 Overview 6‐29
5.2 Safety cabin 6‐29
Check the safety cabin [04] 6‐29
Check the laser protection window [04] 6‐30
Cleaning the laser protection window [04] 6‐30
5.3 Work area illumination 6‐31
Check the work area illumination [03] 6‐31
5.4 Support slats - Pallets 6‐33
Clean the slats and slat supports; 6‐33
exchange, if necessary [25]
5.5 Compact dust extractor 6‐34
Checking or replacing the disposable con- 6‐34
tainer [02]
5.6 Dust chamber in the compact dust extractor 6‐36
Cleaning the dust chamber [22] 6‐36
5.7 The differential pressure indicator on the 6‐37
compact dust extractor
Check differential pressure indicator [23] 6‐37
5.8 Compact dust extractor purging valves 6‐37
Check the purging valves [44] 6‐37
5.9 Compact dust extractor: extinguisher system 6‐38
(option)
Maintain extinguisher system 6‐38
5.10 Tube bend and suction tube of the suction sys- 6‐38
tem
Dismantling and cleaning the pipe elbow 6‐38
and suction tube [45]
5.11 Storage bin for slag and dust 6‐39
Emptying the storage bin [26] 6‐39
5.12 Y measurement system, guideways, covers 6‐40
and track strippers
Cleaning the Y scale [06] 6‐40
5.13 X and Y axis racks and guideways 6‐43

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 Cleaning the X and Y axis racks and guide- 6‐43
ways
5.14 Z axis bellows 6‐45
Checking and cleaning the Z axis bellows 6‐45
5.15 Cable carriers 6‐46
Checking the Y and Z cable carriers [07] 6‐46
5.16 Motion unit 6‐46
Clean the grease collecting tray 6‐46
Cleaning the spray shield 6‐47
5.17 Pallet conveyor cam assembly 6‐48
Replacing the cam assembly of the pallet 6‐48
transport
5.18 Longitudinal conveyor belt 6‐49
Checking the hinge conveyor belt [20] 6‐49
Tightening the hinge conveyor belt 6‐49
5.19 Cover sheets of the longitudinal and transverse 6‐51
conveyor belt
Cleaning the cover sheets 6‐51
5.20 Exhaust module 6‐52
Checking, cleaning and if necessary replac- 6‐52
ing components of the exhaust module [24]
5.21 Pallet changer 6‐54
Check and clean the calibration plate and 6‐54
nozzle-cleaning brushes; replace, if neces-
sary [42]
5.22 Camera for process monitoring 6‐55
Check the protective glass on the camera; 6‐55
clean, if necessary [66]
5.23 Automatic nozzle changer (option) 6‐56
Check nozzles, ceramic body and nozzle 6‐56
threads
Check and clean the nozzle holders 6‐56
Clean or replace the sleeve and internal 6‐57
part of the nozzle (Highspeed Eco)
Check and clean the calibration plate and 6‐59
nozzle-cleaning brushes [42]
Cleaning the drive unit's cover sheet 6‐59
Lubricating the linear guides 6‐60

6 Pneumatics 6‐61
6.1 Overview 6‐61
6.2 Input controller operating pressure 6‐62
Check the operating pressure 6‐62
6.3 40 μm filter for compressed air supply 6‐62

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 Replace the filter cartridge 6‐62
6.4 Filter B compressed air supply 6‐63
Replace the filter cartridge 6‐63
6.5 Filter A compressed air supply 6‐63
Replace the filter cartridge 6‐63
6.6 Activated carbon filter compressed air supply 6‐64
Replace the filter cartridge 6‐64
6.7 Condensation water container for compressed 6‐64
air supply
Emptying the condensed water container 6‐64
[94]
6.8 Cutting gas filter for oxygen nitrogen and argon 6‐65
Replacing filter elements 6‐65
6.9 Filter elements in the compact dust extractor 6‐68
Checking and replacing filter elements 6‐68
6.10 Maintenance unit on compact dust extractor 6‐69
Check the pressure reducer and the com- 6‐69
pressed air supply
Checking and, if necessary, replacing the fil- 6‐70
ter elements
6.11 Filter (only with the compressed-air cutting 6‐70
option)
Replace the filter element [52] 6‐70
6.12 Microfilter (only with the compressed-air cutting 6‐71
option)
Replace the filter element [52] 6‐71
6.13 Activated carbon filter 1 (only for the com- 6‐71
pressed-air cutting option)
Check activated carbon filter 1, replace if 6‐71
necessary[47]
6.14 Activated carbon filter 2 (only for the com- 6‐72
pressed-air cutting option)
Check activated carbon filter 2, replace if 6‐72
necessary[48]
6.15 Spraying equipment 6‐73
Refilling spraying agent [92] 6‐73

7 Machine cooling circuit 6‐76

7.1 Overview 6‐76
7.2 Machine cooler , water-air chiller 6‐79
Checking and refilling the level 6‐79
Checking filter mat; replacing, if necessary 6‐80
Change cooling water 6‐82

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 8 External laser cooling circuit 6‐86
(TruDisk 3001 / 4001, standard version)
8.1 Overview 6‐86
8.2 Process cooler: Laser (water-air) 6‐87
Replacing the filter mat 6‐87
Checking and refilling the level 6‐88
Check the ventilation fan and clean, if nec- 6‐88
essary.
Change cooling water 6‐88

9 Cooling circuit of the machine 6‐93

(TruDisk 6001)
9.1 Overview 6‐93
9.2 Process cooler for machine 6‐93
Exchange filter mat 6‐93
Checking the filling level 6‐94
Replace cooling water 6‐96

10 External laser cooling circuit (TruDisk 6001) 6‐100

10.1 Overview 6‐100
10.2 Laser process cooler 6‐100
Replacing the filter mat [91] 6‐100
Checking the filling level [81] 6‐101
Replace cooling water 6‐102

11 TruDisk 6‐105
11.1 Overview 6‐105
11.2 TruDisk cooling circuit 6‐106
Changing the cooling water and tank 6‐106
Checking the cooling for tightness 6‐106
Cleaning or replacing the contamination fil- 6‐106
ter
Replacing the water microfilter 6‐107

12 Laser cooling circuit with Easy Filter 6‐108

12.1 Overview 6‐108
12.2 Cooling circuit with Easy Filter 6‐109
Reconditioning cooling water 6‐109

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 13 Electrics 6‐112
13.1 Overview 6‐112
13.2 Electrical cabinet 6‐112
Checking and, if necessary, cleaning the 6‐112
electrical cabinet
Checking the door monitoring 6‐113
Checking the power supply 6‐113
Checking the function of the fan on the 6‐113
electrical cabinet
Cleaning the fan [64] 6‐114
Replacing the BIOS battery 6‐115
Replacing the NCU fan unit 6‐116
Replacing the NCU fan battery 6‐117
Replacing the UPS rechargeable battery 6‐119
pack
Replace the buffer battery for the real time 6‐122
clock
13.3 Safety light barriers 6‐124
Cleaning the safety light barrier [51] 6‐124

14 Optics 6‐125
14.1 Overview 6‐125
14.2 Cutting unit 6‐126
Check the nozzle and blowing nozzle, and 6‐126
clean if necessary [93]
14.3 Cartridge in the cutting unit 6‐127
Cleaning the protective glass [08] 6‐127

15 RotoLas 6‐131
15.1 Support housing, outside 6‐131
Cleaning the support housing 6‐131
15.2 Four-jaw collet chuck 6‐131
Checking and cleaning the collet chuck 6‐131
15.3 RotoLas spatter guard 6‐132
Check the buffer and exchange, if neces- 6‐132
sary.

16 CoolLine 6‐133
16.1 CoolLine water container 6‐133
Refilling the water container 6‐133

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 Check the water filter and replace if neces- 6‐134
sary

Chapter 7 Safety light barrier

1 Safety light barrier SICK M 4000 7‐2

2 Installation of safety light barrier 7‐3

2.1 Mounting the posts 7‐3
2.2 Aligning the columns 7‐4

Chapter 8 Test certificate on the noise level of

the TruLaser 3030 (L49),
TruLaser 3040 (L50)

1 Test certificate 8‐2

2 Measurement result 8‐4

3 Position of the measuring points 8‐5

Chapter 9 TRUMPF RotoLas tube cutting unit

Description RotoLas 9‐3

1 Safety information 9‐4

2 Technical data 9‐5

3 The most important assemblies 9‐6

3.1 Rotary unit 9‐6
3.2 Suction system 9‐6
Increasing the suction power 9‐7

B813en 2019-02-01 Table of contents 0‐19

 3.3 Support housing, outside 9‐9
3.4 Roller cabinet 9‐10
3.5 Supports 9‐11
3.6 NC stop 9‐13
3.7 Automatic collet chuck (option) 9‐14
3.8 Clamping methods 9‐15
Clamping workpieces 9‐15
Turning and drilling jaws (clamping method 9‐16
no. 30-35, 40, 41)
Basic jaws 9‐17
Bolt clamping set (clamping method no. 36) 9‐18
Prism clamping set (clamping method no. 9‐19
37, 38)
Clamping with a minimized dead area 9‐20
(clamping method no. 39)
Clamping method table 9‐21

4 Notes on achievable accuracy during tube 9‐23

processing
4.1 Unprocessed material: tubes and profiles 9‐23
Cross section error 9‐23
Length error 9‐24
Tube distortion 9‐25

5 Operating the RotoLas tube cutting unit 9‐26

5.1 Support housing, outside Installing and remov- 9‐26
ing
5.2 Preparing the support housing for tube proc- 9‐28
essing
5.3 Preparing the machine for tube processing 9‐31
5.4 Switching the machine to plane machining 9‐32
5.5 Selecting/Deselecting the longitudinal conveyor 9‐32
belt
5.6 Move support 9‐33
5.7 Measuring the tube center at a certain point 9‐33
5.8 Resetting the coordinate displacement 9‐33
5.9 Utility program CP_RLPRG 9‐34
Cutting spacers 9‐34
Spatter guard for tubes 9‐35
Mounting disks for rectangular tubes 9‐36
5.10 Utility program CP_TRIM_OFF 9‐37
5.11 Working with the automatic collet chuck 9‐37
(optional)

0‐20 Table of contents 2019-02-01 B813en

 Clamping with the automatic collet chuck 9‐37
Relieving with the automatic collet chuck 9‐37
Information on working with the automatic 9‐38
collet chuck
5.12 Changing the dead range of the clamping jaws 9‐39
5.13 Determining the zero point offset 9‐40
5.14 Running test mode 9‐42

Chapter 10 Index

B813en 2019-02-01 Table of contents 0‐21

0‐22 Table of contents 2019-02-01 B813en
 Chapter 1

Safety

1 For your safety 1‐4

2 Terms 1‐6

3 Operational safety 1‐7

3.1 Intended use 1‐7
3.2 Authorized personnel 1‐8

4 Hazards 1‐9
4.1 Overview of laser classes 1‐9
Laser classes of the machine 1‐10
Laser classes of laser device and compo- 1‐10
nents
4.2 Hazards due to laser radiation 1‐10
4.3 Danger due to bright light 1‐12
4.4 Fire hazard 1‐12

B813en 2019-02-01 Safety 1‐1

 Extinguishing a fire in the compact dust 1‐14
extractor (Camfil) with the CO2 extinguisher
system
Manually extinguishing the fire in the 1‐14
compact dust extractor (Camfil)
4.5 Danger due to hot surfaces 1‐15
4.6 Dangers from magnetic fields 1‐15
Linear drives 1‐15
4.7 Dangers due to the open electrical cabinet 1‐16
4.8 Dangers due to live parts 1‐17
4.9 Dangers due to travel motions in enabling 1‐18
mode
4.10 Dangers handling workpieces 1‐18
Risk of injury when removing a workpiece 1‐18
Hot workpieces 1‐18
4.11 Dangers due to accessing the pallet 1‐19
4.12 Hazards due to escaping coolant or cooling 1‐19
water
4.13 Risks due to remote support 1‐19
4.14 Dangers when using the MobileControl app 1‐20
4.15 Hazardous materials 1‐20
Dusts, exhaust air 1‐21
Hazardous materials due to cutting oils 1‐22
Hazardous substances derived from poly- 1‐22
ethylene films

5 Measures to be taken by the manufacturer 1‐23

5.1 Danger zones and safeguarding device 1‐23
5.2 Warning signs at the machine 1‐28

6 Organizational measures to be taken by the 1‐31

user
6.1 Observe warnings and warning signs 1‐31
6.2 Training and instructing operators 1‐31
Measures applicable worldwide 1‐31
Protection against laser radiation: Additional 1‐32
information for Germany
Protection against laser radiation: Additional 1‐33
information for the USA
6.3 Duty of care when handling the machine 1‐33
6.4 Pay attention to water protection 1‐35
6.5 Using spare parts, accessories, software and 1‐35
operating materials

1‐2 Safety 2019-02-01 B813en

 6.6 Safety data sheet on hazardous materials 1‐36

7 Overview of residual risks 1‐37

8 Disassembly and disposal 1‐40

B813en 2019-02-01 Safety 1‐3

 1. For your safety

Regulations and guidelines With the CE marking and the EU Declaration of Conformity,
TRUMPF confirms that the machine meets the basic health and
safety requirements of the EC Machinery Directive.
The machine/automation component safely fulfils its intended
load lifting functions. The required static and dynamic tests were
performed at the production plant. These tests confirm the
machine's suitability for its purpose in accordance with the EC
machinery directive. No additional measures are required at the
point of use for confirming the machine's suitability for its pur-
pose.
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
prevention 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.
Signaling words Tab. 1-1

1‐4 For your safety 2019-02-01 B813en

 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.

B813en 2019-02-01 For your safety 1‐5

 2. Terms

Term Description
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 product Machine, to which a laser device is connected or should be connected later. The
terms "machine" and "laser product" 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

1‐6 Terms 2019-02-01 B813en

 3. Operational safety

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

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

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.
Installation, operating and transport conditions defined by
TRUMPF must be adhered to and maintenance work must be
carried out in accordance with the Operator's manual. The oper-
ator must observe the specifications of the country in which it is
being operated as well as national and regional safety and acci-
dent prevention regulations.
The operator may laser cut the materials described in the data
collection. The user may process other materials only after con-
sulting TRUMPF.

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

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

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

The following is not allowed:

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

B813en 2019-02-01 Operational safety 1‐7

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

Laser protection device The machine's laser protection devices, for example the window
of the safety cabin, are designed for the wavelength and the
power of the laser device delivered with the machine.
If a laser device is connected with a different wavelength or
power, 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.

Disclaimer Any use going beyond this is considered to be unauthorized use.

TRUMPF is not liable for any damage, especially personnel inju-
ries 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, hydraulic, pneumatic
and electrical modules.
− Disassemble the machine and its components.

1‐8 Operational safety 2019-02-01 B813en

 4. Hazards

4.1 Overview of laser classes

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

Class Description
1 The accessible laser radiation is not dangerous under sensibly predictable
conditions.
2 The accessible laser radiation lies in the visible spectral range (400 nm to
700 nm). It is not dangerous for the eyes when the exposure time is 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

B813en 2019-02-01 Hazards 1‐9

 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.
Service mode Service mode is the mode of Service work includes the following: 4
the machine for service work. ■ Setting up optical assemblies of the
machine.
■ Adjustment and checking of the laser beam.
Laser classes of the machine Tab. 1-4

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 device 3R
Pilot laser at the exit of the focusing optics 2
Laser device with closed hood 1
Laser light cable 1
Laser classes of laser device and components Tab. 1-5

4.2 Hazards due to laser radiation

Solid-state laser TruDisk The laser device 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.

1‐10 Hazards 2019-02-01 B813en

 Invisible, high-energy laser radiation!
DANGER
Risk of severe skin burns and damage to the eyes. Vision
impairment and blindness!
Ø Only operate the machine with the safety devices active.
Ø Check the safety devices for damage daily.
Ø Observe warning signs and warning symbols.

Invisible, high-energy laser radiation!

DANGER
Risk of severe skin burns and damage to the eyes.
Impairment of vision and loss of sight!
Ø Check the safety cabin and laser protective screen daily for
damage.
Ø Regularly remove punching slugs and small parts in the
machine interior and on pallets.

Incorrect laser safety glasses!

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

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

Risk of eye injuries due to laser radiation!

WARNING
Laser radiation causes irreparable damage to the eyes.
Ø Do not look directly into the beam.

Wavelength (visible, red) 630 nm to

680 nm
Nominal output power < 5 mW
Output power on the focusing optics < 1 mW
Laser class 3R
Laser class at exit of the focusing optics 1
Pilot laser technical data Tab. 1-6

B813en 2019-02-01 Hazards 1‐11

 4.3 Danger due to bright light

There is secondary radiation during laser processing. It is com-

posed of ultraviolet (<400 nm), harsh, visible and infrared radia-
tion (>780 nm).
The safety cabin and the viewing window screen the ultraviolet
radiation effectively. The proportion of infrared radiation is negligi-
ble..
Looking into the harsh light at the processing point causes per-
manent eye damage. The processing of galvanized sheet steel is
particularly critical. The permissible monitoring duration without
eye protection is only a few minutes per day. For all other mate-
rials permitted by TRUMPF, the monitoring duration without eye
protection is considerably longer.

Danger due to harsh light during laser processing!

WARNING
Intensive visible light causes permanent damage to the
retina!
Ø Never look directly into the harsh light at the processing
point without eye protection.
Ø Protect eyes with dark sunglasses or put dark film on the
windows of the safety cabin.
Ø Do not operate a machine with damaged viewing windows.

4.4 Fire hazard

Note
Fires may only be fought by suitably trained personnel and only
if there is no risk of endangering yourself. If in doubt, call the fire
department.

The following fire extinguishers should be kept ready at the

machine for fire protection:
■ CO2 fire extinguisher (fire class CB)
■ Metal bucket (min. 20 l) with dry sand or fire extinguisher
(fire classification D) for metal fires.

1‐12 Hazards 2019-02-01 B813en

 Combustible objects in the machine's work area; formation
CAUTION of foil lint when cutting film-coated sheet metal.
Fire in the compact dust extractor.
Ø Do not throw flammable objects, such as cigarettes or
paper, into the work area of the machine.
Ø Service the compact dust extractor on a regular basis.
Ø Replace the disposable container when the specified filling
level is reached.
Ø Ensure that the seal on the upper edge of the container
forms an airtight seal. Use the original container from the
manufacturer.
Ø TRUMPF must be informed immediately if there is a fire in
the compact dust extractor.

Fire due to material change!

CAUTION
Fire in the storage bin.
Ø Empty the storage bin before changing the material from
aluminum/aluminum alloys to ferrous materials or vice versa.
Ø Empty the storage bin on a daily basis, regardless of the
machined materials.
Ø In case of fire, put on protective gloves and safety glasses,
completely pull out the storage bin and, at a distance of a
few meters from the machine, extinguish the fire with sand
or a fire extinguisher for metal fires (fire classification D).

Safety package for fire ■ Sensors detect and signal smoke development.
smothering ■ The flaps of the suction chambers of the machine are closed.
■ The current processing is stopped.
− The compact dust extractor is shut down.
■ The shut-off valve of the compact dust extractor is closed.
■ This smothers the fire.
The message The smoke alarm of the suction system has been
triggered appears on the operating panel of the machine.
To prevent the fire from flaming up again and to cool down the
device, only open the filter chamber after 30 minutes. 30 minutes
after extinguishing, the compact dust extractor can be operated
again by Technical Service or by appropriately trained personnel
in accordance with the specifications of the supplier documenta-
tion.

B813en 2019-02-01 Hazards 1‐13

 Extinguishing a fire in the compact dust
extractor (Camfil) with the CO2 extinguisher
system

If there is a fire in the filter chamber, an acoustic and optical

alarm is triggered. The CO2 extinguisher system is automatically
triggered.

Means, Tools, Materials

■ CO2 fire extinguisher (fire classification B) for fires in the
compact dust extractor and smaller fires at the machine.

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.

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.

Ø The following measures should be taken if the extinguisher

system is triggered during a fire:
− Wait for about 5 to 10 minutes.
− Switch off the MAIN SWITCH of the machine.
− After approx. 10 minutes, open the upper door to the
clean gas space with someone else standing by to cover
you. Keep a fire extinguisher to hand at all times. A fire
can re-ignite if oxygen is added.
− Extinguish the fire completely using the fire extinguisher.

Manually extinguishing the fire in the

compact dust extractor (Camfil)

Means, Tools, Materials

■ CO2 fire extinguisher (fire class B).

1‐14 Hazards 2019-02-01 B813en

 ■ Protective gloves.
■ Safety glasses.

Risk of burns due to fires and hot components!

WARNING
Ø Keep a fire extinguisher ready.
Ø Only touch hot components with protective gloves.

1. Put on safety glasses, wear protective gloves.

2. Prepare fire extinguishers.
3. Remove the cover of the spray opening for the fire extin-
guisher. The spray opening is marked with a sign.
4. Push the foam tube of the fire extinguisher all the way into
the extinguisher opening and extinguish.
5. Close the spray opening again with the cover.

4.5 Danger due to hot surfaces

Risk of burns from workpieces and objects that are

WARNING exposed to laser radiation or reflective laser radiation
during processing.
Ø Wear protective gloves when removing the workpieces.
Ø Do not touch hot surfaces.

Hot nozzle during replacement immediately after machine

CAUTION operation
Risk of burns.
Ø Only touch hot components with protective gloves.

4.6 Dangers from magnetic fields

Linear drives

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

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

B813en 2019-02-01 Hazards 1‐15

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

Risk of pacemaker malfunction due to the strong magnetic

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

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

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

Risk of injury due to strong magnetic fields of the linear

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

4.7 Dangers due to the open electrical

cabinet

The electrical cabinet may be opened only by an electrician.

1‐16 Hazards 2019-02-01 B813en

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

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

4.8 Dangers due to live parts

The power supply for the extinguisher system is not

DANGER switched off by the main switch of the machine!
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 in the laser device TruDisk!

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.

B813en 2019-02-01 Hazards 1‐17

 4.9 Dangers due to travel motions in
enabling mode

Travel motions in enabling mode!

DANGER
Impact and crush injuries!
Ø Comply with 1-man operation.
Ø Make sure that no one is within the danger zone.

4.10 Dangers handling workpieces

Processing workpieces can be dangerous. These dangers and

measures are different for every workpiece.

Risk of injury when removing a workpiece

Risk of injury when removing sharp-edged, heavy or stuck

WARNING workpieces!
Ø Wear protective gloves.
Ø Remove workpieces with appropriate additional equipment.

Hot workpieces

Hot workpieces after machining!

WARNING
Burns.
Ø Wear protective gloves.
Ø Use auxiliary tools to remove the workpiece.
Ø Avoid direct contact with hot surfaces.

1‐18 Hazards 2019-02-01 B813en

 4.11 Dangers due to accessing the pallet

Risk of injury due to a fall.

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

4.12 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 mains connection: switch
off the MAIN SWITCH on the process cooler.

4.13 Risks due to remote support

Remote support is used to establish a connection between the

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

B813en 2019-02-01 Hazards 1‐19

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

4.14 Dangers when using the

MobileControl app

The MobileControl app (option) allows the user to remotely

control the machine via a mobile terminal.

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 Use of the remote control is forbidden for maintenance work
on the machine.
Ø Before this mode of control is activated, the operator must
ensure that no one is in the danger zone.

4.15 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.

Non-functioning suction system!

WARNING
Gasses and particles that are hazardous to health enter the
respiratory tract during laser processing.
Ø Only carry out work when the exhaust system is in working
order.

1‐20 Hazards 2019-02-01 B813en

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

Dusts, exhaust air

The machine must always be operated with the bulkheads instal-

led so that the dust can be picked up.

Exhaust air compact dust The user must comply with the national regulations for handling
extractor, regulation outside exhaust air from the compact dust extractor and the dusts it con-
of Germany tains.

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 passed out-
side into the open air.
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.
In some countries, national regulations stipulate that an industrial
vacuum cleaner of "dust class H" must be 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.

B813en 2019-02-01 Hazards 1‐21

 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.

1‐22 Hazards 2019-02-01 B813en

 5. Measures to be taken by the
manufacturer

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

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

5.1 Danger zones and safeguarding

device

1 Main switch 4 Mirror posts 6 Safety cabin

2 Transmitter 5 Receiver and EMERGENCY 7 EMERGENCY STOP push-but-
3 Mirror posts STOP push-button on the start ton on operator panel
post
Machine danger zones with TruDisk 3001 and TruDisk 4001 Fig. 64836

B813en 2019-02-01 Measures to be taken by the manufacturer 1‐23

1 EMERGENCY STOP push-but- 4 Mirror posts with transmitters 7 Start posts with receivers and
ton 5 Mirror posts EMERGENCY STOP push-but-
2 Emergency stop push-button on tons
6 Mirror posts
standard installation laser 8 Safety cabin
3 Main switch 9 Laser warning lamp
Machine danger zones with TruDisk 6001 Fig. 74138

Enabling mode If the automation components malfunction, further processing is

possible in enabling mode only.
Enabling mode:
Moving the pallet changer, for example, is only possible as long
as the enable key is pressed and held. As soon as the enable
keys are released, the travel motion stops. Before moving the
pallet changer, the operator must make sure that nobody is
within the danger zone.

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

Notes
■ In the normal mode, the danger zone of the machine is
secured with the safety light barrier.
■ During operation, an interrupted light beam triggers a feed
hold: All machine movements will be stopped automatically.

Safety cabin The machine with a completely closed safety cabin is supplied,
as a standard, with one or more safety doors. The safety doors
are electrically secured and monitored by the control system.

1‐24 Measures to be taken by the manufacturer 2019-02-01 B813en

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

Hood for laser device Lasers (beam generators) are covered with hoods. The hoods
are monitored by safety switches and should only be opened
with the appropriate tools. Only the technical service engineers
or appropriately trained personnel are allowed to open the
hoods.

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 switch settings:

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- EMERGENCY STOP has the following effect:

button ■ power supply to the machine is interrupted (24 V control volt-
age is maintained).
■ The laser beam is switched off.
■ The shutter switch of the installed light path (LLK) is disabled
in the laser device.
■ The gas supply of the processing gas is interrupted.
■ All axis motions stop.
■ All drives are switched off electrically.
■ The hydraulic unit, the compact dust extractor and the
lengthwise and/or transverse conveyor, respectively, are
switched off.

FEED HOLD A FEED HOLD leads to the following:

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

B813en 2019-02-01 Measures to be taken by the manufacturer 1‐25

 BEAM-BLOCK key switch The BEAM BLOCK key switch is on the control panel.

Left switch setting The beam block is not active: the shutter switch
of the installed light path is released.
Right switch setting The beam block is active: the shutter switch of
the installed light path is disabled.
The key must be removed in this setting.
Tab. 1-8

OPERATION LOCK key The laser device can be protected against unauthorized switch-
switch on the laser device ing on using the OPERATION-LOCK key switch.

Switch setting 0 or locked The laser device cannot be switched on

(closed lock symbol) when the key switch is in this switch set-
ting. The key can be removed.
Switch setting 1 or The laser device can be switched on when
unlocked (open lock sym- the key switch is in this switch setting.
bol)
Tab. 1-9

Safety-Mode key switch The SAFETY-MODE key switch is located on the control panel. It
can be turned to two positions. In the right switch setting (posi-
tion 1) the key must be removed and stored safely.

Left switch setting Normal mode.

(position 0)
Right switch setting The machine and all safety relevant compo-
(position 1) nents is shut down safely.
All axis motions are stopped and locked, the
laser beam is switched off.
Parallel to production operation of components
is not possible.
Tab. 1-10

Exhaust system in the work The workspace of the machine is permanently vacuum-cleaned.
area Depending on the configuration of the system, this can happen
in different ways:
■ Flap channel in combination with exhaust trap
■ Or Suction connection pieces for stationary room suction sys-
tem
■ Or Traveling room suction system
■ Or Suction tube with ventilation grids.
■ Or Suction tube beneath the laser cutting head.
The exhaust and filter system offered in combination with the
machine (referred to as the compact dust extractor in the follow-
ing) is designed such that the emitted aerosols and dusts in the
work area can be suctioned and efficiently separated when the
machine is used as intended.

1‐26 Measures to be taken by the manufacturer 2019-02-01 B813en

 Laser processing can only start once the compact dust extractor
is in operation and at least one of the flaps in the exhaust piping
is open.
After the end of processing, the work area continues to be suc-
tioned according to the applied lag time.

Machine status light The machine status light visualizes the machine's operating sta-
tus (operation, error or idle state).

Laser warning lamp at the Laser warning lamps on the laser device indicate that the laser
laser device light is being emitted at the processing point or that the laser is
ready to emit laser light even when laser light is no longer being
emitted (in the "Laser is on" status).
The laser warning lamp is part of the laser device's safety device
and is monitored. If the LED is faulty, the laser cannot be put
into operation.

1 Laser warning lamp

Laser warning lamp Fig. 87662

B813en 2019-02-01 Measures to be taken by the manufacturer 1‐27

 5.2 Warning signs at the machine

Warning signs draw attention to dangers when operating the

machine.

Location of signs Fig. 64835

Warning signs draw attention to dangers when operating the

machine.

Sign Warning signs at the basic machine Meaning

no.
1 Class 1 laser product

2, 3 Caution - Invisible laser radi-

ation when the cover is open
and the safety lock is
bypassed.
Avoid direct or scattered
laser radiation on your eyes
or skin.

2, 3 Caution, there is invisible

laser radiation when the
cover is open, so avoid
direct or scattered laser radi-
ation on your eyes or skin.

1‐28 Measures to be taken by the manufacturer 2019-02-01 B813en

Sign Warning signs at the basic machine Meaning
no.
5 Laser radiation.
Do not look into the beam.
Class 2 laser.

Caution, this machine's

linear drives are equipped
with strong permanent mag-
nets, which produce strong
magnetic fields and high
attractive forces.

2, 4 Caution - Invisible class 4

laser radiation when the
cover is open.
Avoid direct or scattered
laser radiation on your eyes
or skin.

2 Warning of laser beam.

2 Warning of electrical voltage.

- Warning of hot surface.

6 Do not assemble clamps

(with nozzle changer availa-
ble).

Risk due to magnetic fields

No access for persons with

a pacemaker or with an
implanted defibrillator.

Do not enter (nozzle

changer, machine roof).

B813en 2019-02-01 Measures to be taken by the manufacturer 1‐29

 Sign Warning signs at the basic machine Meaning
no.
10

Warning signs at the machine Tab. 1-11

1‐30 Measures to be taken by the manufacturer 2019-02-01 B813en

 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. Chapter 1 "Safety" forms the basis.
■ Keep personal safety equipment ready.
■ As far as possible, ensure personnel wear protective gear
(e.g. gloves, safety shoes, hearing protection, safety
glasses...).
■ Define responsibilities for safety, operation, maintenance, set-
ting work and service.
■ Require that personnel read the technical documentation of
the machine. Recommendation: obtain written confirmation
from the personnel.
■ Inform personnel about measures for protecting against laser
radiation:
− Instruct the personnel in operating processes of the laser.
− Use laser radiation protection 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 remote support between the machine and
TRUMPF Technical Service. When the machine is commis-
sioned, the user will be informed about the procedure and
possible risks of remote support. The user must provide
safety instruction to operators who are involved in the remote
support.

B813en 2019-02-01 Organizational measures to be taken by the user 1‐31

 Protection against laser Only personnel trained and instructed in laser radiation and
radiation in setup mode appropriately equipped may carry out adjustment and setup work
in setup mode. In setup mode, the machine's laser corresponds
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, ANSI Z87.1 for the USA.
■ 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 setup mode, or car-
officer ries out adjustment and setup work in setup mode, he or she
must designate a laser safety officer in writing.
The user has to observe regulations and laws.
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 laser radiation:

Additional information for Germany

Observe accident prevention In Germany, the employer's liability insurance association acci-
regulations dent prevention regulation "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.

1‐32 Organizational measures to be taken by the user 2019-02-01 B813en

 Protection against laser radiation:
Additional information for the USA

Appointing a laser safety The following instances, the user must appoint a laser safety offi-
officer cer:
■ For class 3B or 4 laser systems.
■ The user operates the machine in setup mode.
■ The user carries out adjustment and setup work in setup
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.

Once per shift, preferably before starting the production:

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

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

Ensuring the perfect 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.

B813en 2019-02-01 Organizational measures to be taken by the user 1‐33

 ■ 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 laser protection window is damaged
during laser operation. Processing may only be continued
once the laser protection window has been replaced.

Observing the shutdown The prescribed switch-off procedures must be adhered to during
procedure all work (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.
■ If the process cooler has its own power supply: switch off the
MAIN SWITCH on 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.

1‐34 Organizational measures to be taken by the user 2019-02-01 B813en

 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 Hydraulic oil and lubri-

cants
Water Hazard Class 2
Volume of water-pollutant materials ≤1000 l (≤264 gal)
Hazard level of the machine A
Hydraulic oil operating pressure 150 bar
Water protection specifications Tab. 1-12

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 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.

B813en 2019-02-01 Organizational measures to be taken by the user 1‐35

 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 material.

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

6.6 Safety data sheet on hazardous

materials

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

1‐36 Organizational measures to be taken by the user 2019-02-01 B813en

 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
user to reduce residual risks are specified in the overview of
residual risks.
For detailed descriptions of the measures: (see "Hazards",
pg. 1‐9).

Residual risks Hazard area Type of danger Measure to be taken by the user
Mechanical elements
Squeezing and Transportation of the Risk of fatal injury ■ Observe the transport regulations.
impacting machine ■ Never walk under a suspended load.
Transport of the laser Risk of fatal injury Secure the brakes of the transport rollers
device after transport.
If the transport rollers of
Platform installation the laser device are not
secured, the laser
device may move and
cause serious injuries.
Tilting the external sup- Risk of injury ■ Do not place a load on the support
port housing (RotoLas housing until after the safety cabin has
option) been installed.
■ Do not use the support housing as a
loading aid.
■ Wear personal safety equipment.
Risk of crushing due to Risk of injury Only press the close button when no per-
closing clamping jaws sons or body parts in the danger zone.
(RotoLas option)
Movement of the con- Risk of injury Wear protective clothing.
veyor belts, slipping or
falling pipes (RotoLas
option)
Cleaning the conveyor Risk of injury ■ Stop the scrap conveyor before clean-
belts ing work and before removing jammed
parts.
■ Do not reach into the conveyor belts.
Use suitable auxiliary tools for cleaning
(e.g. industrial vacuum cleaner).
Roll-back roof Risk of injury Do not grasp or use the upper edge of
the safety cabin in the area around the
guide or the back stop of roll-back roof as
a support.
Pallet changer in ena- Risk of injury Make sure that no one is in the danger
bling mode zone before the pallet changer is moved
in enabling mode.
Falling Roll-back roof Risk of injury Do not step on the roof.
Pallet Risk of injury Do not step on the pallets from the
machine.

B813en 2019-02-01 Overview of residual risks 1‐37

Residual risks Hazard area Type of danger Measure to be taken by the user
Longitudinal conveyor Risk of injury Look out for dirt and clean the longitudi-
belt with slippery slag nal conveyor belt regularly.
Ergonomic Workpiece handling Risk of injury Set up the pallet changer so it is at a
hazard height that is ergonomically favorable.
Loading and unloading with additional
equipment (crane, forklift truck etc.).
Remove heavy workpieces in pairs.
Cutting and Workpiece, scrap skele- Risk of injury ■ Wear protective clothing.
cutting to size ton, machine table ■ Wear protective gloves when inserting
and removing the workpiece and use
tools.
Due to fluids cut assist gas Risk of injury ■ Observe the compulsory maintenance
and gases work requirements. Safely disconnect
Compressed air
being expelled the customer's supply before perform-
under high ing maintenance work on the cutting
pressure gas supply.
Hydraulic oil Risk of injury ■ Maintenance work on the hydraulic
supply may only be carried out when
the machine is switched off.
■ Observe the compulsory maintenance
work requirements. Safely disconnect
the customer's supply before perform-
ing maintenance work on the hydraulic
supply.
Secondary radiation (harsh light at the processing point)
Eye contact Due to plasma forma- Risk of injury ■ Never look directly into the processing
tion, intense, visible point.
Permanent damage to
radiation at the machin- ■ Observe national regulations.
the retina
ing point ■ Protect eyes with a commercially avail-
able dark sunglasses or place dark
film over the observation windows of
the safety cabin.
■ Do not operate a machine with dam-
aged safety cabin observation win-
dows.
Radiation
Laser Class 4 laser radiation Risk of injury Wear protective clothing, laser safety
during service work. glasses and laser protective wall.
Radiation due to a Risk of injury ■ Remove punching slugs and small
damaged safety cabin. parts in the machine interior and on
the pallets.
■ Check the safety cabin and laser pro-
tective screens regularly for damage.
■ Do not put the machine into operation
if the safety cabin is damaged.
Pilot laser Radiation during adjust- Risk of injury Do not look directly into the beam.
ment work.
Electrics
Contact with Servo inverter of the Risk of fatal injury ■ Only qualified electrician personnel are
parts which main axis drives (electri- allowed to carry out work.
store electrical cal cabinet) ■ The residual voltage is >60 V. Note a
load discharge time of more than 5 s (see
warning sign).
Heat

1‐38 Overview of residual risks 2019-02-01 B813en

 Residual risks Hazard area Type of danger Measure to be taken by the user
Thermal radia- Ejected slag spatters Risk of injury Wear protective clothing.
tion or spurting
melted parts
Touching Hot workpieces Risk of injury Use gloves and tools to remove workpie-
ces.
Materials
Contact with or Cutting gas, dust, aero- Health hazard ■ Only carry out work when the exhaust
inhaling of sols, cutting oils, PE- system is in working order.
toxic fluids, coated profiles ■ Ensure sufficient ventilation at the work
gases, mist, station.
fumes or dust
Change the container of Health hazard ■ Observing the manufacturer's operating
the dust extractor instructions.
■ Wear personal safety equipment with a
breathing mask of the safety class
FFP3.
Fire
Fire hazard Entire system Risk of injury ■ Estimate risk of fire as part of the
operational risk assessment.
■ Implement appropriate fire protection
measures in accordance with valid
national regulations.
Compact dust extractor Risk of injury ■ Keep a CO2 hand-held fire extin-
guisher ready (fire classification B).
■ Keep a powder hand-held fire extin-
guisher ready (fire classification D).
Magnetic fields
Strong mag- Linear drives Risk of fatal injury for Persons with pacemakers must keep a
netic field due persons with pacemak- minimum distance of 30 cm from the
to permanent ers linear drives of the X and Y directions.
magnets
Fanning magnets on Risk of fatal injury for ■ Persons with pacemakers: maintain a
the LoadMaster (option) persons with pacemak- minimum distance of at least 1 m.
ers ■ Inform the employees, visitors and per-
sonnel from other companies about the
dangers for persons using pacemak-
ers.
High attractive Linear drives Risk of injury ■ Do not carry any heavy ferromagnetic
force parts (metal sheets, tools) in the hands
near the drives.
■ Keep watches and magnetic storage
mediums (diskettes, credit cards) away
from the drives.
Fanning magnets on Risk of injury ■ Do not hold any heavy ferromagnetic
the LoadMaster (option) parts (metal sheets, tools) in the hands
near (<1 m) the fanning magnet.
■ Keep watches and magnetic storage
mediums (diskettes, credit cards) away
from the drives.
Residual risks Tab. 1-13

B813en 2019-02-01 Overview of residual risks 1‐39

 8. Disassembly and disposal

TRUMPF recommends that TRUMPF machine tools be disas-

sembled and disposed of by Technical Service or a specialist
disposal company. The following information is to be passed on
to the specialist disposal company performing the disposal work,
to guarantee fast, environmentally sound and safe disposal.
The following points should be observed when disposing of a
TRUMPF machine tool.

Preparing disassembly ■ Remove dirt, in particular dust that can be stirred up or that
can be hazardous during disassembly.
■ 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.
■ Depressurize components under pressure (e.g. compressed
air line).
■ Wait at least an hour to allow any residual voltage in the
machine to dissipate and hot components to cool down. All
assemblies/components can then be touched.

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

materials according to applicable legislation prior to disassembly:

Hazardous substance Installed in assembly

Arsenic Diodes (Solid-state laser)
Refrigerant Process cooler, electrical cabinet
cooling
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. 1-14

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)

1‐40 Disassembly and disposal 2019-02-01 B813en

 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
Compact dust X O O O O O
extractor
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. 1-15

Remove ■ Poisonous vapors can result when thermally cutting painted

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

B813en 2019-02-01 Disassembly and disposal 1‐41

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

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

1‐42 Disassembly and disposal 2019-02-01 B813en

 Chapter 2

Installation conditions
TruLaser 3030 (L49),
TruLaser 3040 (L50)
To what does this apply? 2‐3

1 Planning aid 2‐4

2 Installation site 2‐6

2.1 Space requirements 2‐6
2.2 Floor requirements 2‐6
Surface 2‐6
Floor quality 2‐8
2.3 Weight load 2‐9
2.4 Stress due to vibration 2‐10
2.5 Ambient conditions 2‐10
2.6 Exhaust air system of the compact dust extrac- 2‐12
tor
2.7 Cable racks for laser light cables 2‐12
2.8 Installation of the process cooler 2‐13

B813en Installation conditions TruLaser 3030 (L49), TruLaser 2‐1

3040 (L50) - Version 14
 3 Gas supply 2‐16
3.1 Cutting gases 2‐17
Purity 2‐17
Cutting gas consumption 2‐17
Supply lines for cutting gas supply 2‐19
Requirements on the connection point of 2‐22
the machine
Cutting gas supply with cylinders or bundles 2‐22
Cutting gas supply with gas tank 2‐23
3.2 Nitrogen for cutting unit ventilation 2‐24

4 Compressed air supply 2‐25

5 Electrics 2‐27
5.1 Power supply 2‐27
Connected loads 2‐27
Startup power 2‐28
Connecting cables 2‐29
5.2 Power supply 2‐30
Uninterruptible Power Supply (UPS) 2‐30
Residual current device (RCD) 2‐30
Power supply configurations 2‐31
Isolating transformer 2‐32
5.3 Remote support 2‐34
5.4 Cloud connection 2‐34
5.5 Network link 2‐34

6 Operating materials 2‐36

6.1 Gases 2‐36
6.2 Cooling water 2‐36

7 Transportation of the machine 2‐40

7.1 Measures to be taken by the customer 2‐41
Transport TruDisk laser device 2‐42
7.2 Service work by Technical Service 2‐44

2‐2 Installation conditions TruLaser 3030 (L49), TruLaser B813en

3040 (L50) - Version 14
 To what does this apply?
The installation conditions contain all information for preparing
the installation and start-up of the machine including the laser.

Note
The TruLaser 3030 / TruLaser 3040 is a system for laser cutting
metal materials. The machine is designed for processing flat
sheets as well as for the use of the RotoLas option for machin-
ing tubes and tube profiles.
Laser cutting of plastics with the TruLaser 3030 /
TruLaser 3040 is not permissible.

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 Technical Service engineers will not
be able to put the machine into service.
Pass along the respective subsections in accordance with the
following planning aid to the specialist companies/plants (e.g.
electrical installer, specialist plant for industrial gases...) in a
timely manner.

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

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

Technical Service engineers.

This includes:
■ Installing, aligning, leveling and securing the machine.
■ Filling up the process cooler.
■ Connecting the machine to the supplies (with the exception
of the electrical power supply).
■ Perform function check.
■ Instructing personnel.

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

B813en Installation conditions TruLaser 3030 (L49), TruLaser 2‐3

3040 (L50) - Version 14
 1. Planning aid

The planning aid provides an overview of the measures to be

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

Time before the delivery Planning criterion Required measures

of the machine
15 weeks Personnel and training ■ Appoint a member of staff to be responsible for
preparations for the delivery of the machine.
■ Appoint operating and service personnel and pro-
grammers.
■ Arrange training schedules for specialist personnel.
■ Check whether a laser safety officer is needed.
Observe national laws and regulations (Germany:
DGUV regulation 11). Further information in the
standards: IEC/EN 60825 and ANSI Z136.1 (for the
USA)
14 weeks, but no later Installation site ■ Determine the installation site of the machine, taking
than week... into account the space requirements according to
the installation plan.
■ Check floor requirements:
− Floor quality.
− Flatness.
− Oil-resistant floor without expansion joints.
■ Take the weight and dimensions of the machine into
account.
■ Check the requirements for ambient conditions:
− Room temperature.
− Exposure to sunlight.
■ Check the transport route:
− Load capacity of the transport route.
− Gateway openings.
− Doors.
− Cable rack heights.
− Room to move freely around corners etc.
12 weeks, but no later Electrical system ■ Install electrical connections at the installation site.
than calendar week ... ■ Lay the conductor cross-section and fuse protection
according to the legal requirements.
■ Have the work required for remote support carried
out.
Please note: In some installation versions, e.g. when
the laser device is set up at a distance from the
machine, the basic machine, laser device and process
cooler of the laser each need a separate electrical con-
nection.
12 weeks, but no later Gas supply ■ Arrange for the installation of the laser and cutting
than calendar week ... gas supply at the installation site.
■ Decide about the gas supply method (cylinders, cyl-
inder bundles, gas tank).
− Procure the required fittings.
■ Together with the gas supplier: design gas conduits.

2‐4 Planning aid - Version 14 B813en

 Time before the delivery Planning criterion Required measures
of the machine
12 weeks, but no later Compressed air supply ■ Arrange for the installation of the compressed air
than calendar week ... supply at the installation site.
− Take into account connection, purity, com-
pressed air requirements.
8 weeks For network connection: Install network connection at the installation site.
network connection
Return the network questionnaire to TRUMPF.
Four weeks, but no later Transport Provide auxiliary transport equipment.
than week ...
Note: If the machine is conveyed to the customer's site
by Technical Service, the required means of transporta-
tion and auxiliary transport equipment is provided by
them.
Four weeks, but no later Laser safety Valid for Germany: Register the laser machining
than week ... system with the employer's liability insurance associa-
tion and with the trade board.
Observe the regulations applicable in the country of
operation.
Make laser safety glasses available for service
work: .Safety glasses for laser light with a wavelength
of 1030 nm
Depending on the laser: provide laser safety glasses
for service work.
Four weeks, but no later Operating materials Keep a stock of operating materials:
than week ... ■ Demineralized water in the required quantity and
quality is to be provided for 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.
■ Cutting gases.
During installation and Electrical installation At the start of the installation process: have the system
start-up connected by a trained electrician.
Planning aid Tab. 2-1

B813en Planning aid - Version 14 2‐5

 2. Installation site

What does the customer Please consult a structural analyst for professional support, par-
need to do? ticularly regarding the topic of floor requirements. Give the
structural analyst the "Installation site" section and the foundation
plan/installation layout.

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.

Automation Note
For machines with automation components: see installation con-
ditions of the automation components.

2.1 Space requirements

The arrangement of the components and required space for the

installation of the system have been documented in the
TRUMPF installation plan.

2.2 Floor requirements

The quality of the prepared parts can be guaranteed only when

the floor conditions meet TRUMPF requirements.

Surface

Flatness The floor on which the system stands must be flat.

Permissible flatness deviation (flatness tolerance):

■ Footprint range: max. 12 mm (1/2 in) per 10 m (33 ft).
■ Load-bearing point range (wedge mounts or air cushions):
max. 2 mm (0.08 in) per 0.5 m (1.64 ft).

2‐6 Installation site - Version 14 B813en

 The flatness tolerance can be determined for different measuring
point distances from the following diagram.

A Flatness tolerance B Measuring point distance

Flatness tolerance depending on the measuring point distance Fig. 65278

Measuring point distance Flatness tolerance Area

in m (ft) in mm (in)
0.5 (1.64) 2 (0.08) Load-bearing points (e. g. wedge
mounts).
10 (33) 12 (1/2) Footprint range.
Examples Tab. 2-2

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

1 Straightedge l1 Measuring point distance

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

B813en Installation site - Version 14 2‐7

 Expansion joints ■ The entire installation surface must not have any expansion
joints.
− No joint of any kind is permitted in the load-bearing point
range of the machine and within at least 1.0 m (3 ft) of it.
− In the vicinity of a plug bore hole/a load-bearing point of
an automation component, the minimum distance to the
nearest edge of the concrete floor must be 300 mm
(12 in).

Floor quality

Note
The floor must be oil-proof.

Elastically cushioned base ■ Steel reinforced concrete with the following properties:
plate − Characteristic rated value: fy ≥435 N/mm2.
− Modulus of elasticity: Es ≥200 000 N/mm2.
− Upper reinforcement crosswise 3.7 cm2/m each.
− Lower reinforcement crosswise 3.7 cm2/m each.
− US specification: 2 layers of #5 rebar, spaced 12 in on
center, on both the top and bottom faces and oriented in
both the longitudinal and transverse directions.
■ Elastic cushioning of the base plate on a foundation with a
minimum bedding value of C ≥5000 kN/m3 (loess loam).

Machine Weight Load Minimum thick- Concrete quality of the tensile

capacity ness strength C25/30
kg (lb) kN/m2 (psi) mm (in) Fck, cyl Fck, cube
N/mm2 (psi) N/mm2 (psi)
TruLaser 3030 8000 (17600) 15 (2.2) 200 (8) ≥25 (3700) ≥30 (4400)
(L49)
TruLaser 3040 11800 (26000) 15 (2.2) 200 (8) ≥25 (3700) ≥30 (4400)
(L50)
Fck, cyl: Cylinder compressive strength

Fck, cube: Cube compressive strength

Requirements for a flexibly cushioned base plate Tab. 2-3

When is a structural analyst A structural analyst must be consulted under the following condi-
generally required? tions:
■ The previously named requirements for an elastically embed-
ded base plate are not met.
■ The system is to be set up on a ceiling plate/free-span base
plate.
■ A bearing is to be installed.

2‐8 Installation site - Version 14 B813en

 ■ The system is to be set up on fiber-reinforced concrete or
roller-compacted concrete.
■ The system is to be installed on a floor other than the one
named above.

2.3 Weight load

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

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

Foundation load

Component Machine Weight kg (lb) Distribution of weight

Basic machine including laser L49 approx. 8000 Weight is distributed over 6 surfa-
unit (17600) ces.
L50 approx. 11800 Weight is distributed over 9 surfa-
(26000) ces.
Pallet changer incl. two pallets L49 approx. 3600 (7950) Weight is evenly distributed over 4
with all support slats and (2x) surfaces.
L50 approx. 6500
max. workpiece weight
(14300)
Pallets L49 2 x 250 (2 x 550)
L50 2 x 370 (2 x 815)
Support rails (pallet loaded up to L49 2 x 150 (2 x 330)
50 %)
L50 2 x 200 (2 x 441)
Max. workpiece weight L49 900 (1985)
L50 1700 (3750)
Transverse conveyor (option) L49 440 (970) The edges support the main load
L50 520 (1150)
Compact dust extractor L49 960 (2116) Weight is evenly distributed over 4
surfaces.
L50
TruDisk laser device L49 approx. 860 (1896) Weight is evenly distributed over 4
adjustable legs.
L50
Process cooler for machine (with- L49 230 (507) The edges support the main load.
out cooling water)
L50
Process cooler for laser (without L49, L50 430 (948) The edges support the main load.
cooling water)
Isolating transformer L49 550 (1220) The edges support the main load
L50

B813en Installation site - Version 14 2‐9

Component Machine Weight kg (lb) Distribution of weight
RotoLas exterior support housing L49, L50 Support housing 3
including max. tube weight meter variant:
350 (770)
Support housing 6
meter variant:
450 (992)
Tab. 2-4

2.4 Stress due to vibration

In the immediate area around the system, external influences

can lead to vibration loads. Vibration loads can effect the quality
of workpieces.

External influences are e.g.:

■ Fork lifts, industrial trucks, etc.
■ The installation or removal of other machines in the immedi-
ate vicinity of the system.
■ Machines which excite vibrations during operation, such as
punch presses etc.

Maximum stress due to Vibration acceleration in vertical 0.01 g (100 mm/s2)

vibration for TruDisk Laser and horizontal directions
Maximum stress due to vibration Tab. 2-5

If the vibration at the installation site is higher, then shock-

absorbing pads must be used. To correctly dimension the shock-
absorbing pads, the vibration at the installation site must be
measured.

2.5 Ambient conditions

Ambient conditions Temperature

Operation between +10 °C / +50 °F and +43 °C / +109 °F
According to NFPA 79, the maximum temperature in
the USA and Canada is +40° C / +104°F.
Storage between +5 °C / +41 °F and +43 °C / +109 °F
Transport between 0 °C / +32 °F and +43 °C / +109 °F
Relative humid- Standard version: maximum of 100% at +24°C /
ity +75.2°F. See the following dew point diagram.
Tropical version: maximum of 100% at +32°C /
+89.6°F. See the following dew point diagram.
Permissible ambient temperature Tab. 2-6

2‐10 Installation site - Version 14 B813en

 Notes
■ One-sided exposure to direct sunlight and unidirectional
drafts must be avoided (e.g. with Venetian blinds if installed
near a window).
■ The ambient temperature should be kept constant while oper-
ating the system. Sufficient ventilation should be ensured in
the shop.

Tropical version When the ambient temperature is between +35°C (+95 °F) and
+45°C (+113 °F) the system is delivered in tropical version.

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

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

must be within specific limits.

U Ambient temperature 1 Standard version

RL Relative humidity 2 Tropical version
Dew point diagram Fig. 68666

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 dehumidifier
can become.

B813en Installation site - Version 14 2‐11

 2.6 Exhaust air system of the compact
dust extractor

Note
The exhaust air system beginning at the clear gas duct of the
compact dust extractor must be installed by the customer.

International/national Regulation outside of Germany:

regulation ■ The user must comply with the national regulations for han-
dling exhaust air from 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 passed
outside into the open air.
− 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 must be installed as follows:
■ Max. of two 90° tube bends (radius = diameter x 1.5).
■ Max. length: 10 m (33 ft).
■ Transition piece on the compact dust extractor, TRUMPF
mat. no.:0382628.
■ Pipe diameter: 315 mm (12.4 in).

Note
For other configurations, a ventilation technician or the manufac-
turer of the compact dust extractor must be consulted. The max.
resistance of 100 Pa (0.0145 psi) must not be exceeded.

2.7 Cable racks for laser light cables

Note
The cable racks are only inserted in connection with an external
laser device.
The laser light cable is installed by Technical Service.

2‐12 Installation site - Version 14 B813en

 ■ 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 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).

2.8 Installation of the process cooler

Danger of freezing due to improper installation of the

NOTICE process cooler.
Outdoor installation of the process cooler is not permitted.
The "water temperature monitoring" function does not
provide protection against freezing if the process cooler is
installed outdoors.
Ø Do not install the process cooler in areas with a risk of
freezing.

Version of the cooling water hose:Take the length of the cool-

ing water hoses into consideration when installing the process
cooler. The following versions are permitted:
■ Standard installation: maximum permitted clearance between
the connection point at the machine and the output at the
process cooler = 30 m.
■ Platform installation: maximum permissible height of the out-
put on the process cooler = 3.2 m.

Note
It is not permitted to combine the versions listed above!

B813en Installation site - Version 14 2‐13

 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 ambient temperatures below 0 °C, the process cooler's
MAIN SWITCH must not be switched off.
■ At ambient temperatures of < +6 °C 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

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

Escaping cooling water or oil!

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

2‐14 Installation site - Version 14 B813en

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

B813en Installation site - Version 14 2‐15

 3. Gas supply

Professional gas installation is a basic prerequisite for smooth

commissioning and trouble-free operation of the installation. The
following chapter must therefore be passed along to the special-
ist company for industrial gases you have contracted with in a
timely manner in accordance with the planning aid.

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

Short circuit or fire hazard when gas lines and electrical

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

2‐16 Gas supply - Version 14 B813en

 3.1 Cutting gases

Purity

Cutting gas Purity

Oxygen (O2) 3.5 99.95 % by vol.
Nitrogen (N2) 5.0 (see "Using 99.999% by vol. (see
nitrogen with "Using nitrogen with low
low degree of degree of purity")
purity")
Argon (Ar) 4.6 99.996 % by vol.
Compressed air (option) - (see "Compressed air
supply", pg. 2‐25)
The following applies to ≤100 particles (for particles ≤0.3 µm; based
all gases: on 2.83 l ≙ 0.1 ft3)
Inert gases: purity Tab. 2-7

Using nitrogen with low Notes

degree of purity ■ To achieve optimum cutting results and maximum process
stability, TRUMPF recommends using nitrogen having a
degree of purity of 5.0 (99.999% by vol.).
■ Nitrogen with a degree of purity of 4.0 (99.99% by vol.) can
also be used. Nitrogen with this degree of purity is sufficient
for ventilating the cutting unit. However, this may impair the
cut quality (e.g. discoloration) and the cutting process stabil-
ity.

Cutting gas consumption

Cutting gas consumption depends on the following factors:

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

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

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

Standard pressure cutting Standard pressure cutting is cutting with a pressure of ≤6 bar
(≤87 psi) on the nozzle. Oxygen and/or nitrogen are used as cut-
ting gases.

B813en Gas supply - Version 14 2‐17

 O2
Standard pressure
Minimum input pressure (flow pressure) bar (psi) 8 (116)
(minimum flow pressure which must be available on the
machine's connection point)
at:
Cutting gas pressure p bar (psi) 6 (87)
Nozzle diameter d mm 1.7
Cutting gas consumption Vn/t (volume under standard condi- m3/h (cfm) 10 (6)
tions)
Example: Standard pressure cutting with oxygen Tab. 2-8

d Nozzle diameter Vn/t Cutting gas consumption (vol- p Pressure

ume under standard conditions)
Maximum cutting gas consumption per hour at a laser duty cycle of 100% (O2 standard Fig. 55214
pressure)

High-pressure cutting High-pressure cutting is cutting at a pressure of >6 bar (87 psi)
on the nozzle. Normally, nitrogen is used as cutting gas, in rare
cases also oxygen.
High-pressure cutting is an option for machining stainless steel,
aluminum alloys and copper.

O2 N2
High pressure High pressure
Minimum input pressure (flow pressure) bar (psi) 15 (210) 27 (400)
(minimum flow pressure which must be available on
the machine's connection point)
Cutting gas pressure p bar (psi) 11 (160) 20 (290)

2‐18 Gas supply - Version 14 B813en

 O2 N2
High pressure High pressure
Nozzle diameter d mm 2.7 2.7
Cutting gas consumption Vn/t (volume under stand- m3/h (cfm) 50 (29.4) 80 (47)
ard conditions)
High-pressure cutting with oxygen and nitrogen Tab. 2-9

d Nozzle diameter Vn/t Cutting gas consumption (vol- p Pressure

ume under standard conditions)
Maximum cutting gas consumption per hour during 100% ON-time Fig. 55213

High-speed cutting with nitrogen specifically utilizes the formation

of metal vapor plasma to increase the cutting speed.

Note
In the event of different nozzle diameters and/or greater pres-
sures, the cutting gas consumption per cutting unit is increased
considerably.

Supply lines for cutting gas supply

To provide the customer with a flexible connection option, special

hoses and clamping ring screws are provided by TRUMPF. The
customer-provided connection point may thus be found at a
radius of 5 meters around the connection point on the
machine. The customer must provide the cutting gas supply
lines up to the customer's connection point on the
machine.The connection point on the machine is indicated on the
installation plan by the following symbol: The connection point on
the machine is indicated on the installation plan by the following
symbol:

B813en Gas supply - Version 14 2‐19

 1 Connection point for cutting gas on the machine
Fig. 70414

■ Pipes should be used for the entire gas installation from the
gas cylinder or central gas tank to the customer-provided
connection point.
■ The vaporizer must be designed to accommodate the maxi-
mum consumption of all connected machines. The line from
the vaporizer to the connection point must be kept as short
as possible for this purpose.
■ The external gas installation should be set up in such a way
that the supply lines to the machine connection and the con-
nection point itself are unable to ice up.
■ Stop valves must be built in to all supply lines to the individ-
ual machines. This allows the supply lines to be blocked off
during maintenance and bled via the bleed valves on the
machine.

Notes
■ The gas temperature may not exceed +50 °C (+122 °F). This
is of particular significance if the required gas pressure is
generated by means of pressure booster systems!
■ To avoid damage to the machine parts due to pressure
surges, only open or close the stop valves slowly.

Pipes ■ Oil and grease-free lines made of special quality copper pip-
ing ("refrigerator quality", inert-soldered with simple shielding
gas) are required for the cutting gases.
■ The tubes must be processed without oil and grease.
■ Swagelok clamping ring screw fittings or constructionally
equivalent clamping ring screw fittings made of brass are to
be used on screw fittings. No press-fitting systems may be
used.
■ All sealing points must be secured with flat gaskets.
■ Sealants such as liquid Teflon, sealing sprays, lubricants and
lubricating pastes, hemp or grease must not be used. Teflon
tape may be used for sealing in exceptional cases if the first
3-4 threads remain free.
■ Stainless steel tubes are permitted, but not necessary. If
stainless steel tubes are used, stainless steel fittings must
also be used.
■ The pipe ends must be sealed securely to avoid dirt in transit
and storage.

2‐20 Gas supply - Version 14 B813en

1 Vaporizer 4 Customer connection 7 Machine
2 Main supply strand 5 Machine connection with clamp- A Customer responsibility
3 Tapping point ing ring screw B TRUMPF responsibility
6 Flexible supply hose
Gas supply Fig. 75434

Pipeline section Pipe dimensions Nominal width in

mm
For tank installation: 1" or 28 x 1.5 25
Main supply line (2) downstream of evaporator (e.g. as ring pipe-
line)
From the main supply line (2) to the tapping point (3) 3/4" or 22 x 1.0 20
From the tapping point (3) to the connection by the customer (4) N2: 3/4" or 22 x 1.0 20

O2: 1/2" or 15 x 1.0 13

Requirements relating to gas supply by the customer Tab. 2-10

Customer connection (4) Pipe dimensions Minimum length in

mm
Nitrogen line: 12 x 1.0 40
Tube piece made of copper
(connection to the clamping ring screw on the machine
(5, swagelock Ø12))
Oxygen line: 8 x 1.0 40
Tube piece made of copper
(connection to the clamping ring screw on the machine
(5, swagelock Ø8))
Customer connection: requirements Tab. 2-11

Note
As a general principle, a stop valve must be mounted before
each branch in a ring pipeline in order to make it possible to
shut down each ring pipeline segment separately

B813en Gas supply - Version 14 2‐21

 Requirements on the connection point of
the machine

O2 N2 Additional Com-
cutting gas pressed air
(option) as cutting
gas
(option)
Standard High pres- High pres- BrightLine High pres- Standard
pressure sure sure fiber sure pressure
(option)
Min. input pressure 8 (116) 15 (220) 27 (390) 28 (406) 27 (390) 7.5 (109)
(flow pressure) in
bar (psi)
Max. static input 21 (305) 21 (305) 33 (480) 33 (480) 33 (480) 12 (174)
pressure1 in bar (psi)
Max. cutting gas 6 (87) 12 (174) 25 (364) 19 (275) 25 (364) 6 (87)
pressure in bar (psi)
Volume flow rate per 10 (5.9) 50 (29.4) 98 (58) 120 (71) 98 (58) 10 (5.9)
cutting unit (volume (distance of
under standard condi- nozzle to
tions) 2 in m3/h (cfm) sheet 0.4
mm)
Nozzle diameter in ∅ 1.7 ∅ 2.7 ∅ 2.7 ∅ 7.5 ∅ 2.7 ∅ 2.7
mm
Requirements on the connection point of the machine Tab. 2-12

Cutting gas supply with cylinders or

bundles

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

Cylinders or bundles ■ The easiest and most economical way of supplying cutting
gas is with pressure reducers for cylinders or bundles. The
handling requirements are higher however, due to the volume
of consumption. One bundle consists of twelve cylinders =
approx. 120 Nm3 (13 200 gal) gas.
■ The gas flow is interrupted when changing the cylinder or
bundle.

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

input pressure, thereby generating a whistling sound.
2 The volume flow rate results from the selected maximum cutting gas
pressure and the specified nozzle diameter.

2‐22 Gas supply - Version 14 B813en

 Cylinder banks or cylinder ■ Switchover devices are required for uninterrupted operation
bundle banks with bottle or cylinder banks and also for changing cylinders.
■ Switching is accomplished either manually or automatically.3
■ 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
specifications
O2 Standard pressure N2 high pressure
Admission pressure bar (psi) 0-200 (0-2900) 0-200 (0-2900)
Max. perm. back bar (psi) 25 (363) 40 (580)
pressure
Min. flow rate (volume m3/h 30 (18) 90 (53)
under standard condi- (cfm)
tions)
Other requirements - Suitable for oxygen; free of oil and Free of oil and grease
grease
Cutting gas supply: pressure control specifications Tab. 2-13

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

Cutting gas supply with gas tank

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

consumption (volume under standard conditions) of about
200 - 400 m3 (0.7 cfm - 1.4 cfm) per week.
■ The optimum tank size depends on the tapping quantity and
on the local conditions.
■ The customer should consult the gas supplier.

The requirements for high-pressure cutting with nitrogen are as

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

3 A signaling unit is recommended for automatic switching, because oth-

erwise both sides of the cylinder or bundle bank could become empty
without being noticed.

B813en Gas supply - Version 14 2‐23

 Tank system

O2 N2
Standard pressure High pressure High pressure
Required pressure bar 18 (260) 36 (520) 36 (520)
(psi)
Minimum required tap- 14 (205) 16 (232) 29 (420)
ping pressure
Cutting gas supply: Tank system Tab. 2-14

Pressure control
specifications
O2 N2
Standard pressure High pressure High pressure
First pressure stage (tank)
Safety pressure regula- - Optional Optional Recommended
tion station4
Second pressure stage (tapping point)
Tapping points, - Recommended Recommended Not recommended
pressure regulator
Back pressure bar 0-16 (0-232) 4-25 (58-365) -
(psi)
Other requirements - Suitable for oxygen; Suitable for oxygen; Free of oil and grease
free of oil and grease free of oil and grease
Tab. 2-15

3.2 Nitrogen for cutting unit ventilation

Purity (see "Purity", pg. 2‐17)

Nitrogen consumption Up to 10kW: 55 ml/min (< 0.1 cfm).
(volume under stand-
From 10kW: 3 - 3.5 l/min (0.11-0.12 cfm).
ard conditions)
Nitrogen for cutting unit ventilation Tab. 2-16

Note
It is recommended not to switch off the nitrogen supply after
switching off the machine, so that nitrogen still flows through the
cutting unit when the machine is switched off. This creates con-
stant excess pressure in the cutting unit, which prevents particles
of dirt from entering the cutting unit from the ambient air.

4 The safety pressure regulation station is installed near 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).

2‐24 Gas supply - Version 14 B813en

 4. Compressed air supply

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

Compressed air supply The compressed air connection may be flexible or may consist
of a fixed pipeline to the machine.
The compressed air supply must be equipped with a hand-oper-
ated 3/2 directional valve with air exhaust on the machine imme-
diately in front of the machine input.

Connection and The requirements for all compressed air connections established
consumption values at the system are identical.

Required network pressure bar (psi) min. 6 (min.

(minimal pressure=fluid, maximum pres- 87) 5
sure=static)
Average consumption (required volume m3/h (cfm) Approx. 31
flow rate according to ISO 1217 or DIN (18)
1945):
Increased consumption with com- m3/h (cfm) approx. 20
pressed air cutting (option) (12)
Excess consumption with automation See installa-
(option) tion condi-
tions of the
automation
components
Compressed air supply: connected loads Tab. 2-17

Supply lines compressed air Inside diameter of the connection line min. 12.5 mm (½ in)
supply Length of the connection line from the ring max. 5 m (16 ft)
circuit to the connection point on the
machine
Inside diameter of the ring pipeline min. 25 mm (1 in)
Ring circuit length max. 50 m (164 ft)
(due to condensation
water formation)
Supply lines for compressed air supply Tab. 2-18

Compressed air properties The compressed air at the connection point of the machine must
at the tapping point possess the following properties:

5 The max. possible network pressure (e. g. for existing compressed air
networks) is 12 bar/174 psi. When a nozzle (Ø 2.7 mm) is used for
compressed-air cutting (option), a minimum network pressure of 7.5
bar (109 psi) is required.

B813en Compressed air supply - Version 14 2‐25

 Charac- Request Quality Recommendation
teristic class 6
Dust-free Maximum particle size: 7 Air filter on the com-
40 µm pressor
Maximum particle den-
sity: 10 mg/m3
Conden- Cooled down to +3 °C 4 Cold dryer
sate-free (+37 °F) (pressure
dew point)
Oil-free Maximum oil content: 4 Oil-free sealing screw-
5 mg/m3 type compressor with
active carbon filter
Compressed air properties at the tapping point Tab. 2-19

6 ISO 8573-1; 2010 edition

2‐26 Compressed air supply - Version 14 B813en

 5. Electrics

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

met by a company which specializes in electrical installations.

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

5.1 Power supply

Note
The central connection point is on the electrical cabinet and is
shown on the installation plan with the illustrated symbol.
The other components (laser, exhaust system, process cooler)
are also supplied from this connection point.

NEC conditions for the Notes

electrical connection of the ■ The laser device can be supplied with electricity via the
laser device by the customer
machine. If the laser device is connected to the building's
power supply, a main switch must be installed upstream of
the laser device's connection point according to the UL489
standard.
■ For more information on the specification of the main switch,
please refer to the operator's manual of the laser device.

Connected loads

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

B813en Electrics - Version 14 2‐27

 Rated power: Frequency
400 V ±10%7 50 Hz ± 1%

460 V +10%/–5%8 60 Hz ± 1%
Nominal voltage and Frequency Tab. 2-20

TruDisk TruDisk TruDisk

3001 4001 6001
Connected load incl. laser, 35 kVA 42 kVA 52 kVA
process cooler, and possi-
ble automation (apparent
power input).
Fuse protection (IEC) 60 A. 80 A. 100 A.
■ at 400 V
■ gL/gG (fuse type)
Fuse protection (NEC) 63 A 80 A. 100 A.
■ at 460 V
■ RK1/Class J (fuse type)
Maximum acceptable inter- See EN 60204, part 1, sec. 4.3.2, Alternat-
ruption of the nominal volt- ing current supply
age [ms]
Connected loads Tab. 2-21

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

Startup power

The electrical power input of the machine depends on the laser

power.

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

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

2‐28 Electrics - Version 14 B813en

 Startup power Unit TruDisk 3001 TruDisk 4001 TruDisk 6001
Average power input in production9 kW 13 15 18

Auto-shutdown active10 4.5 4.5 4.5

Standby mode11 5.5 5.2 5.7

Tab. 2-22

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

[kW]laser [%] power
Electrical power input including suction unit and process Fig. 65731
cooler at an ambient temperature of +25 °C

Connecting cables

Establish the electric power supply in accordance with DIN EN

60204-1/4.3.1:

IEC
Supply line Copper line, at least four-core (L1, L2, L3, PE)
Conductor cross-section Designed according to:
IEC 60364-4-43 (VDE 0100-430)
Grounding cable Designed according to:
IEC 60364-5-54 (VDE 0100-540)
Requirements for the connecting cable Tab. 2-23

9 The value describes the power input of the machine with a beam of
50% for a even distribution between nitrogen cutting of stainless steel
and oxygen cutting of mild steel.
10 The value describes the power input of the machine in not-ready-for-
use status (laser, process cooler are switched off; machine control is
active).
11 The value describes the power input of the machine in ready-for-use
status (0% laser power).

B813en Electrics - Version 14 2‐29

 NEC
Supply line ■ Copper line, four-core (L1, L2, L3, PE).
■ THHN copper or equivalent is recommended (2000 V test voltage) designed
for a maximum temperature of +90° C (+194° F).
■ No aluminum lines may be used for the machine connection.
Conductor cross-section ■ The conductor cross-section must meet NEC 670-4 (a). The conductor cross-
section must be designed for at least 125 % of the nominal current. The
nominal current is specified on the nameplate.
■ To ensure voltage stability and rating, the line dimension should be larger
than specified in the NEC table 310-16.
Requirements for the connecting cable Tab. 2-24

5.2 Power supply

Uninterruptible Power Supply (UPS)

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

the system to an uninterruptible power supply (UPS):
■ When working out the dimensions of the UPS, the short-cir-
cuit and overload responses of the UPS system are to be
taken into account alongside the continuous power and the
electrical connected loads.
■ As a rule: overload capacity of the UPS ≥200 % for 0.5 s.

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

Residual current device (RCD)

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

A fault current circuit breaker provides protection from fault cur-

rents due to directly or indirectly touching live parts.

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

2‐30 Electrics - Version 14 B813en

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

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

TRUMPF recommends the following fault current circuit breakers:

■ Dipl. Ing. W. Bender GmbH & Co. KG, Postfach 1161,
D-35305 Grünberg, Germany. E-mail: info@bender-de.com.
− RCMA series.
■ Doepke Schaltgeräte GmbH & Co. KG, Stellmacherstrasse
11, D-26506 Norden, Germany. E-mail: info@doepke.de.
− DFL 8 B SK series.

Power supply configurations

Note
A TN system with grounded star point is the standard power
supply configuration for the connection.

Power supply with grounded outer conductor (corner-

grounded delta network)

When connecting the machine to a power supply with a

grounded outer conductor, an isolating transformer must be used.
For IT and TT systems, as well as for asymmetrical power sup-
plies (one phase grounded - "corner grounded"), the machine
must be connected via an isolating transformer by the customer.

NEC conditions Grounding:

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

B813en Electrics - Version 14 2‐31

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

IT system

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

system.

TRUMPF recommends surge diverters from the following manu-

facturers:
■ Phoenix Contact GmbH & Co. KG, Flachsmarktstraße 8,
D-32825 Blomberg, E-mail: info@phoenixcontact.com.
■ Dehn+Söhne, PO Box No. 1640, D-92306 Neumarkt, E-mail:
info@dehn.de.

Isolating transformer

The manufacturer's documentation is applicable for the isolating

transformer.

Notes concerning Define a location. The location is not indicated on the installation
installation plan.

2‐32 Electrics - Version 14 B813en

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

Machine
Type - MD 125000
Length (a) x width (b) x height (h) mm 1050 x 750 x 1400
Minimum distance (d) 100
Safety distance for escape routes (e) 800
Isolating transformer, made by Roller und Fischer Tab. 2-25

■ The isolating transformer must be installed in such a way

that access via the door hung on the front side (door with
nameplate) remains free. The required safety distance for
escape routes is 800 mm according to IEC or 1070 mm
(3.5 ft) according to NEC.
■ A minimum clearance of 100 mm must be maintained on the
sides and at the rear due to the generation of heat.
■ Provide a power cable.
■ The connection cable to the isolating transformer and from
the isolating transformer to the machine are not included in
the isolating transform's scope of delivery.
− There are suitable and terminals for wire end ferrules on
the isolating transformer available for connection.

B813en Electrics - Version 14 2‐33

 5.3 Remote support

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

Remote support via Internet Note

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

For remote support via the Internet, the following configuration is

required in the LAN for the user:
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.

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

Telepresence Box to the internal customer network.

5.4 Cloud connection

For the cloud connection, the following configuration is required

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

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

5.5 Network link

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

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

2‐34 Electrics - Version 14 B813en

 Establish an alternating If several machines are to be connected to the network, a per-
current supply for the sonnel switch (network distributor) is necessary. The network dis-
personnel switch tributor can be found in the electrical cabinet of the machine.
The alternating current supply must be provided, since the net-
work distributor must work even if the machine is switched off.

Note
The same nominal voltage and frequency tolerances as those for
the machine are applicable when using a personnel switch (net-
work distributor) (see "Power supply", pg. 2‐27).

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

B813en Electrics - Version 14 2‐35

 6. Operating materials

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

6.1 Gases

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

6.2 Cooling water

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

Requirements The cooling water must be demineralized or de-ionized.

Notes
■ The required amount of cooling water is to be provided by
the customer at system start-up.
■ 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.

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. 2-26

2‐36 Operating materials - Version 14 B813en

 Ambient Internal cooling External cooling External cooling
condi- circuit for laser circuit for the circuit for laser
tions machine (KLH chiller type
(KLH chiller L 0/5 RL 12/0 TK,
TK) RL 14/0 TK,
RL 16/0 SK)
- Volumet- Required Volumet- Required Volumet- Required
ric water ric water ric water
capacity quantity capacity quantity capacity quantity
of cool- of cool- of cool-
ing cir- ing cir- ing cir-
cuit cuit cuit
Quantity of cooling water in l
(gal)
TruDisk 3001 Standard 55 110 - - 140 140
(FD27) RL 16/0 (14.5) (29.1) (37.0) (37.0)
SK
Tropical 55 110 80 80 140 140
version (14.5) (29.1) (21.1) (21.1) (37.0) (37.0)
RL 12/0
TK
TruDisk 4001 Standard 55 110 - - 140 140
(FD27) RL 16/0 (14.5) (29.1) (37.0) (37.0)
SK
Tropical 55 110 80 80 140 140
version (14.5) (29.1) (21.1) (21.1) (37.0) (37.0)
RL 14/0
TK
Cooling water requirements for TruLaser 3030 and TruLaser 3040 (with TruDisk 3001 or Tab. 2-27
TruDisk 4001)

Cooling water Internal cooling External cooling External cooling

circuit for laser circuit for machine circuit for laser
(Riedel chiller, type
RL 13/0 TR, RL
24/0 TR)
Required amount of water per cooling cir- approx. 280 approx. 160 about 600
cuit in l (gal)12 (75) (43) (158.5)
Conductivity for newly replaced water Max. 10
[μS/cm]
Conductivity for newly replaced water after max. 20
10 minutes of circulation [μS/cm]
Conductivity limit of the cooling water dur- Max. 200
ing operation [μS/cm]
Max. permissible carbonate content [mg/l] Less than 100
Color Colorless
Cloudiness None
Odor odorless
Cooling water requirements for TruLaser 3030 and TruLaser 3040 (with TruDisk 6001) Tab. 2-28

12 The required amount of cooling water per cooling circuit is four times
the tank volume.

B813en Operating materials - Version 14 2‐37

 Notes
■ The specified chemical/physical characteristics must be
observed.
■ Do not use distilled water! The quality of distilled water can
fluctuate considerably.
■ 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. 2-29

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

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

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

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

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

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

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

2‐38 Operating materials - Version 14 B813en

 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. 2-30

B813en Operating materials - Version 14 2‐39

 7. Transportation of the machine

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

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 arrangements and transport of the system from the truck to
its final installation site need to be prepared and carried out by
the customer. Such questions as the transport route to the final
installation position should be clarified well in advance of the
machine's arrival. In particular, gates, header heights, cable rack
heights, ground conditions for armored rollers etc. must be
checked. The installation site must be free of obstructions.
The transport route must take the dimensions of the machine
into account according to the installation plan!

Component Machine Length in Width in Height in

mm mm mm
(inches) (inches) (inches)
Machine body L49 5800 3200 2400
(229) (126) (94.5)
L50 7000 3700
(276) (145.7)
Pallet changer L49 3500 2800 1000
(137.8) (110.3) (39.4)
L50 4400 3350
(173.3) (132)
TruDisk 3001/4001 L49, L50 1175 725 1430
laser device (46.3) (28.5) (56.3)
TruDisk 6001 laser L49, L50 1600 (65) 950 (40) 1550 (60)
device
Process cooler for L49, L50 654.5 654.5 1704 (67)
machine (25.8) (25.8)
(for TruDisk
3001/4001 only)

2‐40 Transportation of the machine - Version 14 B813en

 Component Machine Length in Width in Height in
mm mm mm
(inches) (inches) (inches)
Process cooler for L49, L50 765 (30) 640 1321 (52)
machine (25.2)
(for TruDisk 6001
only)
Process cooler for L49, L50 775 845 1775
laser (30.5) (33.3) (69.9)
(for TruDisk
3001/4001 only)
Process cooler for L49, L50 1544 816 1554
laser (60.8) (32.1) (61.8)
(for TruDisk 6001
only)
Compact dust extrac- L49, L50 1400 1280 2200
tor (55.1) (50.4) (86.6)
Isolating transformer L49, L50 1050 750 1400
(41.4) (29.6) (55.1)
Dimensions of system components incl. transport devices Tab. 2-31

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

weighs 8000 kg (17637 lbs).

Transport regulations Refer to the following transport regulations for detailed conditions
for the transportation of the system.
■ TruLaser 3030 (L49): drawing no. 93735-8-10
■ TruLaser 3040 (L50): drawing no. 93746-8-10
A copy of the transport regulations can be found in a clear plas-
tic envelope on the machine upon delivery.

7.1 Measures to be taken by the

customer

Please observe ■ All transport work must be carried out in accordance with the
transport regulations.
■ The machine may not be lowered onto the ground without
supports since otherwise the bottom of various components
will be damaged! The distance from the machine bearing
plates to the floor must be ≥100 mm. This distance to the
floor must also be maintained during the transportation of the
machine to its installation site.
■ The floor requirements at the installation site must comply
with the installation requirements. Cutouts, bore holes, etc. in
the factory floor must be prepared by the customer in
accordance with the foundation plan prior to installation of
the machine.
■ Keep the transport devices in case the machine is moved
again at some point.

B813en Transportation of the machine - Version 14 2‐41

Unloading the machine from ■ Unload the machine from the truck using a crane truck of
the truck suitable lifting power.
■ If there is no indoor crane available at the installation site,
remove the eyelets for securing the load on the truck next to
the machine legs, provided the machine is connected to the
crane shackles.
■ The control cabinets, process cooler, exhaust system and
laser device can be transported directly from the truck to the
installation side of the machine using a forklift truck.

Transporting the machine Note

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

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

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

Transport TruDisk laser device

The laser device can be transported by pallet jack 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 pallet jack: insert the pallet
jack so that front rollers do not touch the bottom plate of the
laser device.

2‐42 Transportation of the machine - Version 14 B813en

 Conditions
■ Laser device is switched off.
■ Laser light cable (LLK) is disconnected.
■ Supply connections have been removed.
■ At temperatures below 0 °C / 32 F or for long-distance trans-
port: The cooling circuit has been drained completely and
blasted using compressed air.

Means, Tools, Materials

■ Protection mat.
■ Pallet jack or forklift truck.

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 Protection mat 3 Belt

2 TruDisk
Transporting TruDisk Fig. 87661

1. Cover laser device with a protection mat.

2. Move the pallet jack or forklift to underneath the laser device
according to Fig. 87661.

B813en Transportation of the machine - Version 14 2‐43

 3. When transporting using a forklift truck: Secure the laser
device with a transport belt.
4. Lift and transport the device.

1 Brakes (4x)
Transport rollers TruDisk Fig. 91268
5. After setting up the laser device, lock the brakes into position
at all four rollers.

7.2 Service work by Technical Service

Leveling of the machine The machine is leveled by Technical Service.

Putting machine into service The machine is put into service by Technical Service. This
includes the installation of the components according to the
installation plan, the connection of the system to the supplies as
well as instructing personnel and the functional inspection of the
machine.

2‐44 Transportation of the machine - Version 14 B813en

 Chapter 3

Description

1 The most important assemblies 3‐4

1.1 Nameplate 3‐5
1.2 Closed machine frame 3‐6
1.3 Closed safety cabin with sliding roof 3‐6
1.4 Motion unit 3‐7
1.5 TruDisk Laser 3‐8
1.6 TRUMPF laser light cable 3‐10
1.7 Cutting unit 3‐11
1.8 Exhaust system 3‐12
1.9 Compact dust extractor 3‐13
1.10 Longitudinal conveyor belt 3‐13
1.11 Storage container 3‐13
1.12 Automatic pallet changer 3‐14
1.13 Spraying equipment 3‐15
1.14 Pilot laser 3‐15

2 Control system 3‐17

2.1 Operator panel with touchscreen 3‐18

B813en 2019-02-01 Description 3‐1

 2.2 Order List 3‐18
2.3 Shop floor programming 3‐19

3 The most important functions 3‐20

3.1 High-speed technology package 3‐20
3.2 Multi-sheet processing 3‐20
3.3 FocusLine 3‐21
3.4 FastLine 3‐21
3.5 FlyLine 3‐22
3.6 AdjustLine 3‐22
3.7 PierceLine 3‐23
3.8 Laser power control 3‐23
3.9 NitroLine 3‐24
3.10 ControlLine 3‐24
3.11 Cutting flaw detection with PlasmaLine 3‐25
3.12 ContourLine 3‐25
3.13 Microweld 3‐26
3.14 Auto-shutdown 3‐26
3.15 Drive-based collision detection 3‐27

4 The most important options 3‐28

4.1 BrightLine fiber (option) 3‐28
4.2 TruTops Boost 3‐29
4.3 Drop&Cut image-based post-production 3‐30
(option)
4.4 Smart Collision Prevention (option) 3‐30
How does Smart Collision Prevention work? 3‐32
4.5 Technology package Highspeed Eco (option) 3‐33
4.6 Compressed-air cutting (option) 3‐34
4.7 DetectLine (option) 3‐34
4.8 Automatic nozzle changer (option) 3‐35
4.9 Pipe cutting with RotoLas (option) 3‐36
4.10 CoolLine (option) 3‐37
4.11 Cleaning brush (option) 3‐38
4.12 Reconditioning cooling water with Easy Filter 3‐39
(option)
4.13 Clamps (option) 3‐40
4.14 Camera for process monitoring (option) 3‐41

5 Industry 4.0 with TruConnect 3‐42

5.1 What is Industry 4.0 at TRUMPF? 3‐42

3‐2 Description 2019-02-01 B813en

 5.2 Production overview 3‐43
5.3 Production control 3‐45
5.4 Connectivity 3‐46
5.5 Remote support 3‐48
5.6 Digital enhancement of the TRUMPF machines 3‐48

6 Safety 3‐50
6.1 CE marking 3‐50

7 Automation components and their functions 3‐51

7.1 Example 3‐53

8 Technical data 3‐54

B813en 2019-02-01 Description 3‐3

 1. The most important assemblies

The TruLaser 3030 fiber and TruLaser 3040 fiber complete

TRUMPF's current laser flatbed machine portfolio. The machines
from the TruLaser Series 3000 have a solid-state laser which
offers a high level of flexibility in regard to material and material
thickness. Whether processing thin sheets, thick mild steel or
non-ferrous metals, such as titanium, copper and brass, the
TruLaser 3030 fiber and TruLaser 3040 fiber masterfully and reli-
ably manages all processing tasks.
The laser unit has been integrated in the machine body, making
the machine very compact meaning that it only requires a small
installation surface. Moreover, installation and start-up are even
simpler and can be performed in a minimum of time.

1 Laser TruDisk 4 Sliding roof 7 Universal cutting unit

2 Integrated electrical cabinets on 5 Cabinet for machine accessories 8 Safety cabin
the rear side of the machine 6 Laser protective glass 9 Pallet changer
3 Control panel
Most important assemblies Fig. 65033

3‐4 The most important assemblies 2019-02-01 B813en

1 Laser TruDisk 4 Safety cabin with door 6 Cutting unit
2 Motion unit 5 Control panel 7 Pallet changer
3 Sliding roof
Most important assemblies of the machine with TruDisk 6001 Fig. 81023

1.1 Nameplate

The nameplate is located on the left side of the machine (as

seen from the control panel), under the device panel.

B813en 2019-02-01 The most important assemblies 3‐5

 1.2 Closed machine frame

Closed machine frame Fig. 68660

Stable basis for all The closed machine frame is a steel/welded design. It limits the
components processing area of the machine.

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

1.3 Closed safety cabin with sliding roof

The safety cabin is equipped with a manually activated sliding

roof and is thus completely enclosed. In this way it fully meets
the requirements for certification for systems with a solid-state
laser. The machine can be equipped with an automatic rolling
roof (option) if necessary.

3‐6 The most important assemblies 2019-02-01 B813en

1 Viewing window 2 Sliding roof, half closed 3 Protective enclosure
Fig. 64832

1.4 Motion unit

Motion unit Fig. 66903

Motion unit for high- The motion unit is based on a very robust cross beam calculated
precision processing using FEM techniques, which has a lightweight welded steel
design. Design features and manufacturing methods enabling
extremely lightweight construction were deliberately selected with
this purpose in mind.

B813en 2019-02-01 The most important assemblies 3‐7

 The machine operates according to the flying optics principle.
The workpiece stays still and the cutting unit moves.
Rack and pinion systems execute the travel motion.

Advantages ■ High dynamics with simultaneously high accuracy, because

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

1.5 TruDisk Laser

TruDisk 6001 Fig. 87660

The laser device is installed outside the machine and thus can
be flexibly integrated into different customer layouts.

3‐8 The most important assemblies 2019-02-01 B813en

 Generating the laser beam

1 Deflection mirror 5 Pump laser beam

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

The laser active medium is a thin crystal disk made from

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

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

mode thanks to its diode pumped simulation.

Advantages of the solid state laser:

■ Very good beam shape due to a small opening angle with a
small beam waist.
■ High levels of efficiency.
■ High beam quality.
■ No laser gas required.
■ Beam guidance through a laser light cable.
■ Low power consumption.
■ Free of wear parts.
■ Maintenance-free.
■ Network-compatible: The laser can optionally be equipped
with an additional beam outlet and can supply several sys-
tems at the same time.

B813en 2019-02-01 The most important assemblies 3‐9

TRUMPF LaserNetwork (TLN) The laser can be equipped with several outlets. This makes it
possible to set up a laser network where several machines are
supplied by one laser source. Through the network, the
utilization rate and cost-effectiveness of the beam source can be
significantly increased.
For further information on the TRUMPF LaserNetwork, refer to
the technical telegram "TRUMPF LaserNetwork (TLN)".

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

1.6 TRUMPF laser light cable

Transmitting the laser beam

1 Cable conduit with steel shell 3 Protective covering

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

The laser light of the disk laser is coupled into a laser light
cable.
The optical fiber comprises silica fiber with two layers: the fiber
core and the coat. The laser light spreads in the fiber core. Its
diameter amounts to 100 µm. The coat encloses the fiber core
and keeps the laser light inside it. A plastic layer encloses the
silica fiber and protects it from damage.

Advantages ■ No contamination of the beam guidance.

■ No complicated mirror systems.
■ Few mechanical parts.
■ Depending on the laser power, different laser light cable
lengths can be made, which allows a very flexible installation
of the laser device.

3‐10 The most important assemblies 2019-02-01 B813en

 1.7 Cutting unit

1 Status LEDs, drive 4 Sensor system status LEDs

2 Adjustment unit 5 Air nozzle
3 Adjusting screws for beam cen- 6 Cutting nozzle
tering
Cutting unit Fig. 74131

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

The optical system of the cutting unit allows for the following
functions:
■ Automatic offsetting of the focal position. For optimum cutting
results, the focus must be set to a defined point relative to
the workpiece surface.
■ Automatic switching between two focal diameters.

B813en 2019-02-01 The most important assemblies 3‐11

Deflection of the cutting unit If a collision occurs between the cutting unit and obstacles in the
in case of a collision work area (e.g., elevated parts), a deflection mechanism will stop
the machine axes within a defined stopping path. The deflection
of the cutting unit prevents collision forces from being transferred
into the axis system (guides, gearbox, structure). This prevents
the axis system from being damaged. The cutting unit can then
be manually moved back into its original position.
For small collisions, the cutting unit automatically returns to the
original position. Afterwards, the processing can be resumed
without further setting work.
For machining, the laser beam and the cutting gas are directed
onto the workpiece through the cutting nozzle.

Advantages ■ The entire material and material thickness spectrum can be

cut with one cutting unit.
■ The protective glass in the cutting unit directs the optical sys-
tem in the direction of the beam emission point, so that dirt
cannot enter the cutting unit.
■ No cleaning of the lens required.
■ During a collision, structural damage of the machine and the
cutting unit can be prevented by the deflection mechanism.

1.8 Exhaust system

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

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

Note
For the selection and sheet layout of the pallet, utilize the work-
ing range as completely as possible to achieve an optimum
effect of the exhaust system.

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

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

3‐12 The most important assemblies 2019-02-01 B813en

 1.9 Compact dust extractor

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

Advantage In the compact dust extractor, the exhaust air is cleaned and the
dust removed.

1.10 Longitudinal conveyor belt

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

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

1.11 Storage container

On the front and rear deflection shaft of the longitudinal

conveyor belt, there is one storage bin each which collect the
accumulating slag, small and waste parts. The storage bins are
also available in a tripartite design (option).
The storage bins must be emptied regularly.
Due to the tripartite design (option), the storage bin does not
have to be pulled out completely but can be pulled out piece by
piece and emptied.
Instead of a storage bin, a transverse conveyor belt (option) can
also be attached under the rear deflection shaft.

Fire due to material change!

CAUTION
Fire in the storage bin.
Ø Empty the storage bin before changing the material from
aluminum/aluminum alloys to ferrous materials or vice versa.
Ø Empty the storage bin on a daily basis, regardless of the
machined materials.
Ø In case of fire, put on protective gloves and safety glasses,
completely pull out the storage bin and, at a distance of a
few meters from the machine, extinguish the fire with sand
or a fire extinguisher for metal fires (fire classification D).

B813en 2019-02-01 The most important assemblies 3‐13

 1.12 Automatic pallet changer

Automatic pallet changer Fig. 64998

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

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

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

3‐14 The most important assemblies 2019-02-01 B813en

 1.13 Spraying equipment

1 Nozzle of the spraying equipment

Fig. 68659

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

Advantages ■ Low spray material consumption.

■ After-purification can be dispensed with as a rule.
■ Low filter contamination.
■ Protective of the environment.

1.14 Pilot laser

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

B813en 2019-02-01 The most important assemblies 3‐15

 Advantages ■ Optimum utilization of the sheet.
■ Exact positioning of the cutting unit, even manually.

3‐16 The most important assemblies 2019-02-01 B813en

 2. Control system

Fig. 74193

Control panel The control panel enables personalized adjustment to the opera-
tor and simple operation due to a reduced number of keys. The
swivelable screen with height adjustment can be ideally adapted
to the operator and the current light conditions.
The keyboard can be pulled out and is located under the large
support surface for drawings and setup plans.

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

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

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

Software is protected by The software installed on the machine, including any storage
copyright media and documentation supplied may only be used for this
machine. The software may 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 be subject to a
corresponding obligation.

B813en 2019-02-01 Control system 3‐17

 2.1 Operator panel with touchscreen

Fig. 53109

Operating and programming The important and useful aspects have been determined in
directly numerous practical tests. The user interface is easy to operate
and reflects the test results for maximum rapid operation and
programming.
The order of the main operations (e.g. production, setup, pro-
gramming) and tabs is based on the procedures in production.

■ Tabular concept:
− All parameters for processing are available in the tables
on the control.
− All values can be quickly and securely adjusted or modi-
fied.
■ Network options or remote support are possible at any time.

Advantages ■ Intuitive, easy-to-operate operating environment with direct

input via the touchscreen.
■ Optimized operating procedures take you quickly to your tar-
get.
■ High-resolution TFT color display.
■ Online help systems.

2.2 Order List

Executing linked programs An order list consists of several production packages arranged in
a sequence. Several programs generated one after the other can

3‐18 Control system 2019-02-01 B813en

 be combined in the order of their creation or in the context of a
job to form one production package.
The production package can also make information available to
TruTops Fab or a control system.

Advantages ■ With automation: Unattended execution of programs.

■ Without automation: Intervention of the operator required only
for loading and unloading.

2.3 Shop floor programming

Easy shop floor In 5 steps from the geometry to the program. The easy shop
programming floor programming integrated in the control enables rapid pro-
gram creation directly from available geometry data. The latter
can, for example, be loaded from a USB stick. Offline program-
ming away from the machine is thus no longer necessary. The
automatic nesting assistant provides optimum and material-effi-
cient sheet layout.

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

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

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

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

B813en 2019-02-01 Control system 3‐19

 3. The most important functions

3.1 High-speed technology package

Reduced gas consumption When cutting with the high-speed technology package, the flow-
at higher sheet throughput optimized nozzles and the technology parameters optimized for
this cutting process ensure reduced gas losses and a higher
sheet throughput.

Prerequisites ■ Required laser power: 6 kW.

■ Materials that can be processed and max. sheet thickness
that can be processed:
− Mild steel (N2): 4-8 mm
− Stainless steel (N2): 4-8 mm

Advantages ■ Up to 40% reduced gas consumption at 60% higher sheet

throughput.
■ Oxide-free cuts in mild steel up to 8 mm.
■ One nozzle (EAU100) for the entire area of application.
■ Significantly higher feed rate compared to standard cutting
method.

3.2 Multi-sheet processing

1 Machine 2 Pallet A 3 Pallet B

Fig. 81043

The "multi-sheet processing" function allows processing of very

different materials and material thicknesses on one or both pal-
lets and is especially suitable for production without an operator.

3‐20 The most important functions 2019-02-01 B813en

 Prerequisites ■ Nozzle changer (option).
■ Clearance of the sheets in all directions: 100 mm.
■ It is recommended to start with pallet B (no falling parts on
pallet B).

Advantages ■ Processing of very different material and material thick-

nesses.
■ Cost-effective utilization of the machine even at a low propor-
tion of oversize format.
■ The two pallets can be processed one after the other.
■ Working without operator possible.
■ Working with templates possible.

3.3 FocusLine

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

Advantages ■ The focus is automatically adjusted to the relevant material

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

3.4 FastLine

FastLine The transition from piercing to cutting the contour is carried out
more quickly and with higher quality with FastLine. This is ach-
ieved by changing decisive process parameters that cooperate to
significantly improve the process regarding speed and quality
especially with thin sheets.
The pure piercing time is slightly longer. Parameters that would
take time to modify remain unchanged. Thus the waiting times
when converting the gas pressure, when changing the setting
dimension, and during the lateral air blast can be eliminated.

B813en 2019-02-01 The most important functions 3‐21

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

3.5 FlyLine

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

tively when machining hole grids.

The most important machining features of FlyLine are:

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

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

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

3.6 AdjustLine

Simply adjust the cutting The material quality is not always ideal, particularly with thicker
process materials. If cutting problems result from this fact, the operator
can simply and quickly select alternative cutting parameters
which will then frequently enable trouble-free cutting.

Advantages Increased material tolerance: Reduces waste parts and material

costs.

3‐22 The most important functions 2019-02-01 B813en

 3.7 PierceLine

Monitoring the process PierceLine is able to monitor every piercing process – and does
this regardless of material type and thickness. PierceLine is used
together with a ramp cycle. For this, piercing is carried out with
in a controlled ramp cycle and the end of the piercing process is
detected by PierceLine.

Advantages ■ Significantly reduced piercing times.

■ Less heat input into the material.
■ Piercing-end-recognition across the entire material and mate-
rial thickness spectrum.
■ The piercing spot does not need to be sprayed for mild steel
s ≤12 mm – the refinishing operation associated with this is
also not required.
■ Reduced wear of the support slats due to punctual ending of
the piercing process.

3.8 Laser power control

Regulating laser power for The laser power control system controls the laser power and the
specific applications heat application depending on the path velocity. The laser power,
and thereby the heat application, are reduced during the cutting
process.

A Upper side of the sheet 1 Without laser power control 2 With laser power control
B Bottom of the sheet
Example with and without laser power control Fig. 34686

B813en 2019-02-01 The most important functions 3‐23

 Advantages Optimum cutting quality at corners and smaller contours through
targeted regulation of the laser power.

3.9 NitroLine

Fig. 37022

For optimum cutting edges NitroLine means: fusion cutting with nitrogen and a cutting gas
pressure of no more than 25 bar, which quickly drives out the
melt downwards.

Advantages ■ Oxide-free cutting edges.

■ Reduction of the burr formation.

Characteristic features Especially recommended for the machining of the following mate-
rials:

■ Stainless steel
■ Mild steel
■ Aluminum alloys

3.10 ControlLine

ControlLine controls the ControlLine coordinates and controls various machine functions
processes centrally:
■ Capacitive distance regulation for constant nozzle - sheet dis-
tance.
■ Automatic measurement of the workpiece position and cor-
rection the coordinate system if required.

3‐24 The most important functions 2019-02-01 B813en

 ■ PierceLine.
■ Cutting flaw detection with PlasmaLine.

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

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

3.11 Cutting flaw detection with

PlasmaLine

More process reliability When laser cutting with a solid-state laser, the "PlasmaLine" sen-
sor system is used to detect cutting errors during nitrogen
machining. If there is a malfunction in the cutting process, the
sensor system triggers a feed hold and prevents the nozzle from
getting damaged.
The parameterization of the threshold value at which the cutting
flaw detection is activated depends on the laser power, material
and processing type (nozzle, distance between nozzle and sheet,
feed).
The threshold value can be adjusted for each technology table
as needed. This is required, for example, when the cutting flaw
detection does not work reliably during running material process-
ing (cutting flaw detection is activated too early or too late).

Hereby, a % value of the PlasmaLine signal is set in the field

Cutting error detection threshold:
■ 20 % = Cutting error detection responds sensitively.
■ 100 % = Cutting error detection responds late.

Advantages ■ Enhanced process reliability.

■ No squandering of expensive material.
■ Protection of machine component parts.

3.12 ContourLine

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

B813en 2019-02-01 The most important functions 3‐25

 Example part: Material thickness s = 10 mm, hole diameter Fig. 37021
4 mm

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

3.13 Microweld

Connecting with dots It is frequently the case in everyday production that

specifications require that processed parts remain connected
with the sheet instead of being cut free completely.
In the case of Microweld processes, the part is connected with
the sheet with the aid of one or more weld points.

Advantages ■ The contour is damaged only slightly – refinishing operations

are usually unnecessary.
■ Parts can be readily detached.
■ Utilization is also possible with large material thicknesses.

3.14 Auto-shutdown

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

3‐26 The most important functions 2019-02-01 B813en

 Advantages In addition to energy savings, the auto-shutdown also reduces
wear-and-tear on the machine.

Characteristic feature Auto-shutdown is only practical in combination with machine

automation for unmanned operation.

3.15 Drive-based collision detection

Detecting collisions, With the "drive-based collision detection" function, collisions of

reducing damage the motion axes and collision contours (e.g. with workpieces) are
detected immediately. An EMERGENCY STOP for all axes will
be triggered directly after a collision to prevent axes from con-
tinuing their programmed sequence of movements. This allows
the extent of damage from a collision to be limited.

Advantages ■ Collisions and mechanical malfunctions are detected in the

entire power train.
■ Consequential damage is reduced.
■ Increased machine protection.

B813en 2019-02-01 The most important functions 3‐27

 4. The most important options

4.1 BrightLine fiber (option)

Fig. 68817

Highest cut quality for solid- BrightLine fiber was developed in order to considerably improve
state lasers the quality of the cutting edges when machining thick mild steel
and stainless steel.
TruDisk Laser automatically switches between thin and thick
sheet metal mode. In daily operation, this makes it possible to
choose between high feed rates with thin sheet metal and opti-
mal cut quality in thick sheet metal.

Advantages ■ Higher quality: Besides the high-grade cutting edge in thin

sheet metal, now the cutting edge is also the best in thick
stainless steel, mild steel and aluminum.
− Homogeneous cutting surface.
− Significantly fewer burrs.
■ Improved flexibility:
− For Series 3000 machines (L49, L50, L66, L75 and L79):
cutting of mild steel up to 25 mm.
− For Series 5000 machines (L56, L57, L68, L69): cutting
of stainless steel and aluminum up to 25 mm.
■ Greater process reliability: Improved process reliability for
cutting of mild steel.
− Saving on material costs due to reduced number of
waste parts.

3‐28 The most important options 2019-02-01 B813en

 ■ Highest piercing quality and minimal contours: free of bulg-
ing, multi-staged piercing with the smallest piercing holes.
− Greater freedom for geometry.
− Higher part quality.
− Lower material costs due to tighter nesting.
■ Simpler part removal: Larger kerfs for simple removal.
− Time saving during manual removal.
− Greater process reliability for automatic removal.

Additional documents “BrightLine fiber” technical telegram.

4.2 TruTops Boost

Programming 2D laser TruTops Boost combines design and programming for 2D laser
machines processing.
The machine and production system form a precisely
coordinated unit.

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

data) with technological knowledge of TRUMPF.
■ Continuous process in one software program, from the order
to the program.
■ Automated and efficient processes increase the programming
speed and productivity.
■ The system adapts itself to individual user requirements.
− Process multiple orders in parallel.
− All common 2D/3D data formats are read in.
■ Simple automatic program creation on the PC (program is no
longer created on the machine control).
■ The Boost nesting processor:
− Excellent sheet utilization.
− Offers an optimal overview of the parts still to be pro-
duced.
■ Order data is also registered directly when the drawing is
transferred.
■ Collision check if there are formed sections.

B813en 2019-02-01 The most important options 3‐29

 4.3 Drop&Cut image-based post-
production (option)

Fig. 73852

User-friendly and economic A camera, which is firmly installed in the machine room, displays
post-production images of the working area and enables image-based post-pro-
duction. The operator keeps the sheet layout in view and can
make optimal use of the remainder sheet. Available parts are
shown in a selection list from a preloaded part program. These
can be moved into the live picture, rotated and positioned with
one click (augmented reality). In this way, the operator can
quickly and easily create post-production.

Prerequisites ■ One or two integrated camera for process monitoring

(option).

Advantages ■ Saves time during post-production of parts.

■ Material-efficient sheet layout thanks to flexible positioning on
scrap skeleton.
■ Easy operation – can be used without training.
■ Optimal process reliability thanks to cutting preview in live
picture.

4.4 Smart Collision Prevention (option)

What is Smart Collision Smart collision prevention is for collision avoidance during laser
Prevention? cutting.

3‐30 The most important options 2019-02-01 B813en

 For this, the processing sequence is modified intelligently. Proc-
essing is no longer carried out part by part, but is modified in
such a way that any tilting of parts no longer results in collisions.

This results in significant differences compared to conventional

processing during laser cutting:
■ Sheets are no longer cut piece by piece.
■ Contours are processed in several separate steps.
■ Outer contours are sometimes cut before inner contours, but
never completely as long as not all inner geometries have
been cut yet.

Sheet cut using smart collision prevention Fig. 80785

Advantages ■ The machine operator does not have to permanently monitor

the cutting process and has time for other tasks.
■ The effort required to remove parts from the scrap skeleton
is significantly less than for parts that are held in the scrap
skeleton with microjoints.
■ Process reliability is increased.
■ Machine downtime due to collisions is kept to a minimum.
■ Material efficiency increases, as Smart Collision Prevention
allows a tighter parts distance to the sheet.
■ Programming takes place quickly and simply.

Application ■ Smart collision prevention is ideal for material of thin and

medium thickness (s = 2-6 mm).
■ Best results are achieved with nitrogen as the cutting gas.
■ With thinner materials, sheet warping problems may occur
with contour precision.

B813en 2019-02-01 The most important options 3‐31

 ■ High-performance cutting processes:
− CrNi steel up to a sheet thickness of 6 mm with N2 cut-
ting
− Mild steel up to a sheet thickness of 6 mm with N2 cut-
ting
■ Support of additional nozzles:
− EAU25
− EAU30
− EAU40
− EAU60

How does Smart Collision Prevention

work?

Smart collision prevention applies intelligent algorithms for ensur-

ing automatic collision avoidance during the cutting process.
In doing so, Smart Collision Prevention combines various proc-
esses into one.

Calculation of the tilting Smart collision prevention calculates how each part to be cut
height could tilt in the worst case.

Calculation of sheet Smart collision prevention calculates for each part to be cut how
deformation by static and it will deform as a result of static and thermal effects.
thermal effects
Separating cuts HERE1 Smart collision prevention separates cuts in such a way that the
cutting unit no longer needs to be moved into the collision range
of any tilting parts.

Intelligent microjoints If separation is not possible, smart collision prevention automati-

cally places intelligent microjoints.
The microjoints are set as rarely as possible and only at geome-
tries at which they cause the least interference.
Smart collision prevention always positions intelligent microjoints
at the original approach point of a geometry.

Automatic cropping of Inner geometries at which intelligent microjoints were positioned

scraps can also be separated automatically by smart collision
prevention.
The quality-optimized cutting up of scrap can now be used for
any contours.

Adaptive cutting unit height When running empty, the cutting unit is only raised as high as
necessary for collision-free processing. The cutting unit remains
almost at the process height if it is not moving near parts that

3‐32 The most important options 2019-02-01 B813en

 have already been cut free. The positioning speed has been
increased and thus also productivity without putting the process
reliability at risk.

Automatic bypass Since the cutting gas jet remains switched on when running
empty, this can cause parts that have already been cut free to
tilt or be blown away. Smart collision prevention bypasses these
parts so that they are not hit by the cutting gas jet. The path for
running empty has been optimized resulting in an increase in
productivity due to higher path velocities.

Automatic gas off If automatic bypassing is not possible, smart collision prevention
automatically shuts off the cutting gas jet when moving over
parts that have already been cut free.

4.5 Technology package Highspeed Eco

(option)

Minimum gas consumption During the cutting process Highspeed Eco the flow-optimized
at higher sheet throughput touchdown nozzle seals the kerf. Gas consumption is reduced
and a higher sheet throughput is achieved with the associated
optimized technology parameters.

Fig. 88042

Prerequisites ■ Materials that can be processed and max. sheet thickness

that can be processed:
− Mild steel (N2): 4-12.7 mm
− Stainless steel (N2): 4-25 mm

B813en 2019-02-01 The most important options 3‐33

 Advantages ■ Up to 70% reduced gas consumption at up to 100% higher
sheet throughput.
■ Oxide-free cuts in mild steel up to 12.7 mm.
■ One nozzle (EAV 3.0) for the entire area of application.
■ Significantly higher feed rate compared to standard cutting
method.

4.6 Compressed-air cutting (option)

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

Advantages Economical cutting gas.

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

4.7 DetectLine (option)

DetectLine is an intelligent, camera-based measurement system

with the following functions:
■ Precise sheet position detection.
■ Automatic correction of focal position.

Precise sheet position It is particularly important for precut processing that the position
detection of the workpiece is precisely determined. This is the only way to
guarantee that other contours are cut into the workpiece with the
necessary precision.
With the aid of DetectLine, the workpiece position can be accu-
rately detected based on measurements on the inner contours or
on the outer sheet edges. Here an accuracy of up to ±0.1 mm is
achieved.
Standard gauge, rectangular sheets can also be detected with
DetectLine.

Advantages ■ Increased cut accuracy.

■ This saves time in comparison to manual workpiece meas-
urement.

3‐34 The most important options 2019-02-01 B813en

 Automatic correction of DetectLine extensively automates the correction of focal posi-
focal position tions.

Advantages ■ Consistently high cut quality.

■ No more potential operating errors, thanks to objective evalu-
ation of the kerf.
■ Significant time savings in comparison to manual evaluation
of the focus search program.

4.8 Automatic nozzle changer (option)

Function Using the automatic nozzle changer, nozzles are removed from
the cutting unit and replaced with different ones.

The nozzle changer can be used in the following cases:

■ Changeover to different material thicknesses.
■ Changes of materials.
■ Nozzle changes controlled by a program to prevent worn-out
nozzles from being used.
■ Other applications which necessitate nozzle replacements.

Design

1 Nozzle-cleaning brush 3 Nozzle holder

2 Calibration plate 4 Nozzle changer extension
Fig. 61830

B813en 2019-02-01 The most important options 3‐35

 ■ The nozzle changer has 18 nozzle holders for automatic noz-
zle change.
■ Positioning and lift motions are performed using the machine
axes.
■ The screwing in and out motions of the nozzle holders are
carried out by a central drive via a toothed belt.
■ The 18 nozzle holders are arranged linearly in 3 lines on the
nozzle changer.
■ The screwing-in of the nozzle into the ceramic part is torque
controlled.

Advantages ■ Minimum machine idle times: a programmed nozzle change

is carried out immediately after the program end.
■ No waiting times of the machine: the machine need not
"wait" till an operator changes the nozzle.
■ Increased process reliability: the change process is program-
controlled and thus performed without the operator's interven-
tion. In addition, replacement of worn nozzles is also pro-
gram-controlled and thus always on time.
■ Flexibility in unmanned multi-shift operation: unmanned oper-
ation is possible even in cases of a wide variety of large
parts and materials.
■ Ideal supplement to the one-cutting-head strategy.

4.9 Pipe cutting with RotoLas (option)

1 RotoLas with external support (support housing) 2 Parts cut with RotoLas
Fig. 69163

3‐36 The most important options 2019-02-01 B813en

Machining tubes and profiles The RotoLas tube cutting unit enables the processing of tubes
and profiles. This concept makes it possible to alternate between
tubes and flat workpieces when processing with the laser beam.
The machine can be quickly converted from flat to tube process-
ing due to the integration of the tube cutting facility in the
machine's frame.
Shorter tubes can be machined inside the machine with 100%
laser safety.
In order to support long tubes or tube profiles outside the safety
cabin and to guide them into the machining position inside the
safety cabin, there is an optional external support with the Roto-
Las option (support housing, external) with a length of 3 m or
6 m. Even the support housing doesn't let any laser through,
thereby guaranteeing complete safety.
The TruTops Tube production system from TRUMPF is available
for the programming of round and rectangular tubing.

Advantages ■ Processing sheets, tubes and profiles on a single machine.

■ Fast and simple conversion from flat to tubular processing.
■ Easy tube repositioning with external support.
■ With the extended travel range of the Z axis, conversion of
the cutting head is no longer necessary.

4.10 CoolLine (option)

The machine can be optionally equipped with the CoolLine func-

tion for water spraying.

Note
The CoolLine option is only possible with TruDisk 4001,
TruDisk 6001 and BrightLine fiber.

Cooling the processing point ■ Cooling of the process through targeted coaxial spraying of a
water-air mix around the processing point via a special noz-
zle.
■ The vaporization energy ensures strong local cooling of the
material around the laser beam.
■ The temperature remains nearly constant and thus ensures
high process reliability during laser cutting.
■ The cooling effect is greatly enhanced through the complete
vaporization of the water.
■ The demineralized water for cooling vaporizes completely
and thus does not cause any corrosion.

B813en 2019-02-01 The most important options 3‐37

 1 Laser beam 4 Integrated water supply
2 Cutting unit 5 CoolLine nozzle
3 Water fog (about 20 ml/min) 6 Workpiece
Principle of function with adjusted cutting unit and new noz- Fig. 73079
zles

Prerequisites ■ The CoolLine option is available.

■ Programming system TruTops, available from ≥ V5.0 with
service pack 2.

Advantages ■ The cutting process in mild steel is stabilized. This enables a

range of functional improvements.
■ Narrower parts distances are possible with identical material
quality.
− New geometries with thin webs are possible.
− Narrower allocation of parts reduces waste significantly.

4.11 Cleaning brush (option)

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

3‐38 The most important options 2019-02-01 B813en

 Advantages Enhanced process reliability: No impurities are to be found on
the sheet during processing.

4.12 Reconditioning cooling water with

Easy Filter (option)

Easy Filter: reconditioning For the maintenance of cooling circuits, there is an alternative to
instead of replacement the annual water change:
"Easy Filters" recondition used cooling water in such a way that
no water change is required any more.
The cooling water remains in the cooling circuit during recondi-
tioning, thus reducing cooling circuit maintenance work signifi-
cantly.

Exceptions Additional cooling water is still required in the following situa-

tions:
■ Cooling circuits with glycol.
■ Dirty tanks.
■ Cooling circuit KK4 (hot-water circuit) for energy-efficient
TruFlow lasers.

B813en 2019-02-01 The most important options 3‐39

 4.13 Clamps (option)

1 Pallet (3 m) 3 Calibration plate 5 Standard clamp positions

2 Pallet (4 m and 6 m) 4 Alternative clamp positions
Clamp positions Fig. 66904

Risk of collision caused by incorrect pin assignment of

NOTICE clamp positions!
Ø Do not use standard positions (Fig.66904, Pos. 5) when
using the nozzle changer (option) or RotoLas (option).

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

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

are specified in the following:
■ Very thin sheets of lightweight stainless steel can slip during
high-pressure cutting.
■ With small blanks, e.g. strips, since they can fall between the
support slats.

3‐40 The most important options 2019-02-01 B813en

 ■ When machining semifinished products, e.g. angle pieces, in
order to clamp the workpiece in a defined position for
machining.
■ With prepunched sheets and slightly curved sheets, since
they do not rest cleanly on the carrier slats and can therefore
slip during machining.

Note
When using the nozzle changer, the clamps may only be
mounted at the provided clamp positions (see Fig. 66904, Pos.
4)

Advantages ■ Secure fastening of very thin and lightweight stainless steel

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

4.14 Camera for process monitoring

(option)

Camera for process monitoring Fig. 87690

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

plays images of the working area and enables the monitoring of
the cutting process.
The second camera can be used to monitor both sides of the
machine. The entire working area within the machine can be
seen better with both cameras. This makes it easier to use
Drop&Cut (image-based post-production).

Advantages ■ Optimum control of the cutting process.

■ Optimum control of the cutting and unloading process

B813en 2019-02-01 The most important options 3‐41

 5. Industry 4.0 with TruConnect

5.1 What is Industry 4.0 at TRUMPF?

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

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

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

TruConnect With TruConnect, TRUMPF provides both the necessary interfa-

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

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

3‐42 Industry 4.0 with TruConnect 2019-02-01 B813en

 5.2 Production overview

Condition Guide The machine status is monitored with sensors and is displayed
in the "Condition Guide". This includes parameters of the cooling
unit, cutting system and laser. If a parameter is in the yellow or
red range, the operator receives a recommendation for what he
should do in order to return to the green range.
In addition, the future action needed can be estimated from the
previous course of the monitored parameters, e.g. when a value
continuously worsens. This way, the cutting capability of the
machine is maintained without interrupting production.

1, 2 Signal lamps 3 Recommended action 4 Progression diagram of the

quality value
Example: Condition Guide Fig. 81006

MobileControl app The machines can be monitored and controlled using an iPad
with the MobileControl app. The app transfers the user interface
of the control panel to the iPad touchscreen. The operator can
call up information at different locations in the work environment
of the machine or change the program.

B813en 2019-02-01 Industry 4.0 with TruConnect 3‐43

 It is also possible to access the user interfaces of other
machines that have been equipped with a Wireless Operation
Point.

WebCalculate With WebCalculate, customers can upload their drawings and

enter the material, quantity and processing type online, so that
they can have the manufacturing costs for their part calculated.
The calculation functions of TruTops Calculate can be accessed
via an additional web server which communicates with
TruTops Fab. This way, the time and costs for the overall pro-
duction process can be determined.

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

Example Fig. 78487

3‐44 Industry 4.0 with TruConnect 2019-02-01 B813en

 5.3 Production control

Dot Matrix Code Dot Matrix Code enables quick and reliable parts labeling with a
standardized industrial code.Parts with different sheet thickness
values and material types can be marked. Applied to a sheet,
the code contains information for the sheet metal process chain.
This simplifies production control significantly and the sheet
passes through the production chain with process reliability.

Sample part with a dot matrix code Fig. 75979

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

The following modules belong to TruTops Fab:

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

B813en 2019-02-01 Industry 4.0 with TruConnect 3‐45

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

5.4 Connectivity

The ability to establish connections between computers, systems

and networks is called connectivity.

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

Central Link overview Fig. 85015

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

3‐46 Industry 4.0 with TruConnect 2019-02-01 B813en

 The message interface outputs production data of the machine in
real time, thereby making system monitoring possible, e.g., with
TruTops Monitor.

MDA interface The signal-controlled MDA interface (Machine Data Acquisition)

outputs messages about the status of the machine, such as idle
states, error messages, causes of faults, pauses and mainte-
nance periods.
These messages can be evaluated via corresponding systems.
This way, an evaluation of the machine runtimes is also possible
for machines which do not have another software interface.

Factory Gate and Device Factory Gate and Device Gate network the machines in the com-
Gate pany network or the cloud.
Factory Gate connects entire device pools; Device Gate con-
nects individual devices.
The data is transferred from the on-site hardware to the Factory
Gate via a local network. This establishes a secure data connec-
tion to the online service and end devices on the Internet.

Factory Gate Fig. 85016

Wireless Operation Point The Wireless Operation Point is a wireless network connection of
the machine. This way, the machine's control can be accessed
externally, via the Mobile Control app for example. The machine
does not have to be integrated in the customer network here,
and the control is protected by a firewall.

B813en 2019-02-01 Industry 4.0 with TruConnect 3‐47

 5.5 Remote support

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

Visual Online Support Visual Online Support (VOS) can be used to establish a connec-
tion between a tablet PC or a smartphone and Technical Service.
Image, audio and video files can be exchanged with TRUMPF's
Technical Service via the existing remote support connection.
This way, even complex cases can be clarified without an on-site
service mission.

5.6 Digital enhancement of the TRUMPF

machines

Apps for displaying machine data Fig. 87687

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

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

3‐48 Industry 4.0 with TruConnect 2019-02-01 B813en

 The information will be provided in the following apps:

App Function
Live Status Shows the current status of the machines connected to the Cloud and informs users in
the event of an idle state. It provides access to the machine status from everywhere and
enables the remaining time of programs to be read.
Machine Analytics Indicates the machine data and statuses for the past three days. It indicates the operating
hours and when there were idle states or interruptions in the production process.
Program Analytics Shows the status of the programs started.
Material Analytics Shows which material and which volume of material has been processed in a specific
period of time.
Punching Tool Ana- This app indicates which tools are being used and how often and supports the user in
lytics selecting the standard tools. The strokes overview can help the user to decide when to
regrind a tool or order a new one.
Tab. 3-1

B813en 2019-02-01 Industry 4.0 with TruConnect 3‐49

 6. Safety

6.1 CE marking

Legal specifications TRUMPF confirms compliance with all requirements in accord-

areobserved ance with the following directives of the European Community
with the CE marking (CE = French Communauté Européenne)
and the corresponding EU Declaration of Conformity:
■ EC machinery directive.
■ EU directive on electromagnetic compatibility.
■ EC pressure equipment directive (depending on the machine
type).

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

■ No additional measures are required by the customer.

3‐50 Safety 2019-02-01 B813en

 7. Automation components and their
functions

The 2D laser cutting machines are high-speed laser cutting

machines for processing flat sheets with high precision. A flexible
automation concept has been developed by TRUMPF for auto-
mation of the loading and unloading processes.
This concept makes it possible to meet the requirements of the
customer specifically. The degree of automation of the machine
is adapted to the requirements of the customer.

Note
It is not possible to combine all machines with all automation
variants.

LoadMaster ■ Automatic loading.

■ Connection to storage possible via storage cart.

LiftMaster ■ Automatic loading and unloading.

■ Optional, separate depositing of scrap skeletons and finished
parts.
■ Connection to storage possible via storage cart.

SortMaster ■ Sorted depositing of finished parts.

■ Connection to storage possible via storage cart.

LiftMaster Compact ■ Automatic loading and unloading.

■ Space-saving installation.
■ Optional with PartMaster.
■ Connection to storage possible.

PalletMaster Tower ■ Fully automatic pallet change.

■ Integrated storage tower for pallets.

LiftMaster Linear Basic ■ Automatic loading and unloading from one or two machines.
■ Space-saving installation, short installation time.
■ Optional with PartMaster.
■ Connection to storage possible via storage cart.

LiftMaster Store ■ Automatic loading and unloading.

■ Optional, separate depositing of scrap skeletons and finished
parts.
■ Optional with synchronous loader.
■ Optional with PartMaster.
■ With connection to storage.

B813en 2019-02-01 Automation components and their functions 3‐51

 LiftMaster Store Linear ■ Automatic loading and unloading from one or several
machines.
■ Optional, separate depositing of scrap skeletons and finished
parts.
■ Optional with synchronous loader.
■ Optional with PartMaster.
■ With connection to storage.

LiftMaster Linear ■ Automatic loading and unloading from one or several

machines.
■ Optional, separate depositing of scrap skeletons and finished
parts.
■ Optional with PartMaster.
■ Connection to storage possible via storage cart.

LoadMaster LiftMaster (R) LiftMaster (RP) LiftMaster (R)

with the Sort
extension
Automatic loading x x x x
Automatic unloading - x x x
Separate unloading of maxi-parts - - - x
and scrap skeletons
Part sorting - - - -
Pallet operation - - x -
Connection to PartMaster - - - -
Multi-machine connection - - - -
Connection to storage via x x x x
storage cart
Direct connection to storage - - - -
Tab. 3-2

LiftMaster (RP) SortMaster LiftMaster PalletMaster

with the Sort Compact Tower
extension
Automatic loading x - x x
Automatic unloading x - x x
Separate unloading of maxi-parts - - - -
and scrap skeletons
Part sorting x x - -
Pallet operation - - x x
Multi-machine connection - - - -
Connection to storage via x x x -
storage cart
Direct connection to storage - - x -
Tab. 3-3

3‐52 Automation components and their functions 2019-02-01 B813en

 LiftMaster LiftMaster LiftMaster LiftMaster
Linear Basic Store Store Linear Linear
Automatic loading x x x x
Automatic unloading x x x x
Separate unloading of maxi-parts - x x x
and scrap skeletons
Part sorting - - - -
Pallet operation - x x x
Multi-machine connection x - x x
Connection to storage via x - - x
storage cart
Direct connection to storage - x x -
Tab. 3-4

7.1 Example

Fig. 64999

B813en 2019-02-01 Automation components and their functions 3‐53

 8. Technical data

TruLaser 3030 TruLaser 3040 (L50)

(L49)
Laser TruDisk 3001
TruDisk 4001
TruDisk 6001
Working ranges Working range X/Y axis 3000 x 1500 4000 x 2000 mm
mm
Working range Z axis without RotoLas: 115 mm
with RotoLas: 205 mm
Accuracy13 Maximum position range Ps max ±0.03 mm
Positioning deviation Pa ±0.05 mm
Smallest possible increment 0.001 mm
control TRUMPF CNC based on SINUMERIK 840D sl
Main memory PC 2 GB
Hard disk drive 2 x 160 GB
Color screen, TFT 17"
Monitor screen resolution 1280 x 1024 px
USB port Yes
Ambient temper- Permissible ambient temperature Standard version: +10 to 35°C
ature
Tropical version: +35 to 43°C
Dimensions Length 9300 mm 11400 mm
Width 5100 mm 6730 mm
Height 2400 mm

13 The positioning accuracy specifications are based on the entire work-

ing length. The positioning accuracy is inspected and approved at the
production facility in accordance with VDI/DGQ 3441.

3‐54 Technical data 2019-02-01 B813en

 TruLaser 3030 TruLaser 3040 (L50)
(L49)
Maximum Sheet Mild steel O2 20 mm (with TruDisk 3001)
Thickness
20 mm (with TruDisk 4001)
25 mm (with TruDisk 4001 and with BrightLine fiber)
25 mm (with TruDisk 6001)
Stainless steel N2 15 mm (with TruDisk 3001)
20 mm (with TruDisk 4001)
20 mm (with TruDisk 4001 and with BrightLine fiber)
20 mm (with TruDisk 6001)
25 mm (with TruDisk 6001 with BrightLine fiber)
Aluminum N2 15 mm (with TruDisk 3001)
20 mm (with TruDisk 4001)
20 mm (with TruDisk 6001)
25 mm (with TruDisk 6001 with BrightLine fiber)
Copper 6 mm (with TruDisk 3001)
8 mm (with TruDisk 4001)
10 mm (with TruDisk 6001)
Brass 6 mm (with TruDisk 3001)
8 mm (with TruDisk 4001)
10 mm (with TruDisk 6001)
Titanium 4 mm (with TruDisk 3001)
4 mm (with TruDisk 4001)
4 mm (with TruDisk 6001)
Technical specifications of the TruLaser 3030 (L49), TruLaser 3040 (L50) Tab. 3-5

B813en 2019-02-01 Technical data 3‐55

3‐56 Technical data 2019-02-01 B813en
 Chapter 4

Operation

1 Description of the operating elements 4‐8

1.1 Operating elements outside the control panel 4‐8
1.2 Operating elements on the start post 4‐8
1.3 Operating part at the control panel 4‐11
1.4 USB port 4‐15
1.5 Keyboard 4‐15
1.6 User interface 4‐16
Status line 4‐16
Message bar 4‐17
Login status 4‐18
TRUMPF logo 4‐18
Main menus 4‐19

2 User administration 4‐22

2.1 Log on user group 4‐23
2.2 Change password 4‐24
2.3 Deleting the password 4‐24

B813en 2019-02-01 Operation 4‐1

 3 Switch the machine on and off 4‐25
3.1 Unlock EMERGENCY STOP push-button 4‐25
3.2 Switching on the machine 4‐25
3.3 Switching off the machine 4‐26
3.4 Automatic switch on and shutdown 4‐26
Activating/deactivating auto-shutdown 4‐26
Activating/deactivating auto-switch on 4‐27

4 Activating the energy-saving mode 4‐28

4.1 Activating the energy-saving mode via "Laser 4‐29
energy-saving mode"
4.2 Activate energy-saving mode via "Automatic 4‐30
shutdown, machine+laser"

5 Water temperature monitoring 4‐31

6 Basic settings 4‐32

6.1 Calibrate the touchscreen 4‐32
6.2 Set language, measuring system, date and 4‐33
time
6.3 Activate the on-screen keyboard 4‐33
6.4 Open TRUMPF Operating System (TOS) 4‐34
6.5 Online Update Manager 4‐34
Call up Online Update Manager (on 4‐34
machines with TOS)
Switch off Online Update function 4‐36
6.6 To show the installed options 4‐36
6.7 Close user interface 4‐37
6.8 Switching to the TruControl interface 4‐38

7 Production 4‐40
7.1 Prepare program 4‐40
7.2 Execute program 4‐41
7.3 Switching the view for programs 4‐42
7.4 Pause program 4‐43
7.5 Aborting a program 4‐43
7.6 Carry out post-production 4‐44
7.7 Show status 4‐44
Machine 4‐44
Automation 4‐45

4‐2 Operation 2019-02-01 B813en

 7.8 Triggering the manual transport procedure 4‐47
(automation)
7.9 Viewing active travel to storage (automation) 4‐48

8 Working with the production plan 4‐49

8.1 Creating a single job 4‐51
8.2 Create job for automatic systems 4‐53
For systems without connection to storage 4‐53
For systems with connection to storage 4‐54
For systems with SortMaster 4‐56
8.3 Modifying jobs 4‐57
8.4 Creating production packages 4‐58
8.5 Modifying the sequence of the jobs in the pro- 4‐58
duction plan
8.6 Preparing production plan/tool setup check 4‐59
Starting tool setup check during non-pro- 4‐60
ductive time
8.7 Starting a production plan 4‐60
8.8 Pause (stop) production plan 4‐60
8.9 Resuming production plan after a malfunction 4‐62
Correct error in the inventory management 4‐62
Correct malfunction at a component 4‐63
8.10 Disabling job in the production plan 4‐63
8.11 Deleting a job from the production plan 4‐63
8.12 Stocks 4‐64
Creating inventory 4‐65
Modifying inventory 4‐66
8.13 Manual handling (option) 4‐66
Manually loading the sheet 4‐67
8.14 Manual sorting (option) 4‐67
Manually sort parts 4‐67
8.15 Displaying the status in currently running pro- 4‐67
duction plan
8.16 Production options 4‐68
Manual loading of raw sheet 4‐68
Manually unloading the sheet 4‐69
Manually remove the small part. 4‐69
Single pallet mode 4‐69
8.17 Execution with intermediate storage (option) 4‐70
Creating a job with intermediate layer 4‐70
8.18 Preparatory loading (option) 4‐70
Activating preparatory loading 4‐70

B813en 2019-02-01 Operation 4‐3

 9 Flexible entry into the program 4‐71
9.1 Restarting the program after an interruption 4‐72
Entry at the point of interruption 4‐72
Entry at a piercing 4‐74
Entering at a specific part 4‐75

10 Manually adjust technology parameters 4‐77

10.1 Select technology 4‐77
10.2 Loading 4‐78
10.3 Program properties 4‐79
10.4 Sheet technology 4‐79
10.5 Measuring sheet position 4‐80
10.6 Laser technology 4‐81
10.7 Microjoint 4‐82
10.8 Tube technology (RotoLas) 4‐83
10.9 Load tube (RotoLas) 4‐85
10.10 Part technology (RotoLas) 4‐85
10.11 Edge technology (RotoLas) 4‐86
10.12 Loading sheet (automation) 4‐88
10.13 Removal (automation) 4‐89
Small part removal - receiver 4‐90
Small part removal - palletizing 4‐91
Maxi part removal - receiver 4‐92
10.14 Skeleton separation (automation) 4‐93
10.15 Unload scrap skeleton (automation) 4‐93

11 Manual functions 4‐95

11.1 Using manual functions 4‐95
11.2 Engraving 4‐95

12 Move the zero point of the NC program 4‐97

12.1 Defining the new zero point 4‐97
12.2 Deleting "Offset zero point" 4‐97

13 Setup 4‐98
13.1 Moving the axes manually 4‐98
13.2 Releasing brakes for the Z axis drive 4‐99
13.3 MDA 4‐99
Creating NC programs block-by-block 4‐99
13.4 Activating or deactivating cleaning brush 4‐100

4‐4 Operation 2019-02-01 B813en

 14 Multiple-machine operation with TruTops 4‐101
FMC
14.1 Master/Slave operation 4‐101
Execute an Master/Slave switch 4‐101
Switching off the LiftMaster 4‐102

15 Managing NC programs 4‐104

15.1 Load master file (NC program) in the internal 4‐105
management system
15.2 Editing NC programs 4‐105
Enter NC program in the editor 4‐106
Create NC sub program 4‐106
Modifying tests in the NC program 4‐108
Modifying technology tables in the NC pro- 4‐108
gram
Searching and replacing in the NC program 4‐109
Renumbering program blocks 4‐110
15.3 Output (export) NC program as master file 4‐110
15.4 Deleting NC program 4‐111
15.5 Copying a NC program 4‐112

16 Creating programs 4‐113

16.1 Process part 4‐113
Add a part to the partlist 4‐113
Process part 4‐113
16.2 Generate program 4‐115
16.3 Managing parts 4‐116
Manage files 4‐116
Delete files or clear folder 4‐116

17 Multi-sheet processing 4‐117

17.1 Edit several sheets 4‐117

18 Drop&Cut image-based post-production 4‐119

(option)
18.1 Start image-based post-production 4‐119

19 MobileControl app (option) 4‐121

19.1 Safety: MobileControl App 4‐122
19.2 Operating procedure 4‐122

B813en 2019-02-01 Operation 4‐5

 19.3 Making settings 4‐124
19.4 Activating or deactivating the MobileControl 4‐125
app
19.5 Backup during service work 4‐125
19.6 Name for identification of the machine 4‐126
19.7 Setting up and connecting WLAN 4‐126
19.8 Wireless operation point – WLAN network of 4‐127
the machine
Changing the settings on the wireless oper- 4‐128
ation point

20 Wireless operation point 4‐129

20.1 Changing the settings on the wireless opera- 4‐129
tion point

21 Operating CoolLine 4‐130

21.1 Select technology table 4‐130

22 Smart Collision Prevention 4‐131

22.1 Use in TruTops 4‐131
Activation in TruTops Boost HERE2 4‐131
Activation in TruTops Laser 4‐132
22.2 Configuring Smart Collision Prevention 4‐132
22.3 Notes on use on the machine 4‐133
Restrictions 4‐134

23 Operation of automatic nozzle changers 4‐135

(option)
23.1 The replacement procedure 4‐135
23.2 Translating axes 4‐135
23.3 Manual functions 4‐136
23.4 Nozzle management 4‐137
Nozzle holder allocation 4‐138
23.5 Tooling dialog in the production plan 4‐140
23.6 Defining the service life of the nozzles 4‐141
23.7 Loading nozzle changers 4‐142
23.8 Canceling an automatic nozzle change 4‐143
23.9 Minimizing and/or preventing malfunctions and 4‐144
failures
Examples of damaged nozzles and ceramic 4‐145
bodies
Example of a damaged nozzle holder 4‐145

4‐6 Operation 2019-02-01 B813en

 24 Diagnostics 4‐147
24.1 Pending messages 4‐147
Displaying alarm and warning messages 4‐147
24.2 History of messages 4‐147
Displaying message history 4‐147
24.3 Condition Guide 4‐148
Showing signal lamps for monitored proper- 4‐148
ties
24.4 Displaying software versions 4‐148

25 Help when problems arise 4‐149

25.1 Switch off the machine if malfunctions occur 4‐149
25.2 Activating remote support 4‐149
25.3 Start Visual Online Support (option) 4‐150
25.4 Measures after a collision detection 4‐152
25.5 Conversion software 4‐153
25.6 Performing spot image 4‐153
Recording a spot image 4‐153

B813en 2019-02-01 Operation 4‐7

 1. Description of the operating elements

1.1 Operating elements outside the

control panel

Operating element Conditions Description

- Switches the machine's power supply on or off.

MAIN SWITCH
- Lights up if the protection door is locked.
Unlocks the protection door. The protection door can be opened.

OPENING THE
SAFETY DOOR
Tab. 4-1

1.2 Operating elements on the start post

Systems where the pallet changer is set up transversely to the

machine (transverse layout) are not equipped with an additional
start post. The working range of the pallet changer can be
viewed from the control panel of the machine.

Fig. 61264

4‐8 Description of the operating elements 2019-02-01 B813en

 1 Key switch enabling mode 2 Pulse trigger switches
Start post with key switch (enabling mode) Fig. 90985

Operating element Conditions Description

- EMERGENCY STOP push-button
■ The power supply to the entire system is disconnected (the
24 V control voltage is maintained).
− All axis motions stop.
− All drives are switched off electrically.
EMERGENCY ■ The processing is interrupted:
STOP push-button
− The laser beam is switched off.
− The beam block is closed.
− The gas supply of the cutting gas is interrupted.
− An active program is aborted and must be restarted, if
required.
− The machine's home position has to be approached.
− The reference points of the axes are retained.
■ The hydraulic unit, the compact dust extractor and the length-
wise and/or transverse conveyor, respectively, are switched off.
■ All pneumatic movements are stopped or transferred to a dan-
ger-free state. The compressed air supply remains unaffected.
■ Vacuum remains.
- Key switch for ENABLING MODE:
If an automation component should fail, the key switch must be
Key switch for ENA-
turned to the right in order to be able to carry out the pallet
BLING MODE:
change in enabling mode.

B813en 2019-02-01 Description of the operating elements 4‐9

Operating element Conditions Description
The safety circuit of Enable key:
the automation com-
If a travel command is pending, both enable keys on the start post
ponent is inter-
will flash.
rupted.
<Enable key>
Press both enable keys until the pallet changer has reached its
No-one is present in
end position.
the danger zone.
- Flashes when the safety light barrier which shields the pallet
changer is interrupted.

LIGHT BARRIER Reactivate the light barrier:

INTERRUPTED ■ Machine with longitudinal layout: press the ACKNOWLEDGE
THE LIGHT BARRIER foot switch at the start pedestal.
■ Machine with transverse layout: press LIGHT BARRIER INTER-
RUPTED on the control panel.
Continue the paused movements of the pallet changer: press
START.
No errors present. Flashes when FEED HOLD is present.
The light barrier has Acknowledge FEED HOLD. Paused movements of the pallet
been acknowledged. changer are continued.
PLAY / START
- Is illuminated when pressed.
Lights up if FEED HOLD is triggered.
Stops all movements of the pallet changer.
FEED HOLD
Processing in the machine continues.
Further movements are not possible while FEED HOLD is active.
Acknowledge the active FEED HOLD: press START.
- Flashes when a pallet from the machine has reached its loading/
unloading position. The control waits for the loading acknowledge-
ment.

ACKNOWLEDGE The pallet changer moves to the tool-change height by pressing

PALLET CHANGER the flashing button. The next time the program is called, a pallet
change will be carried out automatically.
- Reactivate the light barrier for the securing of the pallet changer.

ACKNOWLEDGE
THE LIGHT BAR-
RIER
Tab. 4-2

4‐10 Description of the operating elements 2019-02-01 B813en

 1.3 Operating part at the control panel

1 USB connection 4 Button for control panel height

2 Operating elements adjustment
3 Beam block key switch 5 Keyboard
6 User interface with touchscreen
Fig. 72931

B813en 2019-02-01 Description of the operating elements 4‐11

Operating element Conditions Description
- Push-button EMERGENCY STOP:
■ The power supply to the entire system is disconnected (the
24 V control voltage is maintained).
− All axis motions stop.
− All drives are switched off electrically.
■ The processing is interrupted:
− The laser beam is switched off.
− The beam block is closed.
− The gas supply of the cutting gas is interrupted.
− An active processing program is aborted and needs to be
restarted, if required.
− The machine's home position has to be approached.
− The reference points of the axes are retained.
■ The hydraulic unit, the compact dust extractor and the length-
wise and/or transverse conveyor, respectively, are switched off.
■ All pneumatic movements are stopped or transferred to a dan-
ger-free state. The compressed air supply remains unaffected.
■ Vacuum remains.
For switching on: Switches the machine On.
■ The button ■ Lights up when the machine is ready for operation.
MACHINE ON/OFF flashes.

Switches the machine Off.

■ Goes out when machine switched off.

Machine Off is also triggered by:

■ EMERGENCY STOP push-button.
■ errors which trigger an EMERGENCY STOP.
Scrolls a list up/down.

PAGE UP/PAGE
DOWN
Increases/decreases the view.

MAGNIFYING
GLASS
Locks touch-screen operation, e.g. to clean the screen.

TOUCHSCREEN
Switches between applications, e.g. between the TRUMPF Operat-
ing System (TOS) and the user interface.

CHANGE OF
APPLICATION

4‐12 Description of the operating elements 2019-02-01 B813en

Operating element Conditions Description
Moves the cursor to the next input field.

TAB
- Is lit if the machine is in test mode.
The selected processing program will run without the laser beam
LASER TEST being ignited.

- Starts the automatic switch-on cycle of the laser:

■ Flashes while the switch-on cycle is being carried out.
LASER ON/OFF ■ Is lit if the laser is ready for operation.

Starts the automatic switch-off cycle of the laser:

■ Flashes while the switch-off cycle is being carried out.
■ Goes out when machine switched off.
The main operation Flashes when the safety light barrier which shields the pallet
Setup is activated. changer is interrupted.

Status display: EMERGENCY Reactivate the light barrier: press the ACKNOWLEDGE THE
SAFETY LIGHT STOP is not active. LIGHT BARRIER foot switch on the start pedestal. Then press
BARRIER INTER- START button on the control panel.
No FEED HOLD is
RUPTED active. Continue the paused movements of the pallet changer: press
START.
- Controls the travel speed of the X and Y axes between 4 and
120%:
■ The travel regulation in the main operation Production is 4-100
m/min.
■ The travel regulation in the main operation Setup is 4-15 m/min
FEEDRATE POTEN- with simultaneous axis motion.
TIOMETER
- Moves the selected NC axes in the (+) or (-) direction.
■ Moves the axes in the +/- direction.
■ The plus/minus buttons increase/reduce the value of "Manual
functions" with the symbol ±.
NAVIGATION KEYS
- Deletes active fault messages.
Cancels an active program.
RESET (STOP) Resets the control to switch-on condition.
The reference points are maintained.
The home position might be lost.

B813en 2019-02-01 Description of the operating elements 4‐13

Operating element Conditions Description
- Is illuminated when pressed.
Lights up if FEED HOLD is triggered.
FEED HOLD ■ All axis motions stop.
(PAUSE) ■ The processing is interrupted:
− The laser beam is switched off.
− The beam block is closed.
− The gas supply of the cutting gas is interrupted.
− An active processing program is paused and can be further
executed by acknowledging.
■ The hydraulic unit, the compact dust extractor and the length-
wise and/or transverse conveyor, respectively, are switched off.
■ All pneumatic movements are stopped or transferred to a dan-
ger-free state. The compressed air supply remains unaffected.
■ Vacuum remains.
Acknowledge the active FEED HOLD: press START.
No errors present. Flashes if an error is present or a FEED HOLD has been triggered
(for example, by interrupting the safety light barrier).
The light barrier has
been acknowledged. Acknowledges active error.
ACKNOWLEDGING
FEED STOP (FEED Acknowledge FEED HOLD.
START)
No errors present. The START button has the following functions depending on the
main operation selected:
Machine is ready to
operate. ■ If the Set up main operation is selected: the machine moves to
START (PROGRAM the home position without starting to execute the production
START) plan or the selected processing program.
■ For all other main operations: the machine moves to the
home position and starts executing the production plan or the
selected processing program.
- OPERATING MODE key switch.

Service mode is activated by turning the switch to position 1:

■ All drives are switched off.
■ The beam block is closed.
■ The beam trap can be opened using "Open/close beam trap".
■ Using the PULSE TRIGGER SWITCH, the laser beam can be
ignited with opened beam trap.
■ Using BEAM ON/OFF, the laser beam can be switched on with
the beam trap closed.
Service mode is only needed during service work for laser pro-
tection class 4.
The safety circuit of the laser is interrupted by turning the switch to
position 1.
The laser beam cannot be ignited if the beam block is active and
the key has been removed.
Safety-Mode is activated by turning the switch to position 1.
Tab. 4-3

4‐14 Description of the operating elements 2019-02-01 B813en

 1.4 USB port

If there is no direct connection between programming system

and machine, the data transfer can take place via the USB inter-
face. The USB port is on the rear side of the control panel (left
side, below).

1.5 Keyboard

Key Description
<F1> Opens the documentation.
<F2> to <F9> Executes the allocated softkey (bottom edge of the user interface).
<F10> Moves the cursor in the menu bar. <F10> corresponds to the FOCUS MENU
button.
<F11> Opens the subject blocks of the menu bar. <F11> corresponds to the FOCUS
button.
<Backspace> Moves the cursor one character to the left each time it is pressed. The charac-
ter to the left of the cursor is deleted.
<Tab> Switches among various screen areas within a mask (input fields, selection
fields, etc.). <Tabulator> corresponds to the FOCUS button.
<Caps Lock> Sets the keyboard to Caps Lock. By pressing again, the function is canceled.
<Enter> Confirms/saves entries.
<Shift> Activates the second key assignment or the capital letter as long as <Shift> is
pressed.
<Insert> Pastes cut or copied contents.
<Delete> Deletes contents.
<Home> Moves the cursor to the beginning of a text line.
<End> Moves the cursor to the end of a text line.
<Page up / Page down> Scrolls among pages.
Cursor Moves the cursor.
<NUM> Activates the number pad on the operating panel.
If the key is active, the relevant LED on the keyboard lights up.
Special keys Tab. 4-4

B813en 2019-02-01 Description of the operating elements 4‐15

 1.6 User interface

1 Login status 5 Message line

2 TRUMPF logo 6 Sub-operations
3 Main activity 7 Context buttons
4 Status bar
Example: TruLaser with touchscreen Fig. 58615

Status line

Symbol Description
Home position missing.

Home position has been established.

Light barrier has been interrupted.

Program is running.

Program status: Pause.

Processing can be continued with .

Program is interrupted.
For further processing, flexible entry into the program
must be carried out.
Laser beam is off, beam trap (TruFlow) or absorber
(TruDisk) is closed.

4‐16 Description of the operating elements 2019-02-01 B813en

 Symbol Description
Laser beam is off, beam trap (TruFlow) or absorber
(TruDisk) is open.

Laser beam is ignited, beam trap (TruFlow) or

absorber (TruDisk) is closed.

Laser beam is ignited, beam trap (TruFlow) or

absorber (TruDisk) is open.

Laser beam is OFF, beam block is active.

Touchscreen is not active.

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).

There are information messages (their quantity is

shown next to the symbol).

Maintenance work is pending.

AdjustLine increased material tolerance is active.

Post-production is active.

Tab. 4-5

Note
The status symbols for the production plan are listed in the pro-
duction plan section (see "Working with the production plan",
pg. 4‐49).

Message bar

The message line is divided into four areas and is used to dis-
play information (gray), warnings (yellow) and error messages
(red):
■ Time when the message was issued.
■ The corresponding message number.

B813en 2019-02-01 Description of the operating elements 4‐17

 ■ A brief description of the message that appeared.
■ Source of the error: Control or machine component that
caused the error message.

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

Login status

Three pieces of information are displayed to the right, next to the

status bar and message line:
■ User who is currently logged in.
■ Current date.
■ Current time.

TRUMPF logo

User Log Off: Press on the TRUMPF logo.

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

When the information displayed in the login status is pressed,

the following parameters are displayed, which can be changed, if
required:
■ Information about the logged-in user
■ Language.
■ Measuring system.
■ On-screen keyboard.
■ Information about the system:
− Date and time.
− Regional settings.
− Calibrate the touchscreen.
− Exit the HMI.
− Shut down the machine.

4‐18 Description of the operating elements 2019-02-01 B813en

 Main menus

Main activities Functions in the main operation

Main operation Production plan

"Production plan" tab:

■ Create and modify jobs.
■ Prepare orders.
■ Enabling jobs.
■ Starting, interrupting and stopping jobs.
■ Deleting jobs with or without the associated program.
■ Displaying job details, program details and status of the cell.
■ Carry out the technology correction.

"Stock" tab:
■ Creating, modifying and deleting inventories.

"Manual handling" tab (option):

■ Execute production plan with manual loading/unloading by the operator.
■ Confirm manual working steps.

"Manual sorting" tab (option):

■ Execute production plan with manual sorting by the operator.
■ Confirm manual working steps.

"Production overview" tab:

■ Have the runtimes displayed.

"Production options" tab:

■ Activate/deactivate automation components.
■ Select single-pallet operation.

B813en 2019-02-01 Description of the operating elements 4‐19

Main activities Functions in the main operation
Main operation Production:

"Current program" tab:

■ Select the program to be run.
■ Carry out a zero point offset.
■ Carry out a flexible entry into the program.
■ Carry out technology correction for the current program.
■ Carry out post-production.

"Prepare a program" tab:

■ Importing programs.
■ Correct technology by programs.

"Machining options" tab:

■ Activate/deactivate AdjustLine for adjusting the cutting process for thicker materi-
als.

"Manual functions" tab:

■ Activate manual functions.

Tab "Laser machine" (option):

■ View the status of the laser machine.

"Automation" tab:
■ Viewing the status of the various components within the system.
■ Carry out manual transport operations with the automation components.
Main operation Setup:
■ Move axes manually (active only with control system: Stop).
■ Activate manual functions.
■ MDA: Create and execute NC programs block-by-block.
Main operation Programming:

"Manage programs" tab:

■ Import and export programs.
■ Copy, rename and delete programs.
■ Edit existing programs.

"Create programs" tab:

■ Process part.
■ Generate program.
■ Manage parts.
Main operation Technology:
■ Change the laser technology parameters.
■ View information about the cutting head.

4‐20 Description of the operating elements 2019-02-01 B813en

Main activities Functions in the main operation
Main operation Maintenance & start-up.

Main operation Diagnostics:

■ Display warnings, alarms and information messages.
■ Sort messages.
■ Display software versions.
■ Display digital inputs and outputs.
■ Carry out remote diagnostics.
The Diagnostics button flashes when a new warning or alarm is received.
Main operation Help:
■ Search.
■ Index.
■ Bookmark.
Tab. 4-6

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

Sub-operations Each main operation can consist of several sub-operations

(tabs).

B813en 2019-02-01 Description of the operating elements 4‐21

 2. User administration

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

"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.
"Technical Serv- Complete access to all of the machine's functions.
ice"
User groups (standard configuration) Tab. 4-7

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 "Technical Service").
When the machine is delivered, only the "Technical Service" user
group is password protected.

4‐22 User administration 2019-02-01 B813en

 2.1 Log on user group

Conditions
■ Password is known.
■ Machining is not active.

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

2. Press the Log off button.

1 User group
Selecting the user group Fig. 74129
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.

B813en 2019-02-01 User administration 4‐23

 2.2 Change password

Conditions
■ Machining is not active.
■ Password is known.

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

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

2.3 Deleting the password

Conditions
■ Machining is not active.
■ Password is known.

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

2. Press the Change password button.
3. Enter the old password.
4. Press OK.

4‐24 User administration 2019-02-01 B813en

 3. Switch the machine on and off

3.1 Unlock EMERGENCY STOP push-

button

The EMERGENCY STOP push-buttons are located on the

control panel of the laser machine and on the start post of the
pallet changer.

Ø To release the EMERGENCY STOP push-button, press it in

and turn it counter-clockwise.

3.2 Switching on the machine

Conditions
■ EMERGENCY STOP is released.
■ Nobody is within the machine's danger zone.

1. Turn the gas supply on.

2. Switch on the air supply.
3. Turn the MAIN SWITCH to I.
The machine control will start up. This may take some time.
The start page of the user interface will appear.
4. Press LASER ON/OFF .
LIGHT BARRIER INTERRUPTED lights up on the control
panel and on the start post of the pallet changer.
5. Press the ACKNOWLEDGE THE LIGHT BARRIER FOOT
SWITCH at the start pedestal.
For machines with transverse layout: press the ACKNOWL-
EDGE THE LIGHT BARRIER foot switch on the control
panel.
The FEED HOLD button lights up. START flashes.
6. To acknowledge FEED HOLD : press ACKNOWLEDGE
FEED HOLD .
The MACHINE ON/OFF button flashes.
7. Press MACHINE ON/OFF .
The axes move to home position, whereby first the Z axis and
then the X and Y axes move into home position.
Pallet changer moves to home position.

B813en 2019-02-01 Switch the machine on and off 4‐25

 3.3 Switching off the machine

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

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

the laser control system is switched off.
The LASER ON/OFF button flashes. The automatic shutdown
cycle is started.

2. Wait until the message appears that the laser control system
is switched off.
3. Press MACHINE ON/OFF .
4. Turn the MAIN SWITCH to 0.
5. Switch off the air supply and lock it.
6. Switch off the gas supply (except nitrogen).

3.4 Automatic switch on and shutdown

Activating/deactivating auto-shutdown

Auto-shutdown is only practical in combination with machine

automation for unmanned operation.

The machine will be automatically switched off in the following

cases:
■ If a program or "job end" is pending for longer than 10
minutes.
■ If no axis moves for 10 minutes.

1. Press Production, "Additional functions".

2. If auto-shutdown is not active: press Activate switch off.
If auto-shutdown is active, the button MACHINE ON/OFF
( ) will flash quickly.
3. To deactivate the auto-shutdown: press Deactivate switch off.

4‐26 Switch the machine on and off 2019-02-01 B813en

 Activating/deactivating auto-switch on

Auto-switch on is only practical in combination with machine

automation for unmanned operation.

Condition
■ The MAIN SWITCH is turned on.

Showing additional functions 1. Press Production, "Additional functions".

Activating auto-shutdown Note

To activate auto-switch on, auto-shutdown must be active.
2. If necessary, press Activate switch off.
If auto-shutdown is active, the button MACHINE ON/OFF
( ) will flash quickly.

Activating auto-switch on 3. Select the desired day.

4. Enter the time and select the "active" checkbox.

B813en 2019-02-01 Switch the machine on and off 4‐27

 4. Activating the energy-saving mode

Energy-saving mode can be activated to save energy during

machine idle times. If the laser is in energy-saving mode, the
machine can not be used for production.
The water temperature monitoring remains active during energy-
saving mode.
There are two possibilities to switch the laser control system into
energy-saving mode:

Using the "Laser energy-saving mode" manual function:

■ Drives are switched off.
■ The laser control system is switched into energy-saving
mode.
■ Water temperature monitoring is active.
■ The light is switched off.

Using the Auto-shutdown, machine+laser manual function:

■ Running programs continue to be processed until the pro-
gram end. After the end of the program, the drives are
switched off and the laser control system is switched into
energy-saving mode.
■ After an error (for example, after a collision), the machine
and the laser control system are switched to optimized
standby mode ten minutes (default setting) after the last axis
motion.
■ Water temperature monitoring is active.
■ The light is switched off.

4‐28 Activating the energy-saving mode 2019-02-01 B813en

 4.1 Activating the energy-saving mode
via "Laser energy-saving mode"

Condition
■ Drives are switched off.

1 "Manual functions" tab 3 Laser energy-saving mode

2 List of manual functions 4 Main activity
Fig. 66902

1. Press the Setup(4) main operation.

2. Press "Manual functions"(1).
3. Use to open the list of manual functions (2).
4. Select Laser machining.
5. Press "Laser energy-saving mode".

B813en 2019-02-01 Activating the energy-saving mode 4‐29

 4.2 Activate energy-saving mode via
"Automatic shutdown, machine
+laser"

1 "Manual functions" tab 3 Automatic shutdown, machine

2 List of manual functions +laser
4 Main activity
Fig. 66901

1. Press main operation Production(4).

2. Press "Manual functions"(1).
3. Use to open the list of manual functions (2).
4. Select General.
5. Press "Automatic shutdown, machine + laser"(3).

4‐30 Activating the energy-saving mode 2019-02-01 B813en

 5. Water temperature monitoring

The water temperature is monitored and, if necessary, regulated

by the laser control system to protect the laser device from
freezing. This function keeps the water temperature constant in a
predefined temperature range.
Water temperature monitoring is activated as soon as the system
is switched on. This function remains active even when the
machine and the laser device have switched to optimized
standby mode.

Danger of freezing when the machine is switched off.

NOTICE
After switching off the machine using the MAIN SWITCH on
the electrical cabinet, the water temperature monitoring is
no longer active!
Ø Leave the MAIN SWITCH at position "1" to ensure the water
temperature monitoring remains activated.

Danger of freezing due to improper installation of the

NOTICE process cooler.
Outdoor installation of the process cooler is not permitted.
The "water temperature monitoring" function does not
provide protection against freezing if the process cooler is
installed outdoors.
Ø Do not install the process cooler in areas with a risk of
freezing.

B813en 2019-02-01 Water temperature monitoring 4‐31

 6. Basic settings

6.1 Calibrate the touchscreen

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

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

Condition
■ Locking the touchscreen may not be pressed.

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

The dialog "Settings" is displayed.
2. Press "System", Touchscreen calibration.
The following dialog will be displayed:

Calibrate touchscreen: one of the destinations Fig. 38281

Note
Do not press on the middle of the screen!
3. Assume the normal operating position and press on the dis-
played target positions one after the other.
4. To confirm the setting: press the button with the green check
mark.
5. Press Apply.

4‐32 Basic settings 2019-02-01 B813en

 6.2 Set language, measuring system,
date and time

Adopt changes 1. Press the date on the user interface next to the TRUMPF
logo.
"Settings" appears.
2. Modify entries and press OK.
The modifications are accepted.

6.3 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. 4-8

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

The dialog "Settings" is displayed.

B813en 2019-02-01 Basic settings 4‐33

 2. Under "User", 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.

6.4 Open TRUMPF Operating System

(TOS)

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

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

6.5 Online Update Manager

If a machine is online, TRUMPF will make suitable software

updates available via a portal.

Call up Online Update Manager (on

machines with TOS)

Condition
■ The machine must be connected to the Telepresence portal.

Open the Trumpf Operating 1. Press Change of application .

System (TOS) ■ The user interface is not closed.
■ The "TRUMPF Operating System - TOSPRO Base" dia-
log is displayed.

4‐34 Basic settings 2019-02-01 B813en

 1 Operator 3 "Network" dialog
2 Network
TRUMPF Operating System Fig. 87656
2. Press Operator, Network ....
The "Network..." dialog appears.

Start the Online Update Tool 3. Select Online Update Manager.

■ The "TRUMPF Online Update" dialog appears.
■ If no updates are available, the following dialog is dis-
played: No updates available. Your system is up to date!
(No updates available. System is up to date.)
■ If updates are available, the following dialog is displayed:
Available updates (Available updates).

Notes
■ Suitable updates for the machine are made available by
TRUMPF and downloaded. Updates in the state Down-
loaded (downloaded) can be installed.
■ You can decide whether downloaded updates should be
installed immediately or at the next restart.
■ Updates marked Service package(Service package)
are complex and can only be installed by TRUMPF Serv-
ice.

B813en 2019-02-01 Basic settings 4‐35

 1 Now (install immediately) 3 Service package (can only
2 On Reboot(installable at be installed by Technical
restart) Service)

Dialog: "Available updates" (available updates) Fig. 91414

4. Under "Install Updates"(Install updates) Select Now (Now) or
On Reboot (On Reboot).

Switch off Online Update function

1. In the "TRUMPF Online Update" dialog, press the "Settings"

symbol.
2. Under "Settings" (Settings): Switch off "Automatic Online
Update" (Automatic Online Update).
3. Press Apply (Apply).

6.6 To show the installed options

In the TRUMPF Operating System (TOS), the options installed

on the machine (licenses) and their license periods are dis-
played.

1. Open TOS (see "Open TRUMPF Operating System (TOS)",

pg. 4‐34).

4‐36 Basic settings 2019-02-01 B813en

 1 Operator 3 "Network" dialog
2 Network
TRUMPF Operating System Fig. 87656
2. Press the Operator button (1).
3. Press the Network button (2).
The "Network" dialog (Fig. 87656, pos. 3) is shown.
4. Choose TRUMPF License Expert Basic Edition and then
press Start.
■ The "Licenses" dialog is shown.
■ The available options and their runtime will be shown.

6.7 Close user interface

The user interface for the machine control system is called HMI
(Human Machine Interface).

B813en 2019-02-01 Basic settings 4‐37

 Fig. 75037

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

The dialog "Settings" is displayed.
2. Select "System" tab.
3. Press Exit.
4. Either
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.

6.8 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.

4‐38 Basic settings 2019-02-01 B813en

 3. Press Laser Application.
The user interface TruControl will open.

B813en 2019-02-01 Basic settings 4‐39

 7. Production

7.1 Prepare program

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

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

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

2. "Select storage location":
− Activate : at "Program name", all programs are listed
that have already been split up and stored in the
program management of the control.
− Activate : enable access to drives that have been set
up. At "Path", select with and select the desired
drive. At "Folder", the folder structure within the drive is
shown. At "Designation", the programs are shown that
are contained in the respective folder.
3. To import programs from one drive to the internal program
administration: press Import.
The "Program selection" screen is shown.
4. If need be, the first letters of the program being searched for
can be entered at "Filter". Only those program names are
shown that start with the entered letters.
Press to delete the input and to show the original selec-
tion.
5. Activate one or several programs.
6. To import all programs: press Select all.
7. Press Import.
The master files are split up and stored in the control's inter-
nal management system.
8. "Select Storage location" .
At "Programs", all programs that have been split up are
listed.

Modifying parameters 9. Mark a program for which the parameters are to be modified.
10. Press Technology correction.
11. Modify parameters if necessary (see "Select technology",
pg. 4‐77).
12. To end the technology correction: press Save and close.
or
Ø To switch to the technology correction selection list: press
Save and selection.

4‐40 Production 2019-02-01 B813en

 Check program 13. Mark a program that is to be checked.
14. Press "Check program".

7.2 Execute program

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

Loading program 1. Press Production, "Current program", Select program.

"Select program: Select program" is opened.
2. Select "Storage location" .
At "Programs", all programs that have been split up are
listed.

Reading in program via USB 3. Connect the USB memory stick.

interface 4. Select "Storage location" .
5. Open "path" with and select the drive (H:\ or G:\) for the
USB memory stick.

Filtering the program Note

The list of programs can be limited by the use of filters.
6. If need be, the first letters of the program being searched for
can be entered at "Filter". Only those program names are
shown that start with the entered letters.
Press to delete the input and to show the original selec-
tion.

Loading program 7. Select a program from the list.

The selected program is highlighted in yellow.
8. Press Continue.
If the installed cutting head or nozzle doe not correspond to
the selected program, the Select program: Load cutting head
mask is displayed.
The required cutting head and nozzle data are listed in the
"TO LOAD" column.
9. To replace the cutting head: press Head change position.
10. Replace the cutting head.
11. To replace the nozzle: press Nozzle change position.

B813en 2019-02-01 Production 4‐41

 Hot nozzle during replacement immediately after machine
CAUTION operation
Risk of burns.
Ø Only touch hot components with protective gloves.

12. Replace the nozzle on the cutting head.

13. Press Apply.
Modified components are accepted by the control system.
The program is loaded. A graphical NC simulation is started,
the sheet graphics will be displayed in the preview. Informa-
tion about the currently loaded program is displayed on the
right side of the screen.

Starting the program 14. If necessary, press ACKNOWLEDGE FEED HOLD .

ACKNOWLEDGE FEED HOLD flashes.
15. Press START .
■ Home position is automatically established.
The machine is working.
■ Service programs are automatically executed after the
program start if necessary; for example, nozzle cleaning
with calibration of the height regulation or a lubrication
cycle.

7.3 Switching the view for programs

Condition
■ A program is active.

1. Press Production, "Current program".

The top line contains program information such as program
name, material, sheet dimension and number of machined
parts.
2. Open the "View" with .
3. Select NC simulation+NC blocks.
The graphics of the sheet and the program data are dis-
played.
or
Ø Select NC simulation+process data.
On the left, the graphics of the sheet are displayed. On
the right, the axis positions, process data of the laser and
the feed are displayed.

4‐42 Production 2019-02-01 B813en

 or
Ø Select NC program + NC blocks call-up sequence.
The order of the programs to be run and the program
data are displayed.
or
Ø Select Axis display + NC blocks
The axis positions and program data are displayed.

7.4 Pause program

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

check the parts.

Condition
■ A program is being executed.

1. Press PAUSE (FEED HOLD) .

PAUSE lights up.
The machine is now at a standstill.
The "Paused" program status is displayed.
2. Open machine gate and check the cutting result.
FEED HOLD (PAUSE) lights up and ACKNOWLEDGE
FEED HOLD flashes.
ACKNOWLEDGE FEED HOLD flashes.
4. To acknowledge FEED HOLD (PAUSE): press ACKNOWL-
EDGE FEED HOLD .
The machine continues to work.
The interrupted program will resume operation.

7.5 Aborting a program

Condition
■ A program is being executed.

1. Press FEED HOLD (PAUSE) .

FEED HOLD lights up.
The machine is now at a standstill.

B813en 2019-02-01 Production 4‐43

 2. Press RESET (STOP) .
The current program is interrupted. To continue the program
again, see "Flexible entry into the program".

7.6 Carry out post-production

Immediately after the execution of a program it is found that

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

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

7.7 Show status

Machine

■ Press Production, "Laser machine".

4‐44 Production 2019-02-01 B813en

1 Current machine status 4 Progress bar for the quantity of 6 Sheet on the pallet changer
2 NC program name the parts for which cutting has 7 Material data
already been completed
3 Total number of parts in the pro-
gram 5 Sheet in the machine

Example Fig. 70346

The current job status on the machine is displayed after Posi-

tions 5 and 6, e.g.: 4:2/10: Fourth job in the production plan.
The second sheet out of ten is currently being processed.

Automation

Press Production, "Automation". The following parameters are

displayed:

Name Description
Status of the component, Current order status.
e.g. program running:

"Transport type" The type of transport, e.g. suction cup.

"Location" Start point of the transport.

B813en 2019-02-01 Production 4‐45

Name Description
"Target location" Place where the material or the auxiliary machine pallet should be put down.
"Maxi part location" Location at which the maxi-parts are placed.
"Rake part location" Location where the parts are placed which are unloaded with the rake.
"Alternative location" Location where those sheets are placed that could not be sorted completely (only
with SortMaster option).
"Job" Designation of the current job.
"Suction cup layout" Display depends on the specified type of transport.
"Weight" and "sheet thick- Sheet characteristics.
ness"
Manual transport Opens the "Manual transport" screen in which a single transport procedure can be
manually adjusted and triggered.
Options
"Peeling" The peeler suction cup is active for separation of sheets that are stuck together
when lifting the sheet stack.
"Double sheet detection" The sheet thickness measuring device for recording the sheet thickness of the
raised sheet is active.
"Spray from below" "Oil spraying from below" is active.
Before loading on to the pallet changer, the unprocessed sheet is sprayed from
below with a liquid so that the cut sheet can be more easily detached from the sup-
port slats.
The spraying equipment is on a system pallet.
This function is only available for the LiftMaster Store.
"Remove intermediate The blower for removing intermediate layers in the unprocessed sheet stack is
layer" active.
An intermediate layer made of chemical pulp or plastic is blown from the sheet
using compressed air.
The blower is on the pallet removal.
This function is only available for the LiftMaster Store.
"During transport rake 0: Standard. The rake is closed or left open depending on the sheet thickness and
should be" lifting height.
1: The rake is always open during the transport operation.
2: The rake is always closed during the transport operation.
This function is only available for the LiftMaster Store.
"Lower stripper" "Lower stripper" is active.
If a sheet with the rake is unloaded, and if the sheet is smaller than the maximum
size of the rake, then the lowerable scraper can be swiveled in. This then prevents
the small sheet from slipping in the rake.
This function is only available for the LiftMaster Sort and the LiftMaster Store with
Sort extension.
"Align sheet" "Align sheet" is active. While the sheet is being transferred to the pallet changer a
sheet (with a max. sheet thickness of 10 mm) is aligned parallel to the X axis.
This function is only available for the LiftMaster Sort and the LiftMaster Store with
Sort extension.
Tab. 4-9

4‐46 Production 2019-02-01 B813en

 7.8 Triggering the manual transport
procedure (automation)

1. Press Production, "Automation", "LiftMaster", Manual trans-

port.
The "Manual transport" screen is opened.
2. At "Saved transport", open the selection list with and
select an already defined transport sequence and press
Transport.
or
Ø Define a new transport sequence:

Field Description
"Transport type" Depending on the system's configuration stage, selection can be made among the
following transport types:
■ Suction cups.
■ Hook
■ Rake
■ Maxi part separation.
■ Pallet transport
■ Depositing.
■ Skeleton separation for thin sheets
■ Pallet picker crane (PalletMaster Tower)
"Suction cups" If the Suction cup transport type is selected, it has to be defined which suction cup
is to be activated:
■
Individual suction cup: press and select the individual suction cup.
■ Suction cup group: suction cups are automatically activated for transporting the
desired formats.
− Small format: 2 m x 1 m.
− Medium format: 2.5 m x 1.25 m.
− Large format: 3 m x 1.5 m.
− Maxi format: 4 m x 2 m
− Format (4 m x 2.5 m).
− Format (6 m x 2 m).
− Format (6 m x 2.5 m).
If the Maxi part separation transport type is selected, then the suction cups have to
be defined individually: press and select the suction cups individually.
"Gripper" If the Skeleton separation for thin sheetstransport type is selected, then it has to be
defined which grippers are to be activated: press and select the gripers individu-
ally.
"Pallet type" If the Hook transport type is selected, "Pallet type" has to be selected at "Option" to
define whether a hook pallet or a rake pallet is to be transported.
All other parameters (see "Automation", pg. 4‐45).
Tab. 4-10

B813en 2019-02-01 Production 4‐47

 3. Press Save.
The transport sequence is saved and is available right away
for selection at "Saved transport".
4. Press Transport.
The transport process is started.
5. Press Home position in order to bring the manufacturing cell
back to home position.

7.9 Viewing active travel to storage

(automation)

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

All of the active store drive cycles will be displayed which
belong to the job sequence.

4‐48 Production 2019-02-01 B813en

 8. Working with the production plan

A production plan can consist of none, one or more than one

production package arranged in a sequence. A production pack-
age can contain several jobs. One job contains an NC program
with any number of repetitions.
At automated machines, the production plan controls the pas-
sage of the sheet through the plant; from loading and machining
all the way to the unloading of finished parts.

Production plan Description

Orders 1 Icon "Jobs view"
2 Job
3 Number of repetitions of the NC program
within of the job.

Orders 1 Icon "Jobs view"

2 ■ *[1/2]:
− * corresponds in this example to
the name of the production pack-
age. The name can be selected
at will.
− [1/2] corresponds in this example
to the first part of the production
package, which is comprised alto-
gether of two parts.
3 Production package
4 Jobs within the production package
5 Number of repetitions of the NC program
within of the job.

B813en 2019-02-01 Working with the production plan 4‐49

Production plan Description
6 Icon "Job details view"
7 Icon "Program details view"
8 Icon "Cell status view"

Depending on the system's version, the

individual components and their statuses
will be shown:
■

Running.
■

After RESET or if a compo-

nent malfunctions.
■

Stationary.
Tab. 4-11

Job status Symbol Status Description

Released The job is released and can be
started.

Locked This job is not to be produced.

Running The job is being produced.

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

started.

Finished The job is completely produced.

Error An error has occurred during execu-

tion. This job will not be produced.

Error The job is missing an NC program.

Tab. 4-12

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

4‐50 Working with the production plan 2019-02-01 B813en

 Symbol Status Description
Stationary The symbol is shown in the following
cases:
■ Production plan is ready and can
be started.
■ The production plan has been com-
pleted.
■ The production plan was stopped
with Pause (stop).
Active The production plan is active.

Tab. 4-13

Buttons

Button Description
Start Starts the sequence of all jobs enabled in the production plan. The sequence is
given by the configuration in the Current/Required table.
Prepare Sends the program data of the NC programs from enabled jobs as a preparatory
measure to the components. A tool setup check is run for the jobs.
Pause (stop) The "Pause production plan" dialog box will open. There you can select whether the
production plan should be immediately aborted or only after the completion of the
current job or after the system has run empty.
Technology correction Technology parameters can be modified.
Continue The production plan remains active even if a system component stops with a mal-
function or after RESET. The operation can be started again after the correction of
the cause of error using the "Continue" dialog box.
Disable Disables the job marked in the production plan for processing. For processing sev-
eral jobs successively (see "production packages"), the disabled job is skipped. Sev-
eral jobs can be disabled at once if a production package is selected.
Release Enables a disabled job for processing.
Position Starts the dialog box for the creation of a new job.
Change Opens the job marked in the table for editing.
Active jobs can be edited. The modifications will be accepted after the next time the
components are started.
Delete Deletes the previously selected job. Jobs that are currently being processed cannot
be deleted.
Tab. 4-14

8.1 Creating a single job

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

The "Program selection" screen opens.
2. "Select storage location":

B813en 2019-02-01 Working with the production plan 4‐51

 − Activate folder: at "Program name", all programs are
listed that have already been split up and stored in the
program management of the control.
− Activate the drive: enables access to set-up drives.
At "Path", select with and select the desired drive.
At "Folder", the folder structure within the drive is shown.
At "Designation", the programs are shown that are con-
tained in the respective folder.
3. If need be, the first letters of the program being searched for
can be entered at "Filter". Only those program names are
shown that start with the entered letters.
Press to delete the input and to show the original selec-
tion.
4. Select the program at "Program name" with for which a
job is to be created.
− Press Next.
The "Job overview" mask is displayed for automated
machines. Depending on the expansion stage, the loading
and unloading steps will be shown individually.
5. Press "Job details".

Note
A sequential list describes the production sequence within
the system for the activated job.
6. Open the "Selected sequential list" with .
7. Select Sequential list.
8. Modify "Required qty", "Designation" and "Description" as
needed.
9. Activate "Enable job" with .
10. If production is to take place in single pallet mode:
− Open the "Used pallets" list with and select Only
pallet A or Only pallet B.
11. Press Next.
12. In the tabs "Platforms" or "Pallets", press on the inventories
in the selection list from which material is to be loaded.
The selected locations are listed under "Designation" and are
no longer available in the selection list.
13. If a material location is to be removed from the selected list,
press .
The deleted location will then be available again in the selec-
tion list.
14. Press Continue.
Depending on the selected sequential list, various masks will
be displayed successively in which the locations for unload-
ing the various types of parts need to be defined.

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 15. Select the unloading locations and stock type (see "Creating
inventory", pg. 4‐65).
If all other defined locations are full or if no locations were
defined, then a search is made in the storage system for a
suitable pallet of the selected stock type.
16. Press Finish.

8.2 Create job for automatic systems

For systems without connection to storage

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

The "Program selection" screen opens.
2. "Select storage location":
− Activate : at "Program name", all programs are listed
that have already been split up and stored in the
program management of the control.
− Activate : enable access to drives that have been set
up. At "Path", select with and select the desired
drive. At "Folder", the folder structure within the drive is
shown. At "Designation", the programs are shown that
are contained in the respective folder.
3. If need be, the first letters of the program being searched for
can be entered at "Filter". Only those program names are
shown that start with the entered letters.
Press to delete the input and to show the original selec-
tion.
4. Select program with for which a job is to be created.
5. Press Continue.
The "Job overview" mask is displayed. Depending on the
expansion stage, the loading and unloading steps will be
shown individually.
6. "Press Job details".
7. Open "Selected sequential list" with .
A sequential list describes the production sequence within
the system for the activated job.
8. Select Sequential list.
− Modify "Required qty", "Designation" and "Description" as
needed.
− Activate "Enable job" with .
9. Press Continue.
The "Material loading" screen will be displayed.

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 For systems without a store connection, "Platforms" can be
selected as loading sites.
10. In the selection list, press the platforms from which material
should be loaded.
The selected locations are listed under "Designation" and are
no longer available in the selection list.
11. If a material location is to be removed from the selected list,
press .
The deleted location will then be available again in the selec-
tion list.
12. Press Continue.
Depending on the selected sequential list, masks will appear,
one after the other, in which the platforms for unloading the
various part types are defined ("Waste grid unloading", "Maxi-
part unloading", "Unloading (alternative position)" and
"Unload small parts").
When the unloading platforms have fixed configurations for
the system, no masks are shown.
13. In the individual masks, activate the respective platform on
which the scrap skeleton/part is to be unloaded.
14. Press Finish.

For systems with connection to storage

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

The "Program selection" screen opens.
2. "Select storage location":
− Activate : at "Program name", all programs are listed
that have already been split up and stored in the
program management of the control.
− Activate : enable access to drives that have been set
up. At "Path", select with and select the desired
drive. At "Folder", the folder structure within the drive is
shown. At "Designation", the programs are shown that
are contained in the respective folder.
3. If need be, the first letters of the program being searched for
can be entered at "Filter". Only those program names are
shown that start with the entered letters.
Press to delete the input and to show the original selec-
tion.
4. Select program with for which a job is to be created.

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 5. Press Next.
The "Job overview" mask is displayed. Depending on the
expansion stage, the loading and unloading steps will be
shown individually.
6. "Press Job details".
7. Open the "Selected sequential list" with .
A sequential list describes the production sequence within
the system for the activated job.
8. Select Sequential list.
− Modify "Required qty", "Designation" and "Description" as
needed.
− Activate "Enable job" with .
9. Press Next.
The "Material loading" screen will be displayed:
10. Either
Press "Inventories".
− In the selection list, select the unprocessed material
which is to be fetched from the store. Only one raw
material can be selected.
or
Ø Press "Pallets".
− In the selection list, select one or more pallets with the
desired unprocessed material.
or
Ø Press "Dynamic palletizing".
− Select the transfer station from which the unprocessed
material is to be loaded.
As standard, there are 4 transfer stations which the
LiftMaster can directly access.
The operator must make sure that the desired material
can be found there.
The selected unprocessed material / pallets / transfer station
is displayed under "Designation".

Tip
Pallet reservation:
If pallet reservation is activated during configuration of the
system, then during the material selection the selected pallet
in the storage system is reserved for use at the machine via
"Pallets". This ensures that the production plan is executed.

11. If the unprocessed material / pallet / transfer station is to be

removed from the selected list again: press .

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 12. Press Next.
Depending on the selected sequential list, screens will
appear, one after the other, in which the unloading of the var-
ious part types are defined ("Waste grid unloading", "Maxi-
part unloading", "Unloading (alternative position)" and
"Unload small parts").
13. If the scrap skeleton / part is to be deposited on a platform:
− Press "Platforms".
− In the selection list, select the platform on which the
scrap skeleton / part is to be deposited.
or
Ø If the scrap skeleton / part is to be deposited on a pallet:
− Press "Pallets".
− In the selection list, select the pallet on which the scrap
skeleton / part is to be deposited.
or
Ø If the scrap skeleton / part is to be deposited on a pallet
of a certain inventory group type:
− Press "Inventory group type"(see "Stocks", pg. 4‐64).
− Select the pallet type on which the scrap skeleton / part
is to be deposited.
14. Press Finish.

For systems with SortMaster

The creation of a job with SortMaster proceeds analogously to

the previously described sequence, but with additional settings
for the SortMaster.

1. In the mask "Job details", open Selected sequential list with

.
2. Select sequential list which contains the working step "Sort".
3. Press Continue.
For systems without a store connection, the alternative posi-
tion is permanently configured and the "Unloading, alternative
location" mask is not displayed.
For systems with a store connection, the "Unloading, alterna-
tive location" mask appears.
4. In the mask "Unloading, alternative location", select the loca-
tion on which the LiftMaster deposits the cut sheets, from
which the SortMaster was not able to remove all of the small
parts.
5. Press Continue.
6. Select the desired sorting data in the "Sorting options" mask:

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Function Description
"Clean suction cup" At the beginning of a sorting process, the gripper head moves over the brushes of
the cleaning station with the suction cups several times to clean the suction cups.
"Clean pallet" After completely unloading the pallet changer, the SortMaster picks up the pallet
brush at the cleaning station and moves with it lengthwise and transversely over the
slats of the pallet to brush off the waste parts.
"Redefine stack heights" ■ Hook set (default): The SortMaster redefines the stack height on the placement
pallet once again (stack search travel) with each first sheet of a production job.
■ Hook not set: Stack heights of the preceding production job continue to be used.
Utilize this only when the palletizing in the programming software has been
designed to be applicable to more than one program.
"Repeats" Maximum quantity of sorting processes when a part cannot be unloaded.
"Behavior after vacuum The function can be selected, if "Clean suction cups" has been previously activated.
error" ■ "Skip part": Suction cups are cleaned when there is a vacuum error.
Then the next part is taken off.
■ "Repeat part": Suction cups are cleaned if there is a vacuum error.
Afterwards, the SortMaster attempts to remove the part again.
Tab. 4-15

8.3 Modifying jobs

1. Press Production plan, "Production plan".

The existing jobs are displayed under "Program".
2. Mark the job which is to be modified.
The marked job receives an orange background.
3. Press Modify.
The "Job details" mask is displayed.
The "Job overview" mask is displayed for automated
machines. Depending on the expansion stage, the loading
and unloading steps will be shown individually.
4. Press "Job details".
5. If desired: Modify "Required qty", "Designation" and "Descrip-
tion".
6. Press Continue.
The "Material loading" screen is shown for automated
machines.
7. To select an alternative loading location, first use to delete
the loading location at "Description". Then select a new load-
ing location from the list.
8. Press Continue.
Depending on the selected sequential list, various masks will
be displayed successively in which the locations for unload-
ing the various types of parts can be modified.
9. Press Finish.

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 8.4 Creating production packages

Production packages are created in the programming system or

in a higher-level order control system (e.g. TruTops Fab) and
then imported. Jobs created singly are always assigned to the
"*" production package.

Viewing production 1. Press Production plan, "Production plan".

packages
The available jobs are displayed.
2. To switch over the view, press: .
The production packages are displayed with their jobs.

Importing production 3. Press Create.

package
The "Program selection" screen opens.
4. Select "Storage location" drives .
5. If need be, the first letters of the program being searched for
can be entered at "Filter". Only those program names are
shown that start with the entered letters.
Press to delete the input and to show the original selec-
tion.
6. Open the desired path with .
7. At "Folder", open the desired directory.
8. Either
Ø At "Designation", select the *.LST (master file) which is to
be imported.
or
Ø At "Designation", *.TPP select a full production package
to be imported.
9. Press Finish.
The master file is split. If the master file contains job informa-
tion, the job is created automatically. The master file can also
contain several jobs.
The statuses of the individual steps within the job are listed
(Hook, green: Step has been defined; Cross, red: Step has
not been defined).

8.5 Modifying the sequence of the jobs in

the production plan

Individual jobs can be moved within the production plan.

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 Note
During the moving process, note that existing production pack-
ages may be divided into two or more parts when jobs are
moved.

1. Press Production plan, "Production plan".

The available jobs are displayed.
2. Select the job to be moved.
The marked job is highlighted with an orange background.
3. Press or to move the job upward or downward by one
position.
4. If necessary, switch to the "Production packages" view and
check the production packages.
Divided production plans are displayed with brackets containing
the corresponding number of parts. Example: [1/2] means Part 1
of a total of 2 parts of the production package.

8.6 Preparing production plan/tool setup

check

The tool setup check compares the current tooling status of the
machine with the necessary tooling status for the individual jobs
in the production plan. Necessary tooling work can thus be car-
ried out before the production plan is started or the next jobs in
the production plan which has been started are executed.
As with a wizard, during the tool setup check all tooling stations
(example: laser cutting head, nozzle, automation components)
are queried and run though in a fixed sequence.
If the tool setup check ends with the result "Tooling not
required", then the production plan will be run through
completely after the start in the case of machines with nozzle
changers. In the case of machines without nozzle changers, no
statement can be made, because the tool setup check "Nozzle"
is executed only for the first job which has been enabled.
The extent to which the tool setup check is carried out depends
on whether the production plan is already active or not at the
time of Prepare and on which status the jobs have.
After the tool setup check has been done, the tooling status of
the individual tooling stations will be displayed.

B813en 2019-02-01 Working with the production plan 4‐59

 Starting tool setup check during non-
productive time

Note
The tool setup check and tooling during non-productive time is
the preferred approach for smooth functioning of the production
plan.

Ø Press Production plan, "Production plan", Prepare.

8.7 Starting a production plan

Condition
■ The jobs to be started are created in the production plan.

1. Press Production plan, "Production plan".

2. To enable jobs which are to be started:
− Mark the order.
− If the job has the "Disabled" status: press Prepare or
Enable.
3. To disable jobs which are not to be started:
− Mark the order.
− If the job has the "Enabled" status: press Disable.
4. To query the tooling status of the system: Press Prepare.
5. Press Continue.
If there is still material in the system, the "Check inventory
situation" mask appears.
6. Check if the displayed inventories and the sequence corre-
spond to the sequence in the production plan.
If yes: Press Continue or Finish.
If not: Press Cancel and adapt the actual inventory situation
to the one displayed manually (Pallet change, Change inven-
tory).

8.8 Pause (stop) production plan

The production plan can be paused (stopped) as follows:

■ After the system has run empty.
■ After the processing of the current sheet.

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 ■ After completion of the current job.
■ Immediately.

Note
Recommendation: select the "Run empty" option when pausing
(stopping) the production plan. Only then is it ensured that all
inventories are correctly booked and no manual intervention by
the operator is necessary.

1. Press Pause (stop).

The "Pause (stop) production plan" dialog box will open.
2. Select "Run empty" to stop the production plan after all
sheets which are still in the system have been completely
processed.
The action is completed if no further inventories are in the
system.
or
Ø Select "Stop after sheet" to stop the production plan as
soon as the current sheet has been processed.
The sheet currently being processed will still be removed
and unloaded.
To continue the execution of the production plan:
− Press Continue.
The "Check inventory situation" dialog will be opened.
− Check if the displayed inventories and their sequence
correspond to the sequence in the production plan and
correct them manually, if necessary.
− Press Continue or Finish.
or
Ø Select "Stop after job" to stop the production plan as
soon as the current job has been executed.
To continue the execution of the production plan:
− Press Continue.
The "Check inventory situation" dialog will be opened.
− Check if the displayed inventories and their sequence
correspond to the sequence in the production plan and
correct them manually, if necessary.
− Press Continue or Finish.
or
Ø Select "Cancel" to immediately stop the production plan.
The production plan does not start any action any more
from this time on. Each device finishes its current action,
however.
To continue the execution of the production plan:

B813en 2019-02-01 Working with the production plan 4‐61

 −If necessary, remove material manually from the suction
frame.
− Press Continue.
The "Check inventory situation" dialog will be opened.
− Check if the displayed inventories and their sequence
correspond to the sequence in the production plan and
correct them manually, if necessary.
− Press Continue or Finish.
3. Press OK.

8.9 Resuming production plan after a

malfunction

The following causes lead to pausing of the production

sequence:
■ Error in the inventory management.
■ One system component reports a malfunction.

Note
The production plan remains active and can be continued
after the malfunction is corrected.

Correct error in the inventory management

1. Correct incorrect inventories at the user interface.

2. Press Continue.

Button Description
Repeat The work cycle of the defective component that was last carried out will be
repeated.
Canceling ■ The machining of the current sheet is aborted.
■ The sheet must be removed manually.
■ The next sheet will proceed once again through the normal cycle.
Exit The current work cycle (e.g. sorting) will be interrupted and reported as being "fin-
ished". The next work cycle will be started afterwards (e.g. unloading).
Close Closes the "Continue" dialog box without triggering an action.
Tab. 4-16

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 Correct malfunction at a component

1. Press Continue.
The "Continue" dialog box is opened in which the defective
component is shown in status .
2. Manually correct the problem at the component.
3. Press Repeat.
or
Ø Press Cancel.
The execution of the production plan will be continued.

8.10 Disabling job in the production plan

An enabled job can be disabled within the current production

plan. The disabled job is skipped in the production plan and not
processed.

1. Press Production plan, "Production plan". The available jobs

are displayed.
2. Mark the job which is to be disabled.
3. Press Disable.

8.11 Deleting a job from the production

plan

1. Press Production plan, "Production plan".

2. Press Delete.
The "Delete jobs" mask is displayed.
3. Use a check mark to mark the type of job which is to be dis-
played in the list.

Filter Description
All jobs All jobs in the production plan.
Finished orders Jobs which have already been processed.
Disabled jobs Jobs which were disabled in the production
plan.
Released jobs Jobs which have not yet been processed and
which are not disabled.
Tab. 4-17

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 4. Mark jobs which are to be deleted with a check mark on the
far left.

Note
If a job to be deleted does not belong to any production
package then it is deleted without any further query when the
following buttons are pressed.
5. Press Delete jobs.
The job is deleted from the production plan; the NC program
remains saved in the internal management.
or
Ø Press Delete programs and jobs.
The job is deleted from the production plan; the NC pro-
gram is deleted from the internal management.
6. If a job to be deleted is part of a production package, then
press OK to acknowledge the message which is shown.

8.12 Stocks

Stock A stock is the quantity of stock items, system pallets or contain-

ers that is present.

Stock type The stock type refers to the type of a stock item. This includes
both the carrier of the stock item as well as the stock item itself.

Stock type Description

SP System pallet without floor
TL (cut) part
BT Sheet
RG Scrap skeleton
NCP Cut sheet from program
MPR Machine pallet for rake mode
SPr14 System pallet for rake operation
MPH Machine pallet for hook mode
SPh System pallet for hook operation
SPm System pallet with floor
Tab. 4-18

System pallet System pallets are the steel pallets in a store in which stock
items are stored. System pallets can also contain other material

14 System pallets can be modified only in warehouse management, not

however directly in the TruTops FMC.

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 carriers. They are often only called "Pallets" for short. Each sys-
tem pallet has a particular basic area format (large format,
medium format, …).

Inventory group type The stock group type describes a container (system pallet, auxil-
iary machine pallet) in a particular status. For example, an empty
system pallet with floor has the stock group type "SPMgl" (based
on German) (Systempalette mit Boden Großformat leer = system
pallet with floor, large format, empty). An empty system pallet
without floor accordingly has the stock group type "SPOml"
(Systempalette ohne Boden Mittelformat leer = system pallet
without floor, middle format, empty).

Inventory Description
group type
SPhl System pallet for hook operation, empty
SPMPHI System pallet with machine pallet for hook operation,
empty
SPMPRI System pallet with machine pallet for rake operation,
empty
SPrl System pallet for rake operation, empty
SPml System pallet with base, empty
SPol System pallet without base, empty
SpMgl System pallet with base, large format, empty
SpOml System pallet without floor, medium format, empty
Tab. 4-19

Notes
■ For systems with store connections, material and pallet
inventories from cell locations (e.g. platforms) must be man-
aged in the order list.
■ Only inventories from cell locations can be adjusted in the
order list. Inventories of storage stations must be modified in
the storage software (TruTops Fab).
■ With Starting with stock, the raw sheet in the suction frame
is also taken into account.

Creating inventory

1. Press Production plan, "Inventory".

Known inventories within the system are listed. Inventories
which are currently located in the production cycle are also
displayed.
2. Press Create.
The "Create/modify inventory" mask is displayed.
3. Open the Stock type with .

B813en 2019-02-01 Working with the production plan 4‐65

 4. Mark the desired stock type in the selection list.
5. Enter the "Designation" and the "Quantity".
6. Open the location with .

Note
Inventries at storage stations cannot be created or modified
at this point. They need to be modified in the warehouse
management feature.
7. Select the location at which the new inventory is to be found.
8. Press Apply.

Modifying inventory

1. Press Production plan, "Inventory".

All known inventories are listed. Inventories are also dis-
played which are currently to be found in the production
cycle.
2. Press Modify.
The "Create/modify inventory" mask is displayed.
3. Subsequent course: (see "Creating inventory", pg. 4‐65).

8.13 Manual handling (option)

For systems equipped with the "Manual handling" option, the

operator can apply one of the LiftMaster processing steps if the
corresponding sequence list has been selected in the production
plan:
■ If the sequence list contains the "Unload manually" step, the
system will pause while the operator manually removes the
cut sheet from the pallet changer.
■ If the sequential list contains the step "Manual loading", then
the operator must first load a sheet onto the pallet changer
before the processing of the production plan can continue.

Note
The LoadMaster is also controlled via the "Manual handling" dia-
log box.

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 Manually loading the sheet

Conditions
■ Production plan in automatic mode.
■ In the job details, a sequential list with manual loading has
been selected and is being processed.

1. If the prompt for manual loading is shown: manually place

the sheet on the pallet changer.
2. After the manual step has been performed: at Production
plan, press "Manual handling" Transport complete.
The next step in the production plan will be carried out.

8.14 Manual sorting (option)

For systems which are equipped with the "Manual sorting"

option, the operator will be prompted to manually sort the parts if
the corresponding sequential list has been selected in the pro-
duction plan. The location at which the parts are lying for manual
removal is shown in the "Sort at location" field.

Manually sort parts

Conditions
■ Production plan in automatic mode.
■ In the job details, a sequential list with manual sorting has
been selected and is being processed.

1. If the prompt for manual sorting is shown: manually remove

the parts at the specified location.
2. After the manual step has been performed: at Production
plan, press "Manual sorting", Parts removed.
The next step in the production plan will be carried out.

8.15 Displaying the status in currently

running production plan

1. Press Production plan, "Production overview".

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Parameter Description
Order Designation of the job which is currently being processed.
Program running time (net) Time remaining until the current job is completely processed.
Next sheet change Time remaining before the next sheet change.
Quantity Quantity of sheets which has already been processed and quantity of
sheets which must be processed in total. Example 1/5: One out of a total
of five sheets has been completely processed.
Remaining production time Time remaining until all of the jobs in the production plan have been proc-
essed completely.
Remaining run-throughs Remaining quantity of sheets still to be processed in the production plan.
Tab. 4-20

2. To switch between displays in the large field: press Switch

display.

Display Description
Expected end The time at which the production plan will have
been completed.
Next sheet change Time remaining before the next sheet change.
Remaining production Time remaining until the current production plan
time has been completely processed.
Tab. 4-21

8.16 Production options

The system normally works with all available automation compo-

nents insofar as the respective sequence lists are stored and
selected.
At Production plan, "Production options", it is possible to access
these automatic sequences and change individual loading and
unloading steps to manual loading/unloading.

Manual loading of raw sheet

1. Select Production plan, "Production options".

2. At "Load raw sheet", activate "Manual".
If the loading step is active, the operator is requested to
place the raw sheet on the pallet changer.
3. Place the raw sheet on the pallet changer.
4. At Production plan, "Manual handling", press Transport com-
plete.
The next step in the sequence list will be carried out.

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 Manually unloading the sheet

1. Select Production plan, "Production options".

2. At "Unload sheet", activate "Manual".
When the unloading step is active, the operator will be
requested to manually unload the cut sheet.
3. Unload the cut sheet from the pallet changer.
4. At Production plan, "Manual handling", press Transport com-
plete.
The next step in the sequence list will be carried out.

Manually remove the small part.

1. Select Production plan, "Production options".

2. At "Remove small parts", activate "Manual".
When the unloading step is active, the operator will be
requested to remove the small parts from the pallet changer.
3. Remove the small part from the pallet changer.
4. At Production plan, press "Manual sorting", Parts removed.
The next step in the sequence list will be carried out.

Single pallet mode

In single-pallet operation, only one pallet is used (Pallet A). This

means it is not loading and unloading sheets during productive
time.
Single-pallet operation is recommended when it is necessary to
ensure that parts which are cut free do not fall onto unprocessed
materials moving in during the pallet change, which could result
in these parts then causing a collision with the cutting head in
the machine.
Express orders can also be processed in single pallet mode.
Here, starting with stock is possible; the stock of the other pallet
is not used.

1. Select Production plan, "Production options".

2. At "Machine", "Used pallets", open the list with and
select Only pallet A or Only pallet B.
The machine only works with the selected pallets.

B813en 2019-02-01 Working with the production plan 4‐69

 Tip
If a single-pallet operation has already been selected when cre-
ating a job at Production plan, "Production plan" in the job
details at "Used pallets", no multi-pallet operation can be subse-
quently activated at "Production options".

8.17 Execution with intermediate storage

(option)

For systems that are equipped with the "Intermediate layer"

option, a protective intermediate layer (e.g., made of plastic) can
be placed between the cut sheets if the corresponding sequential
list has been selected in the production plan.

Creating a job with intermediate layer

1. At Production plan, create a single job

2. In the "Job details" mask, open "Selected sequential list" with
and select a sequential list which contains Unload with
separating layer.
3. Finish the job.

8.18 Preparatory loading (option)

For systems that are equipped with the "Preparatory loading"

option, there is already a raw material sheet at the suction cups
while the cut sheet is being unloaded with the unloading rake
from the pallet changer if the corresponding sequential list has
been selected in the production plan.

Activating preparatory loading

1. At Production plan, create a single job

2. In the "Job details" mask, open "Selected sequential list" with
and select a sequential list which contains Cutting with
preparatory loading.
3. Finish the job.

4‐70 Working with the production plan 2019-02-01 B813en

 9. Flexible entry into the program

The user interface displays the entire sheet in an overview with

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

1 Sheet 2 Zoomed-in section

Overview: flexible entry Fig. 57321

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

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

Possible types of entry:

■ (see "Entry at the point of interruption", pg. 4‐72).
■ (see "Entry at a piercing", pg. 4‐74).
■ (see "Entering at a specific part", pg. 4‐75).

B813en 2019-02-01 Flexible entry into the program 4‐71

 9.1 Restarting the program after an
interruption

Entry at the point of interruption

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

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

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

Determine entry type 5. Select "At the interruption point".

Entry type Note

At the interruption The box is grayed out if the interruption point is
point unknown or the program was not yet started.
Selection of the type of entry Tab. 4-22

6. Press Continue.
The screen "Flexible entry: Distance to interruption point" is
displayed.
For laser processing, "Details" shows the path length, the
path length already processed, and the path length before
and after the interruption point.
7. Select "At block begin" (default setting).
The complete travel command of the NC block for this
machining is performed anew.

4‐72 Flexible entry into the program 2019-02-01 B813en

 or
Ø To move the point of entry in front of the interruption
point for laser processing: Select "Corrected position" and
enter a value.

1 Entry at block begin (yellow 2 Interruption point (white

target) cross)
Flexible entry at block begin Fig. 57322

All performed actions are displayed in the graphic.

8. Press Continue.
The "Flexible entry: Select option" mask is displayed.

Select option, start flexible 9. Activate "Accelerated block search run".

entry
In the background the program is worked through without
positioning motions of the machine and without tools up to
the re-entry point. The option "Accelerated block search run"
shortens this process.

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

B813en 2019-02-01 Flexible entry into the program 4‐73

 Entry at a piercing

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

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

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

Determine entry type 5. Select "At a certain piercing"

Entry type Note

At a certain piercing Piercing:
■ Re-entry takes place in the NC block at the
NC cycle "TC_LASER_ON".
Selection of the type of entry Tab. 4-23

6. Press Continue.
The "Flexible entry: Piercing" is displayed.
7. Enter piercing directly under "Selected".
or
Ø Select piercing via Previous, Next.
or
Ø Select piercing by right-clicking the graphic.
8. Press Continue.
The "Flexible entry: Select option" mask is displayed.

4‐74 Flexible entry into the program 2019-02-01 B813en

 Select option, start flexible 9. Activate "Accelerated block search run".
entry
In the background the program is worked through without
positioning motions of the machine up to the re-entry point.
The option "Accelerated block search run" shortens this proc-
ess.

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

Entering at a specific part

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

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

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

B813en 2019-02-01 Flexible entry into the program 4‐75

 Determine entry type 5. Select"At a certain part".
6. Press Continue.
The "Flexible entry: Part" mask is displayed.
7. Enter part directly under "Selected".
or
Ø Select part via Previous, Next.
or
Ø Select part by right-clicking the graphic.
8. Press Continue.
The "Flexible entry: Select option" mask is displayed.

Select option, start flexible 9. Activate "Accelerated block search run".

entry
In the background the program is worked through without
positioning motions of the machine up to the re-entry point.
The option "Accelerated block search run" shortens this proc-
ess.

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

4‐76 Flexible entry into the program 2019-02-01 B813en

 10. Manually adjust technology
parameters

Technology parameters can be modified either in all programs or

only in a specific program:
■ Technology management (Main activity Technology) can be
used to modify parameters which are applicable to more
than one program.
■ Technology correction can be used to modify all of the tech-
nology parameters which an already started NC program or
an NC program in preparation uses (program-specific and for
all programs).

Note
If an NC program is reimported, then all program-specific modifi-
cations will be lost. Non-program-specific modifications (e.g. in
laser technology tables or in the edge technology) remain in
effect.

Any modification of the technology parameters may result

NOTICE in malfunctions during the production process.
Ø Modifications may only be performed after consulting the
programmer.
Ø Modifications should only be made in exceptional cases.

10.1 Select technology

1. Press Production, select "Prepare program", and activate

"Storage location" .
or
Ø Select Production plan, "Production plan".
2. Mark the program in which the technology correction is to be
made.
3. Press Technology correction.

Icon Description
Program name.

Material type.

Sheet thickness.

Tab. 4-24

B813en 2019-02-01 Manually adjust technology parameters 4‐77

 The "Technology correction: Select technology" screen is dis-
played.
Depending on the configuration stage of the system and the
selected NC program, different technologies are offered for
editing.
4. Select technology that is to be modified:
− "Loading".
− "Program properties".
− "Sheet technology".
− "Sheet position measuring".
− "Laser technology".
− "MicroJoint".
− "Tube technology" (RotoLas).
− "Load tube" (RotoLas).
− "Part technology" (RotoLas).
− "Edge technology" (RotoLas).
− "Removal" (Automation).
− "Load sheet" (Automation).
− "Skeleton separation" (Automation).
− "Unload scrap skeleton" (automation).
5. Press Continue. The corresponding technology is opened
(see the following sections).

10.2 Loading

Symbol/name Description
Name of the technology table (SHL = Sheet Load).

Category:
■ Load: Data for loading the machine with sheets is displayed.
"Loading mode" [1] Manual loading without pallet change.
[5] Loading with the pallet changer.
[6] Loading with the pallet changer and LiftMaster.
[7] Single pallet mode.
[10] Loading with the pallet changer and LiftMaster Sort.
[11] Loading with the pallet changer and LiftMaster Sort with drawing device.
"Measuring the sheet [0] No measuring.
position"
[1] Measure with distance regulation.
Enter measurement range in X and Y.

4‐78 Manually adjust technology parameters 2019-02-01 B813en

 Symbol/name Description
"Sheet back stop" Indicates at what corner of the pallet the sheet was stopped.
[1] Machine zero point (standard).
[2] Position 2 away from the machine zero point.
[3] Position 3 away from the machine zero point.
[4] Position 4 away from the machine zero point.
Positions 2, 3 and 4 are numbered in the clockwise direction.
"Measuring corner" Indicates the corner of the sheet which is to be determined during measuring.
[1] Machine zero point (standard).
[2] Position 2 away from the machine zero point.
[3] Position 3 away from the machine zero point.
[4] Position 4 away from the machine zero point.
Positions 2, 3 and 4 are numbered in the clockwise direction.
Technology correction parameter: Loading Tab. 4-25

10.3 Program properties

Symbol/name Description
Name of the technology table

Category:
■ Program properties.
"Water spraying mode" CoolLine (option): Cooling of the cutting process by spraying a directed, coaxial
water mist around the machining point with a special nozzle.
The water spraying function depends on the program and can fundamentally only be
activated and deactivated if it was programmed in TruTops Laser.
[0] Water spraying off: All contours are machined without water spraying.
[1] Water spraying on: All contours are machined with water spraying.
[2] Water spraying program-controlled: Only those contours are machined with water
spraying which were programmed with water spraying in TruTops Laser. This func-
tion can be used with TruTops V3.0 and higher or TruTops Boost V1.0.
Technology correction parameter: program properties Tab. 4-26

10.4 Sheet technology

Symbol/name Description
Name of the technology table (SHT = Sheet Tech).

Category:
■ Sheet technology: Data on the sheet properties and settings for processing is dis-
played.
"Sheet thickness" Specification of the sheet thickness.

B813en 2019-02-01 Manually adjust technology parameters 4‐79

 Symbol/name Description
"Dynamics level" This parameter describes the dynamics that can be set. The parts productivity can
thus be increased on average by 5 %, particularly with many corner contours.
[0] Standard dynamics level.
[-1] Reduced dynamics with higher quality.
[1] Increased dynamics with reduced quality.
"Target sheet size in X Sheet size specified by TruTops Laser.
and Y"
"Actual sheet size in X The sheet size programmed in TruTops Laser is displayed. If a sheet is inserted
and Y" with dimensions deviating from this, the values must be adjusted accordingly.
"Preferred vaporizing" If the surface of the sheet to be machined is oxidized or rusted or has a foil layer, it
can be vaporized before piercing, even if this is not in the NC program.
[0] No preferred vaporizing.
[1] Circular vaporizing of the piercing point (foil).
[2] Vaporizing of all contours before cutting (foil, scale, rust).
"Vaporizing radius" Recommended value for circular vaporizing: 2 mm.
"Reflection property" This parameter describes the reflective properties of the material surface. It is used
when the sheet position is measured with DetectLine (option). The exposure of the
measurement point strongly depends on the surface properties of the material. If the
material is known, the exposure can be adjusted accordingly.
[0] Unknown.
[1] Deep opaque.
[2] Opaque.
[3] Glossy.
[4] Reflective.
Technology correction parameter: sheet technology Tab. 4-27

10.5 Measuring sheet position

If the sheet is not exactly positioned at the stops during loading,

the sheet position in the machine must be measured before
processing. Also for blank processing and the processing of pre-
punched sheets, the sheet position must be measured. After
measuring the sheet position, a zero point offset is calculated
and, if necessary, the coordinate system is rotated. Afterwards,
processing is started.

Symbol/name Description
Name of the technology table (SHM = Sheet Measure).

Category:
■ Depending on the measuring type selected, different data for measuring the
sheet position is displayed.

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 Symbol/name Description
"Measuring Type" Measurement of the workpiece position or finding the edge of the sheet with
DetectLine (option): Measuring types 1 - 7 and 50 - 51.
[0] Do not measure.
[1] One outside corner.
[2] One inside corner.
[3] Two inside corners.
[4] One round hole.
[5] Two round holes.
[6] One inside corner, one round hole.
[7] An outside corner, a round hole.
[10] One outside corner with distance regulation.
[50] Hole pattern measurement.
[52] Measuring hole patterns with rectangular holes.
"Programmed position Programmed position of the respective corner in the X/Y direction.
X/Y"
"Approximate position Approximate position of the respective corner in the X/Y direction.
X/Y"
Inner contours must be entered with a +/- 5 mm margin of error.
Outer contours must be entered with a +/- 10 mm margin of error.
"Edge length X/Y" Programmed edge length in the X/Y direction.
■ A negative value must be entered if the edge runs in negative direction in
relation to a corner.
■ A positive value must be entered if the edge runs in a positive direction from the
corner.
■ The edge length must be specified with an accuracy of +/- 1 mm.
"Diameter" Diameter of the round hole.
The diameter must be at least 2 mm and be specified with a precision of +/- 0.5
mm.
"Distance to sheet height During positioning between the measuring points of a measuring type, a specific dis-
measurement" tance is traveled. If this distance is greater than the value for the "Distance to sheet
height measurement" parameter, the sheet height is re-determined. This is neces-
sary for focusing and can be adapted according to the flatness of the sheet.
Technology correction parameter: Measuring sheet position Tab. 4-28

10.6 Laser technology

Cutting data (e.g. material thickness, cutting gas type, gating fre-
quency) is required in order to execute an NC program on a
laser cutting machine. The cutting data is uploaded from laser
technology tables which are stored in the control. Laser technol-
ogy tables are tables which are applicable to more than one pro-
gram.
Even if a program has already been started, the cutting data
may still be modified. A modification will be saved at once and
takes effect the next time it is called up in the NC program.

B813en 2019-02-01 Manually adjust technology parameters 4‐81

 A detailed description of the laser technology parameters can be
found in the data collection for the laser machine.

Display on the machine The standard view displays only the parameter values which can
be modified.

Symbol (in front of Comment

parameter value)
Indicates deviations from the TRUMPF default
values.

Shows that a value is outside the specified

range.
The laser technology table cannot be saved,
the values are not transferred to the control.

Tab. 4-29

Fig. 55243

10.7 Microjoint

Microjoints are small webs which connect the cut part with the
sheet. After the sheet is completely machined, the part is broken
out by hand. Microjoints prevent collisions between the cutting
unit and the cut part.

■ Microjoints make sense up to a material thickness of 6 mm.

■ Parameter changes are saved immediately and take effect
the next time they are called up in the program.

4‐82 Manually adjust technology parameters 2019-02-01 B813en

 Symbol/name Description
Name of the technology table

Category:
■ Microjoint: Microjoint processing data is displayed.
"Programmed MicroJoints The microjoints hard-coded in TruTops are set.
active"
"Microjoint length for The length of the hard-coded microjoints specified by TruTops in [mm].
small, medium and large
contour"
"Piercing type after Micro- [10] Normal piercing.
joints"
[11] Gentle piercing.
"Set own microjoints" A microjoint is set automatically at the end of the contour.
"Min. and max. contour Defines a range for the contour length in X in [mm]. A microjoint is set at the end of
dimension in X" all contours whose length lies within the defined range.
"Min. and max. contour Defines a range for the contour length in Y in [mm]. A microjoint is set at the end of
dimension in Y" all contours whose length lies within the defined range.
Technology correction parameter: Microjoint Tab. 4-30

10.8 Tube technology (RotoLas)

Tube technology tables are applicable to more than one pro-

gram, and are stored in the control system. All of the parameters
required to machine the tube rod (raw material) are stored in
these tables.

A non-program-specific tube technology table is set up for each

profile ID. A profile ID contains:
■ Profile geometry (exact dimensions of the round or rectangu-
lar tube).
■ Type of material (mild steel, stainless steel, etc.).

The composition of a profile a_bbb_c_ddd:

ID from TRUMPF
a "Type of profile".
(0 = round tube, 1 = rectangular tube, 2 = any profile
(closed), 3 = double-D profile, 4 = D profile, 5 = ellip-
tic profile, 6 = L profile, 7 = U profile, 8 = C profile,
9 = flat material).
bbb Dimensions / identification for the cross-section of the
profile.
c Material ID.
1 = mild steel, 2 = stainless steel, 3 = aluminum.
dd Material thickness in 0.1 mm.
Examples: 0_600_2_30:
Round profile, 60 mm diameter, stainless steel, 3 mm
material thickness.

B813en 2019-02-01 Manually adjust technology parameters 4‐83

 1_600X300X23_2_15:
Rectangular profile, 60 x 30 mm, 2.3 mm edge radius,
stainless steel, 1.5 mm material thickness.
L_500X400X15_1_10: L channel, 50 x 40 mm,
1.5 mm edge radius, mild steel, 1.0 mm material thick-
ness.
Profile ID composition with examples Tab. 4-31

Category Symbol/name Description

Name of the technology table

Category:
■ Geometry: Data on the tube geometry, material and
clamping method is displayed.
■ General: Data on the acceleration and speed of the A
axis is displayed.
■ Load tube.
Geometry "Type of profile" [0] Round tube.
[1] Rectangular tube.
[2] Random profile.
"Diameter" Diameter of the circular tube.
"Height" Height of the rectangular tube.
"Width" Width of the rectangular tube.
"Edge radius" Transition radius between the two surfaces of a rectangular
tube.
"Outer circle diameter" Outer circle diameter for arbitrary profiles.
"Material" 1: Mild steel.
2: Stainless steel.
3: Aluminum.
"Tube length" Length of the tube rod.
"Material thickness" -
"Clamping method" The type of clamping jaws is displayed with which the tube
must be clamped for processing the current NC program.
[30] Turning jaws stage A inside.
[31] Turning jaws stage B inside.
[32] Turning jaws stage C outside.
[33] Drilling jaws stage A outside.
[34] Drilling jaws stage B outside.
[35] Drilling jaws stage C outside.
[36] Bolt clamping set.
[37] Prism clamping set, continuous.
[38] Prism clamping set, blank.
[39] Minimized dead area.
General "Maximum acceleration, A TruTops defines default values for the acceleration and the
axis" speed of the A axis via the NC program. These default val-
ues depend on the geometry and the weight of the tube. If
"Maximum speed, A axis"
necessary (e. g. with large tubes), the default values can be
reduced.

4‐84 Manually adjust technology parameters 2019-02-01 B813en

 Category Symbol/name Description
Load tube "Table" Name of the table with loading data, which belongs to the
selected tube (TTL = Tube Tech Load)
"Position tube horizontally" The rectangular tube is aligned horizontally at the current
X position.
Technology correction parameter: Tube technology Tab. 4-32

10.9 Load tube (RotoLas)

Category Symbol/name Description

Name of the technology table

Category:
■ Supports: Data on the positions and dead areas of the
supports for tube processing is displayed.
■ General: Move support.
Supports "Position" Depending on the tube length, up to 5 supports can be used
to ensure a stable tube position during processing.
The values for the support positions come from TruTops.
"Dead area in +X direction" A dead area is defined by TruTops around the supports so
that there can be no collision between the cutting head and
"Dead area in -X direction"
the supports.
"Dead area in Y direction"
General "Measure support after dis- Activate if the RotoLas support is to be measured after a
placement" displacement. The measurement ensures that the support is
at the correct position and cannot collide with the cutting
head.
"Check movement range" Activate if a note on collision avoidance is to appear before
moving a support. Before the operator acknowledges the
note and can move the support, he must check if there are
upright coupled parts in the movement area of the support.
Technology correction parameter: Load tube Tab. 4-33

10.10 Part technology (RotoLas)

Part technology tables are program-specific tables.

Category Symbol/name Description

Name of the technology table

Category:
■ General.
■ Sheet layout.

B813en 2019-02-01 Manually adjust technology parameters 4‐85

 Category Symbol/name Description
General "Dynamic level" [-1] Reduced: Least dynamics, greatest contour precision.
The machining time becomes longer.
[0] Standard.
[1] Increased: Greater dynamics, shorter machining time.
The contour precision becomes less.
"Programmed tube length" Programmed reference tube length. When programming a
single part, a reference tube is defined in the programming
software, of which the zero point is used for all measure-
ments in the NC program.
"Longest contour in X" The value comes from TruTops and indicates the length of
the longest closed cut (cut finishes where it started) in the X
direction.
"Processing length" Length of the single part which is being machined (including
the kerf and approach path).
"Part length" Actually measured length of the part (machining length
minus kerf and approach path).
Nesting The parameters are not evaluated for RotoLas.
Technology correction parameter: Part technology Tab. 4-34

10.11 Edge technology (RotoLas)

This technology correction is used for pipe cutting when the

parameters for cutting over edges are to be adjusted.

1 Path with cutting distance 1 4 Nozzle

and cutting feed 1 a Standard cutting distance
2 Path with cutting distance 2
and cutting feed 2
3 Workpiece
Changing the cutting distance when cutting over edges Fig. 63213

4‐86 Manually adjust technology parameters 2019-02-01 B813en

 Symbol/name Description
Name of the technology table

"Cutting distance 1" For edge machining, the cutting distance and cutting feed must be adjusted in
stages. If the cutting head gets close to the edge, the first value pair (cutting dis-
"Cutting distance 2"
tance 1/cutting feed 1) from the table is activated first. To cross over the edge, the
second value pair (cutting distance 2/cutting feed 2) becomes active. Value pair 1 is
reactivated after the edge has been crossed over. Afterwards, machining is contin-
ued with the data from the laser technology table.
The cutting distance around edges is activated by the cycle TC_COR-
NER_LEVEL(1,2) and then deactivated again by the cycle TC_COR-
NER_LEVEL(4.0) (see also the programming manual). The cutting distance from the
laser technology table does not apply here.
"Cutting feed 1" The cutting feed around edges is subject to an upper limit by the value in "Cutting
feed 2".
"Cutting feed 2"
The cutting feed around edges is activated by the cycle TC_CORNER_LEVEL(1.2)
and deactivated again by the cycle TC_CORNER_LEVEL(4.0) (see also the pro-
gramming manual).
Technology correction parameter: Edge technology Tab. 4-35

B813en 2019-02-01 Manually adjust technology parameters 4‐87

 10.12 Loading sheet (automation)

Page Designation Description

Name of the technology table (SHL = Sheet Load).

1 "Align sheet" Activate/deactivate "Align sheet".

While the sheet is being transferred to the pallet changer a sheet
(with a max. sheet thickness of 10 mm) is aligned parallel to the X
axis. This ensures that the position of the finished parts corresponds
to the programmed suction cups.
This option is only available for the LiftMaster Sort and the
LiftMaster Store with Sort extension.
"Peeling" Activate/deactivate peeler suction cup
The peeler suction cup separates sheets that are stuck together
when lifting the sheet stack.
"Rake for transport" 0: Standard. The rake is closed or left open depending on the sheet
thickness and lifting height.
1: The rake is always open during the transport operation.
2: The rake is always closed during the transport operation.
This function is only available for the LiftMaster Store.
"Spray from below" Activating/deactivating oil spray device (option)
Before loading on to the pallet changer, the unprocessed sheet is
sprayed from below with a liquid so that the cut sheet can be more
easily detached from the support slats.
The spraying equipment is on a system pallet.
This function is only available for the LiftMaster Store.
"Remove intermediate layer" Activate/deactivate blower for removing intermediate layers in the
unprocessed sheet stack.
An intermediate layer made of chemical pulp or plastic is blown from
the sheet using compressed air.
The blower is on the pallet removal.
This function is only available for the LiftMaster Store.
"Double sheet detection" Activate/deactivate the sheet thickness measuring device for record-
ing the sheet thickness of the raised sheet.
"Fanning magnet" Activate / deactivate the fanning magnet on the suction frame.
This fanning magnet is only on first generation LiftMasters.
"Rotation cylinder" Activate / deactivate the rotation cylinders to align the sheet in the
suction frame.
These rotation cylinders are only on first generation LiftMasters.

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 Page Designation Description
2 "Format selection" A preset suction cup activation can be selected for the following for-
mats:
■ Small format.
■ Medium format.
■ Large format.
■ Maxi format.
■ Format (4 m x 2.5 m).
■ Format (6 m x 2 m).
■ Format (6 m x 2.5 m).
Individual suction cup: Suction cups can be activated/deactivated
individually in the "Valve number" area.
"Valve number" The suction cups for loading the machine activated via the NC pro-
gram are displayed in red in the graphic, the deactivated suction
cups are displayed in yellow. The suction cups can be selected in
the graphic and subsequently activated or deactivated.
■ "Valve number": The number of the suction cup selected in the
graphic is displayed. In the reverse order, a valve number can be
selected first for which the corresponding suction cup is then dis-
played graphically.
■ "Status":
− [0] Deactivated (the suction cups are displayed in yellow in
the graphic).
− [1] Activated (the suction cups are displayed in red in the
graphic).
"Status" "Status":
■ [0] Deactivated (the suction cups are displayed in yellow in the
graphic).
■ [1] Activated (the suction cups are displayed in red in the
graphic).
Technology correction parameter: load sheet with automation Tab. 4-36

10.13 Removal (automation)

The following automation components are equipped for the

removal of parts from the scrap skeleton:
■ LiftMaster Store with the Sort extension (maxi-parts removal)
■ LiftMaster Sort (maxi-parts removal).
■ SortMaster (small parts removal).

Symbol/name Description
Program name.

"Part designation" Name of the part to be removed. The part is displayed in orange on the graphic. All
information displayed refers to the selected part.

B813en 2019-02-01 Manually adjust technology parameters 4‐89

Symbol/name Description
"Category" ■ "Basic machine": Cannot be selected.
■ "Small part removal - holder": The small part is removed from the pallet changer
with the suction cups of the SortMaster.
■ "Small part removal - palletizing": SortMaster deposits the small part on a pallet.
■ "Maxi parts removal - receiver": The maxi-part is removed from the scrap skele-
ton with the suction cups of the LiftMaster.
"Info" ■ "Number of coupled removals": How often an identical part removal is to be
repeated is displayed.
■ "Number of parts to be removed": Number of parts to be removed in one work
cycle.
■ "Small part removal": The part is removed by the SortMaster.
■ "Maxi parts removal": The part is removed by the LiftMaster Sort or by LiftMaster
Store with the Sort extension.
Tab. 4-37

Small part removal - receiver

Conditions
■ Technology correction, "Removal" is selected.
■ The part to be removed is selected in the graphic and dis-
played in orange.
■ "Small part removal - Holder" is activated.

1. Press Continue.
The "SortMaster - remove parts" mask appears.
2. Check parameters.

Symbol/name Description
Program name.

Category:
■ Pick up: Data on the removal of the parts from the scrap skeleton is displayed.
"Selected" Name of the table with removal data, which belongs to the selected part.
"Coupled removals" How often an identical part removal is to be repeated is displayed.
Tab. 4-38

3. Select "Shared parameters".

Name Description
"Pick-up position X" X and Y coordinates of the removal position, measured between the center of the
SortMaster suction plate and the center of gravity of the part to be removed.
"Pick-up position Y"
"Pick-up angle" Angle of rotation of the C axis, about which the gripper is to be rotated for part
removal.

4‐90 Manually adjust technology parameters 2019-02-01 B813en

Name Description
"Removal test" SortMaster checks if the part to be removed was picked up using suction.
Tab. 4-39

4. Select "Part 1".

Name Description
"Suction cup activation" The suction cups for part removal activated via the NC program are displayed in red
in the graphic, the deactivated suction cups are displayed in yellow. The suction
cups can be selected in the graphic and subsequently activated or deactivated.
■ "Valve number": The number of the suction cup selected in the graphic is dis-
played. In the reverse order, a valve number can be selected first for which the
corresponding suction cup is then displayed graphically.
■ "Status":
− [0] Deactivated (the suction cups are displayed in yellow in the graphic).
− [1] Activated (the suction cups are displayed in red in the graphic).
Tab. 4-40

5. Press Save and close.

Small part removal - palletizing

Conditions
■ Technology correction, "Removal" is selected.
■ The part to be removed is selected in the graphic and dis-
played in orange.
■ "Small part removal - Palletizing" is activated.

1. Press Continue.
The "SortMaster - stack parts" mask appears.
2. Check parameters.

Symbol/name Description
Program name.

Category:
■ Palletizing: Data on the deposition of the parts on pallets is displayed.
"Selected" Name of the table with deposit data, which belongs to the selected part.
"Coupled removals" How often an identical part removal is to be repeated is displayed.
Tab. 4-41

3. Select "Part 1".

B813en 2019-02-01 Manually adjust technology parameters 4‐91

Name Description
"Deposit location" Deposit site where the finished parts are to be deposited:
1: bucket on the unloading platform on the lengthwise side of the pallet changer.
3...6: Deposit site.
"Palletizing type" 1: Depositing.
2: Dropping from maximum stack height preset by TruTops.
3: Dropping from above (highest gripper position).
4: Dynamic dropping (dropping always takes place 2 cm above the current stack
height).
"Stack number" number of the stack to which the selected part belongs.
"Max. stack height" The maximum permissible height of the finished parts stack is preset by TruTops.
"Speed" Speed of the SortMaster axes.
"Acceleration" Start-up acceleration of the SortMaster axes. The acceleration depends on the part
weight and part geometry. Default value: 3 m/s².
"Offset deposit position X" X and Y coordinates of the deposit position, relative to the zero point of the deposit
unit.
"Offset deposit position Y"
"Deposit angle" Deposit angle = angle of rotation of the C axis (option) with which the part is to be
deposited on the deposit unit.
Tab. 4-42

4. Press Save and close.

Maxi part removal - receiver

Conditions
■ Technology correction, "Removal" is selected.
■ The part to be removed is selected in the graphic and dis-
played in orange.
■ "Maxi part removal - receiver" is activated.

1. Press Continue.
The "LiftMaster - remove parts" mask appears.
2. Check parameters.

Symbol/name Description
Program name.

Category:
■ Pick up: Data on the removal of the parts from the scrap skeleton is displayed.
"Selected" Name of the table with removal data, which belongs to the selected part.
"Coupled removals" How often an identical part removal is to be repeated is displayed.
Tab. 4-43

4‐92 Manually adjust technology parameters 2019-02-01 B813en

 3. Select "Part 1".

Name Description
"Suction cup activation" The suction cups for part removal activated via the NC program are displayed in red
in the graphic, the deactivated suction cups are displayed in yellow. The suction
cups can be selected in the graphic and subsequently activated or deactivated.
■ "Valve number": The number of the suction cup selected in the graphic is dis-
played. In the reverse order, a valve number can be selected first for which the
corresponding suction cup is then displayed graphically.
■ "Status":
− [0] Deactivated (the suction cups are displayed in yellow in the graphic).
− [1] Activated (the suction cups are displayed in red in the graphic).
Tab. 4-44

4. Press Save and close.

10.14 Skeleton separation (automation)

For the "skeleton separation for thin sheets" option, the suction
frame is equipped with spreadable grippers, which can pick up
the scrap skeleton in the unloading rake.

Designation Description
"Name" Name of the technology table (PAUD = Part Unload).
"Gripper coding" Hexadecimal code, which can be changed using the Gripper selection button.
Gripper selection ■
Activate individual grippers with .
■ Activate all grippers: Press All grippers on.
■ Deactivate all grippers: Press All grippers off.
Technology correction parameter: Skeleton separation Tab. 4-45

10.15 Unload scrap skeleton (automation)

The "lowerable stripper" option is available for the following auto-

mation components:
■ LiftMaster Sort.
■ LiftMaster Store with the Sort extension

B813en 2019-02-01 Manually adjust technology parameters 4‐93

 Designation Description
"Lower stripper" If a sheet with the rake is unloaded, and if the sheet is smaller than the maximum
size of the rake, then the lowerable scraper can be swiveled in. This then prevents
the small sheet from slipping in the LiftMaster's rake.
■ [0] Never lower stripper.
■ [1] Lower stripper during every unloading process.
■ [2] Lower stripper depending on the sheet size of the sheet to be unloaded.
Technology correction parameter: Unload scrap skeleton Tab. 4-46

4‐94 Manually adjust technology parameters 2019-02-01 B813en

 11. Manual functions

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

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

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

11.1 Using manual functions

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

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

11.2 Engraving

The TC_WRITE cycle can be used to engrave workpieces.

The following options are available:

■ Selecting predefined output modes.
■ Input of free text.
■ Consecutive numbering with free text.

Notes
■ The text is always aligned in X direction.
■ For additional information, see also TruTops (Version 6) soft-
ware manual and TruTops Boost Help.

B813en 2019-02-01 Manual functions 4‐95

 1. Press Production, "Manual functions".
2. Press "Engraving".
The "Define engraved text" dialog opens.

1 Input field for any text 2 Selection of predefined out-

mode modes
Fig. 69004
3. Select output mode
4. Input font height.

Note
At the machine, an attempt must be made to see if the entire
text can be engraved on the workpiece with the input font
height.
5. Enter text and any counters.
6. Press OK.
7. Start the part program that contains the cycle.
The text is engraved until it is deleted from the "Text" field.

4‐96 Manual functions 2019-02-01 B813en

 12. Move the zero point of the NC
program

12.1 Defining the new zero point

The NC program and thus the sheet processing is started from

the redefined zero point. The NC program need not be changed
for this.

1. To shift the current zero point: press Production, Current pro-

gram, Offset zero point.
The "Offset zero point" mask is displayed.
2. Activate "...to the manually selected position" and enter coor-
dinates X, Y for the new zero point.
or
Ø Activate "...to the position of the laser diode position".
or
Ø Activate "...to the nozzle middle position".
3. Press Apply.
In the status line the program status will be displayed with the
shifted zero point .

12.2 Deleting "Offset zero point"

1. To delete the current zero point: press Production, Current

program, Offset zero point.
The "Offset zero point" mask is displayed.
2. Activate "Delete zero point offset".
3. Press OK.

B813en 2019-02-01 Move the zero point of the NC program 4‐97

 13. Setup

13.1 Moving the axes manually

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

machine can be manually traversed via the JOG BUTTON on
the control panel.

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

Note
The axes can also be moved manually in Set-up, "Manual func-
tions". The functions Accelerated and Continuous are available
there.
Accelerated: The axes move with increasing speed while the rel-
evant axis button is pressed.
Continuous: The axes move at full speed while the relevant axis
button is pressed.

Axis designation Direction of movement

X axis Horizontal motion axis of the cutting unit.
Y-axis Horizontal motion axis of the cutting unit.
Z axis Vertical motion axis of the cutting unit.
Tab. 4-47

1. Press Setup, "Axes motion".

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

4‐98 Setup 2019-02-01 B813en

 13.2 Releasing brakes for the Z axis drive

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

be released (bled).

Conditions
■ EMERGENCY STOP is pending.
■ Machine door is opened.

1. Press Setup, "Manual functions".

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

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

13.3 MDA

Note
Only for the Advanced user.

Programs can be compiled block-by-block and immediately exe-

cuted in single block or block-by-block mode under MDA
(Manual Data Automatic). The desired movements can be specif-
ically entered for this purpose in the form of individual NC blocks
using the keyboard.

Note
The control system saves the programmed NC texts perma-
nently. After restarting the HMI they will still be available.

Creating NC programs block-by-block

1. Press Setup, "MDA".

2. Enter the desired NC text.
3. Either
Ø To copy the text: Mark the text and press Copy.

B813en 2019-02-01 Setup 4‐99

 Ø Place the cursor at the new position and press Paste.
or
Ø To cut out the text: Mark the text and press Cut.
Ø Click on the new position with your mouse pointer (cur-
sor).
Ø Press Insert.
A yellow strip on the left border highlights the modified text
segment in the NC text.
4. Press Undo to undo the last operation that was carried out.
5. To execute the created NC text in one piece (in successive
mode): Press Start.
6. To execute the NC text which was compiled block-by-block:
Press "Single block".
7. Press Start to process each NC block individually.
8. Delete the compiled NC text with Delete all.

13.4 Activating or deactivating cleaning

brush

During production The operator can activate or deactivate the cleaning of the sheet
being run-in via the cleaning brush while a program is running.

1. Select main operation Production, "Manual functions", Pallet

change, "Move cleaning brush up or down".

Before the program start The operator can select various functions before starting a pro-
gram.
■ Select pallet A or B, or A and B (which pallet should be
cleaned).
■ Set the cleaning brush offset (how far the ends of the
brushes move below the upper edge of the sheet in millime-
ters).
2. Select the main operation Setup, "Manual functions", "Clean-
ing brush".
3. Press "Sheet cleaning brush" multiple times to select the
desired pallet.
4. Press "Offset" and use the arrow keys to change the value
up or down in order to increase or decrease the cleaning
effect.

4‐100 Setup 2019-02-01 B813en

 14. Multiple-machine operation with
TruTops FMC

Multiple 2D laser machines can be loaded and unloaded using

the automation components LiftMaster Linear, LiftMaster Store
Linear and LiftMaster Linear Basic. This procedure is called
multi-machine mode.

TruTops FMC Flexible Manufacturing Cell.

TruTops FMC program is used for controlling and managing all
components within a manufacturing cell.

TruTops FMC Panel For machines with an MMC200X and Touchpoint control, the
TruTops FMC software is integrated in the machine control.
If machines with GritPlus control are in multi-machine mode,
then the TruTops FMC software is installed on a separate com-
puter – the TruTops FMC Panel.

■ Only machines with GritPlus control: one TruTops FMC Panel

is enough to control the automation components for all
machines.
■ Systems with at least one MMC200X or Touchpoint control:
Every machine with GritPlus control which is connected to
multiple-machine operation must be equipped with its own
TruTops FMC panel. Two GritPlus-controlled machines can-
not be controlled by a single TruTops FMC panel.
The TruTops FMC panel may only be switched on after the
machine has been switched on.
The sequence makes no difference when switching the system
off.

14.1 Master/Slave operation

If several 2D laser machines are loaded and unloaded by one

LiftMaster, one machine has the "master" role and all others are
"slaves". This setting is made using an ETHERNET CONFIGU-
RATION key switch on the electrical cabinet of the LiftMaster
and as an entry in FMCMasterDetector.

Execute an Master/Slave switch

If the master machine is to be switched off e.g. during mainte-

nance purposes, a slave machine must assume the role of the
"master".

B813en 2019-02-01 Multiple-machine operation with TruTops FMC 4‐101

 A slave machine can be switched off at any time while the mas-
ter machine continues to produce.

1. At the slave machine, end user interface:

− On the user interface, press on the TRUMPF Logo.
− Select "System" tab.
− Press Exit.
− Press Close HMI.
2. At the master machine, end the user interface:
− On the user interface, press on the TRUMPF Logo.
− Select "System" tab.
− Press Exit.
− Press Shut down.
3. Switch off the main switch on the electrical cabinet of the
master machine.
4. Turn the ETHERNET CONFIGURATION key switch on the
electrical cabinet of the LiftMaster to the new master
machine (to position I, II or III depending on the configura-
tion).
5. Start the user interface on the new master machine:
− In the TRUMPF Operating System (TOS), press MMC
Start.
The manufacturing cell can continue to produce with the new
master machine. The safety circuit for the LiftMaster remains
closed allowing the LiftMaster to move.

Switching off the LiftMaster

For maintenance purposes or in the event of malfunctions, it

may be necessary to switch off the LiftMaster.

1. End the user interface on all laser machines:

− On the user interface, press on the TRUMPF Logo.
− Select "System" tab.
− Press Exit.
− Press Exit HMI.
2. Switch off the LiftMaster:
− If available: shut down and switch off TruTops FMC
Panel.
− Turn off the LiftMaster's main switch on the electrical cab-
inet.
3. Start the user interface on all laser machines.

4‐102 Multiple-machine operation with TruTops FMC 2019-02-01 B813en

 − In the TRUMPF Operating System (TOS), press MMC
Start.
When starting up the user interface of the master machine,
the FMCMasterDetector will open up automatically and
remains in place with a flashing cursor.
4. After the line "Autodetecting handling device or master
machine..." enter master
Start-up is completed without a connection to the LiftMaster.
A pallet change is only possible in enabling mode.

Note
Enabling mode is not possible on machines with GritPlus
controller and TruTops FMC panel.
5. Switching on enabling mode:
− Turn the key switch on the start post.
− On the control panel of the laser machine, select Set up,
"Manual functions" and enable the Pallet changer ena-
bling mode function.
6. Repeat the procedure for all laser machines.
Now, a pallet change will only be possible by pressing the
enable key on the start post.
The enable key flashes when there is a pending pallet
change.
The enable key must remain pressed during the pallet
change.
The pallet change is carried out at reduced speed.
7. Switch off enable mode:
− Turn the key switch on the start post.
− At the control panel of the laser machine, select Set up,
"Manual functions" and disable the Pallet changer ena-
bling mode function.

B813en 2019-02-01 Multiple-machine operation with TruTops FMC 4‐103

 15. Managing NC programs

NC program management Under Programming, "Programs", programs can be managed

and edited:
■ Load master file (NC program) in the internal management
system.
■ Editing NC programs:
− Modifying texts in the NC program
− Modifying technology tables in the NC program.
− Search and replace in the NC program.
− Renumber program blocks.
■ Output (export) NC program as master file.
■ Copy, rename or delete NC program.

1 Folder structure 4 Filters 6 Path

2 Internal management 5 PDF file of the setup plan 7 Program selection
3 Hard drive/USB
Manage programs Fig. 71606

4‐104 Managing NC programs 2019-02-01 B813en

 15.1 Load master file (NC program) in the
internal management system

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

imported into internal management system of the control system.
For this purpose the NC programs can be imported from a so-
called master file (*.LST) of the machine, from any random net-
work drive or from a local PC. The master file contains the
actual NC program and the table leader.

1. Press Programming, "Program management".

2. At "Storage location", select 'topsmanu.dir' ( ).
3. If necessary, switch to the directory from which the master
file is to be imported (e.g. network drive). Open 'Pfad' with
for this.
4. Press Import.
The "Program selection" screen opens.
5. To filter according to designation: enter search term under
"Filter" (e.g. the first letter or digit of the file name).
All NC programs that have the entered search string in their
name are displayed.
6. Activate one or several NC programs or master files (*.LST)
with . To import all NC programs or master files at once:
Press Check all.
7. Press Import.
The selected NC programs will be applied in the internal man-
agement system of the control.

15.2 Editing NC programs

NC programs located in the internal management system of the

machine can be edited in the NC editor.

Notes
■ The description of a cycle can be called directly from the list
field in the top-left (open list field with , Programming
manual, mark cycle).
■ Can the entire programming manual of the machine can be
called via the main activity Help ? ( ).

B813en 2019-02-01 Managing NC programs 4‐105

 Enter NC program in the editor

Condition
■ The program status is "OK" ( ).

1. Press Programming, "Program management".

2. Under "Storage location" select internal management of the
machine ( ).
All NC programs in the internal management system are dis-
played.
3. To filter according to designation: enter search term under
"Filter" (e.g. the first letter or digit of the file name).
All NC programs that have the entered search string in their
name are displayed.
4. Mark a program that is to be displayed in the editor.
5. Press Edit.
The "Edit program" mask is displayed.
6. To navigate between the main program and any sub pro-
grams:
− Open the list field in top left using .
− Select Navigation

Create NC sub program

Note: The following description is valid for one local subrou-

tine (UP).
"Subroutine macro" .
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

4‐106 Managing NC programs 2019-02-01 B813en

 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.
■ The program status is "OK" ( ).

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.

1. Press Program and select "Manage programs".

2. Under "Storage location" select internal management of the
machine ( ).
All NC programs in the internal management system are dis-
played.
3. To filter according to designation: enter search term under
"Filter" (e.g. the first letter or digit of the file name).
All NC programs that have the entered search string in their
name are displayed.
4. Mark a program that is to be displayed in the editor.
5. Press Edit.
The "Edit program" mask is displayed.
6. Mark the required text in an existing main or sub program.
7. Press New sub program.
The marked text will be inserted into the sub program. In the
main program, the name of the new sub program will be
shown.
8. 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.

B813en 2019-02-01 Managing NC programs 4‐107

 Modifying tests in the NC program

Condition
■ The program status is "OK" ( ).

1. Opening NC programs in the editor (see "Enter NC program

in the editor", pg. 4‐106).
2. Highlight the text to be edited.
3. Either
Ø To copy the selected text: press Copy.
Ø Place the mouse pointer on the new position.
Ø Press Paste.
or
Ø To cut out the selected text: press Cut.
Ø Place the mouse pointer on the new position.
Ø Press Paste.
A yellow strip on the left border highlights the modified text
segment in the NC text.
4. Press Undo to undo the last operation that was carried out.
5. Press Repeat to restore the operation that was undone.
6. Either
Ø To save the changes: press Save.
or
Ø To save the changes and exit the editor: press Save and
close.

Modifying technology tables in the NC

program

During the processing of an NC program the technology table

parameters can be called and directly modified.
Technology tables (e.g. the loading table SHEET_LOAD) are dis-
played underscored in the editor.

Condition
■ The program status is "OK" ( ).

1. Opening NC programs in the editor (see "Enter NC program

in the editor", pg. 4‐106).
2. Place mouse pointer in the call of the table, the technology
parameters of which are to be changed.

4‐108 Managing NC programs 2019-02-01 B813en

 3. Press Go to.
A screen is opened with the corresponding technology
parameters.

Note
Larger technology tables have screens that extend over sev-
eral pages.
4. Changing required technology parameters.
5. Either
Ø To save the changes: press Save.
or
Ø To save the changes and return to the editor: Press Save
and close.
6. To modify more technology tables: repeat steps 2 to 5 until
all the required parameters have been changed.

Searching and replacing in the NC program

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

function in the NC text to replace it if required.

Condition
■ The program status is "OK" ( ).

1. Opening NC programs in the editor (see "Enter NC program

in the editor", pg. 4‐106).
2. Open the list field in top left using .
3. Select Find + Replace.
4. Enter the search string under "Search for".
5. To jump to the next search term: press Find next.
The cursor jumps to the position of the next search term.
6. If the search string is to be replaced: enter the new string
under "Replace with".
7. Either
Ø Press Replace.
The search string is replaced.
or
Ø Press Replace all.
All search strings found in the NC text are replaced.
A yellow strip on the left border highlights the modified text
segment in the NC text.

B813en 2019-02-01 Managing NC programs 4‐109

 8. Either
Ø To save the changes: press Save.
or
Ø To save the changes and exit the editor: press Save and
close.

Renumbering program blocks

There are block numbers at the beginning of each program

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

Condition
■ The program status is "OK" ( ).

1. Opening NC programs in the editor (see "Enter NC program

in the editor", pg. 4‐106).
2. Open the list field in top left using .
3. Select Numbering.
4. To restart numbering after modifying the NC text: enter the
number with which renumbering is to be started under "Start
number".
5. Enter the increment that is to be inserted between the follow-
ing program blocks under "Increment".
6. Press Number.
The NC program is renumbered.
7. Either
Ø To save the changes: press Save.
or
Ø To save the changes and exit the editor: press Save and
close.

15.3 Output (export) NC program as

master file

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.

4‐110 Managing NC programs 2019-02-01 B813en

 The *.LST and *.TPP file types can be selected for the export
file.

Conditions
■ The NC program is stored in the machine's internal manage-
ment system.
■ The NC program is not active.

1. Press Programming, "Program management".

2. Under "Storage location" select internal management of the
machine ( ).
All NC programs in the internal management system are dis-
played.
3. Press Export.
The "Program selection" screen opens.
4. To filter according to designation: enter search term under
"Filter" (e.g. the first letter or digit of the file name).
All NC programs that have the entered search string in their
name are displayed.
5. Activate one or several NC programs with . To export all
NC programs at once: Press Select all.
6. Press Export.
7. If several NC programs are to be exported: edit query that
appears (Together as production package or Individually).
8. Press Continue ( ).
9. Enter the file names.
10. Select storage medium and file type:
11. If necessary, create new folder.
12. Press Apply.
The master file(s) are generated and stored in the selected
export folder.

15.4 Deleting NC program

Condition
■ The NC program is not active.

1. Press Programming, "Program management".

2. Select storage location of the NC program that is to be
deleted.
3. Press Delete.
The "Program selection" screen opens.

B813en 2019-02-01 Managing NC programs 4‐111

 4. To filter according to designation: enter search term under
"Filter" (e.g. the first letter or digit of the file name).
5. Select NC program(s).
6. Press Delete.

15.5 Copying a NC program

Condition
■ The NC program is stored in the machine's internal manage-
ment system.

Note
The program status must be set to "OK" ( ).

1. Press Programming, "Program management".

2. Under "Storage location" select internal management of the
machine ( ).
3. All NC programs in the internal management system are dis-
played.
4. Select the NC program.
5. Press Copy.
6. Enter the new name of the NC program.

Tip
The current name can be copied.

7. Press OK.

4‐112 Managing NC programs 2019-02-01 B813en

 16. Creating programs

Note
There are wizards available for the functions Process part and
Generate program.

The programming functionality provides the following possibilities:

■ Process Part: Load a part (*.GEO,*.DXF, *.GMT) and create
a single program out of it with all laser technology data
added.
■ Generate program: Nest parts on one sheet and generate a
complete program for this.
■ Manage Part Files: Organize part files.

16.1 Process part

Add a part to the partlist

1. Press Programming , "Create program".

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

Process part

Choose a part 1. Press Programming , "Create program".

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

B813en 2019-02-01 Creating programs 4‐113

 Confirm contour Note
If the desired part is a dxf file the correct contour needs to
be confirmed.
5. Press Show Alternatives to switch between the contours
found.
or
Ø Press Confirm suggestion to confirm the part contour.

Rotate part 6. Keep checkbox "Do not rotate" activated.

− Press rotate left or rotate right to rotate the part
manually by 90°.
or
Ø Activate checkbox "Allow rotation" to allow automatic
rotation if needed.
or
Ø Activate checkbox "Rotate only in rolling direction" to
allow rotation in rolling direction if needed.
7. Press Next to continue.

Select technology table Note

The tech table list can be narrowed down by sorting it by
Material, Thickness, Gas or Variant.
8. Highlight the correct tech table out of the list.
9. Press Next to continue.

Choose microjoint options 10. Specify the desired microjoint strategy by activating the cor-
responding radio button.
11. Press Process part to continue.
The laser processings are displayed with red lines for lead-
ins, green lines for contours and blue lines for positionings.

Move Lead In Position 12. Press Show Alternative to move the lead in position to the
desired position.
13. Press Next to continue.

Save part 14. Open the virtual keyboard by pressing next to the
"Enter part name" field.
The virtual keyboard is displayed.
15. Enter the part name.
16. Press Finish to save the part to the default directory (F:\pro-
grammingTool).
The part is saved as a *.GMT file.

4‐114 Creating programs 2019-02-01 B813en

 16.2 Generate program

Note
The program generation procedure can always be aborted by
pressing Cancel.
To undo a step in the process, press Back.

Begin generation 1. Press Programming , "Create programs".

2. Select "Generate program".
3. Enter the desired sheet measurements and the direction of
rolling of the sheet.
4. Press Continue.

Select Part to Nest Notes

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

View Nest Results Note

In the "View Nest Result" screen, the nest result and the list
of nested parts are displayed. The "List of nested parts"
shows the individual quantity nested on the sheet and shows
also if it was not possible to nest all parts on the sheet.
8. Press Continue to continue with the program creation.
or
Ø Press Add another part to add another part to the nest.
− See section "Select part for nesting"
or
Ø Press Delete last part to delete the part added last.

Choose options 9. Activate or deactivate checkbox "Evaporate (whole contour)".

10. Press Next to continue.

Save New program 11. Open the virtual keyboard by pressing next to the
"Enter new program name" field.
The virtual keyboard is displayed.
12. Enter the program name.

B813en 2019-02-01 Creating programs 4‐115

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

16.3 Managing parts

In the mask "Manage parts", files (*.DXF, *.GEO, *.GMT) can be

deleted and copied from a source to a target directory.

Note
GMT files cannot be copied onto the machine.

Manage files

1. Press Programming , "Create programs".

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

Delete files or clear folder

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

1. Select the desired Target directory.

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

4‐116 Creating programs 2019-02-01 B813en

 17. Multi-sheet processing

The "multi-sheet processing" function allows processing of very

different materials and material thicknesses on one or both pal-
lets.

17.1 Edit several sheets

Conditions
■ All LST programs used must contain the "SheetMeasure"
technology.
■ Nozzle changer is available.
■ For the position of the sheet, a template must be created on
the user interface.
■ For every sheet, the position must be entered depending on
the machine zero point and assigned to a program.
■ So that a template can be created, at least two programs
must be selected.
■ When using templates, position measurement must be
switched off in order to avoid a collision.

Notes
■ Recommended minimum distance of the sheet in all direc-
tions: 100 mm.
■ The sheet position template used must be correctly assigned
to the order.
■ The quantity of a multi-sheet layout is always 1.

A Minimum distance of the sheets (100 mm)

Fig. 81044

B813en 2019-02-01 Multi-sheet processing 4‐117

Create template (production 1. To create a sheet layout: press Programming, "Manual sheet
package) layout".
2. Press the New button.
3. In the "Name" field, enter the name of the new template.
4. Press Add program button.
5. Select program.
6. Press the Add button.
Programs have been selected and the newly created tem-
plate has been assigned.
7. Enter the following values:
− X offset
− Y offset
− Position measurement
− Sheet orientation
8. Press the Save template button.
Template has been saved as a production package.

Select template in the 9. To select a created template for multi-sheet processing in the
production plan production plan, press production plan.
10. Press the Create button.
11. Select the item "Multi-sheet processing".
12. Press Next button.
13. Select the desired production package (template) and press
the Complete button.
In the production plan, every program is displayed as a sep-
arate order with "quantity=1".
14. Select the desired file or folder and press the Enable button.
15. Press the Start button.
Files are transferred to the control.

4‐118 Multi-sheet processing 2019-02-01 B813en

 18. Drop&Cut image-based post-
production (option)

18.1 Start image-based post-production

Condition
■ The camera is calibrated (see "Calibrating the camera for the
image-based post-production (option)", pg. 5‐16).

Activate image-based post- 1. Select Production, Current program, Post-production.

production
The "Post-production: Analyze sheet program" screen will be
opened.
2. Activate the radio button "Image-based post-production".

Selecting parts All parts from a program that has previously been split up are in
the list (to the left).

1 Selection of parts 2 Remainder sheet (camera

image)
Post-production screen: Drop&Cut Fig. 74983
3. Select the required part under "Parts" and then position it on
the (remainder) sheet.
The new part will be shown in yellow on the sheet.

Tips
■ In the case of strongly reflective material, such as alumi-
num or copper, switch to the second-darker color
scheme.
■ If two cameras are installed, the view can be changed
under Change camera.
4. To delete one or all parts: Select Delete part or Delete all.

B813en 2019-02-01 Drop&Cut image-based post-production (option) 4‐119

 Positioning parts Note
When placing parts on the remainder sheet, their position is
not checked automatically. Avoid critical positions, e.g. low
spacing of parts or positioning off sheet.
5. Under "Positioning" parts can be freely positioned on the
sheet.
Select the desired part on the sheet.
or
Ø Move the part using the mouse and turn it with the
mouse's wheel.
6. Press Finish.
Manually positioned parts will be nested in the corresponding
position and will be prepared for processing with the stored
laser technology table.

Note
After creating the program, the sheet may no longer be
moved, as otherwise its absolute reference in the machine's
system of coordinates will be lost.
7. Press START .

4‐120 Drop&Cut image-based post-production (option) 2019-02-01 B813en

 19. MobileControl app (option)

With the MobileControl app from TRUMPF, machines can be

monitored and controlled using an iPad.
The machine's own wireless network is used to transmit the
screen surface of the control panel and, as an option, live pic-
tures from a camera to the iPad. This allows the operator to
keep an eye on the production process as well as those working
steps that do not take place directly in front of the control panel.

The following components are needed for the use of the mobile
control:
■ Wireless operation point
Hardware component in the machine's electrical cabinet for
the provision of the secure wireless network in the area
around the machine.
■ MobileControl program
Software in the machine control for activation and setting of
the wireless network.
■ MobileControl app
Operating program on the iPad
■ Optional: camera in the machine room
For transmission of live pictures from the mashine's work
area.
■ iPad
Not included in the scope of delivery

1 iPad with MobileControl app 3 Camera in the machine room 4 Control with MobileControl pro-
2 Wireless operation point gram

Example: Components of the mobile control Fig. 68854

B813en 2019-02-01 MobileControl app (option) 4‐121

 Note
Actions that are performed using the switches and buttons on
the control panel (for example, EMERGENCY STOP, START,
feed regulation, etc.) can not be carried out using the iPad.

19.1 Safety: MobileControl App

Danger during repair work!

CAUTION
Ø Operating the MobileControl app is not allowed during any
repair work.

The MobileControl app includes many mechanisms to ensure

safe operation. However, they are all based on the assumption
that safety equipment such as protection doors, panels and light
barriers are fully functional. The machine must be in a produc-
tion-ready status when it is operated by the app.
If the status of the machine is now known, no travel commands
may be issued to the machine from the tablet.

The following mechanisms are integrated for safe use:

■ Prevention of double operation.
It is possible to operate either from the control panel or from
the tablet.
■ Activation of the remote control via PIN/QR code.
To activate the remote control on the tablet, a PIN code,
which is displayed on the user interface, has to be entered
on the tablet. This changes after each new request. Alterna-
tively, a dynamically generated QR code can be scanned
from the user interface.
■ Operation permission.
When changing to another machine's WLAN, the operator's
permission to operate the previous machine expires. It has to
subsequently reactivated via the QR code.
■ Warning message at the user interface.
While operation is being done with the tablet, a red/yellow
warning frame is shown on the control panel.

19.2 Operating procedure

1. Start iPad.
2. Download the TRUMPF MobileControl app from the App-
Store.

4‐122 MobileControl app (option) 2019-02-01 B813en

 3. Connect the iPad to the machine's WLAN using the iPad's
settings.
If the WLAN is not visible, check whether the MobileControl
app in the MobileControl Manager has been activated (see
"Activating or deactivating the MobileControl app", pg. 4‐125).
Likewise, the SSID and the WPA2 key of the machine can
be read out in the MobileControl Manager.
4. Start app.
You are then in observation mode. The machine cannot be
operated in this mode.
5. Activate the remote control from the iPad via the menu that
is in the fold-down bar on the left.
A QR code or a PIN is shown.

Pin and QR-Code Fig. 71248

6. Scan or enter the QR code of PIN with the iPad.
A warning frame is shown at the control panel if the remote
control is active. The operation by the control panel is
blocked.

B813en 2019-02-01 MobileControl app (option) 4‐123

 Tips
■ The operation blocking at the control panel can be revoked
again by using the unblocking dialog on the touchscreen.
■ The remote control is then in pause mode and can be reacti-
vated or completely ended by using the orange buttons in
the upper area of the screen.

19.3 Making settings

All settings for the MobileControl app can be queried and

changed via the "MobileControl Manager". This is to be opened
via the user interface.

1. Open Trumpf Operating System (TOSh).

TOSh interface Fig. 95108

2. Press Network Settings.
3. Press Mobile Control.
The MobileControl Manager will be opened.

4‐124 MobileControl app (option) 2019-02-01 B813en

 19.4 Activating or deactivating the
MobileControl app

Mobile Control Manager Fig. 73682

1. Open the MobileControl Manager.

− Select "MobileControl enabled".
The application can be completely activated or deacti-
vated from this selection. This will also correspondingly
and automatically switch WLAN on or off.
− Select "MobileControl input allowed" if the tablet is to be
used for operation.
− Select "MobileControl enabled on startup" if the
MobileControl app should be activated directly when the
machine is switched on.
2. Press Disable and Lock to secure the settings against any
modifications.

19.5 Backup during service work

If the service engineer switches off the MobileControl app for

safety reasons, a PIN must be issued. The function is then
secured against being switched on again.

B813en 2019-02-01 MobileControl app (option) 4‐125

 Pin entry Fig. 73681

19.6 Name for identification of the

machine

There are two possibilities to identify the machine in the app:

■ The machine number issued in the production plant.
■ An alias which, for example, includes the location or other
freely selected name.
− Limitation: the alias may only include the following char-
acters: 0-9, A-Z, a-z

19.7 Setting up and connecting WLAN

The tablet upon which the MobileControl app is installed must be

connected with the machine's WLAN.

Notes
■ The tablet is connected with the machine via the SSID and
the WPA2 key if the MobileControl app has been activated.
■ If a new WPA2 key has been generated, the old connection
must be actively deleted from any already connected tablets
and then the new password has to be entered.

1. Open the MobileControl Manager.

4‐126 MobileControl app (option) 2019-02-01 B813en

 Fig. 73680
2. To generate a new WPA2 key, for example: at "Wireless LAN
Settings", press Generate new WPA2-Key.

19.8 Wireless operation point – WLAN

network of the machine

The machine has its own WLAN network – the wireless opera-
tion point.
The installed access point broadcasts a wireless network which
can be used to access the components installed in the machine.

Note
All applications which are designed for the wireless operation
point can only be used with the original wireless operation point
by TRUMPF. The applications can not be used if they are instal-
led in anything other than the TRUMPF WLAN Access Point.

Network structure The access point is integrated in the machine network, where
the controls, lasers, operator PC and other components are net-
worked.
With this structure, the broadcast WLAN is not a security risk for
the IT infrastructure. The only connection to the customer's net-
work is by the HMI PC, upon which, however, no connection
between the otherwise separate networks has been established.
The machine network itself is protected from the dangers from
the WLAN network by a firewall.

B813en 2019-02-01 MobileControl app (option) 4‐127

 Changing the settings on the wireless
operation point

Possible settings:
■ Country setting.
The country setting must be correctly set to adhere to the
statutory limit values and channel limitations.
■ Frequency band.
2.4 or 5 GHz. Notice: most mobile devices support only 2.4
GHz.
■ Channel.
The automatic channel selection is standard. However, spe-
cific channels can also be selected.
■ Transmission power reduction.
The transmission power is reduced by 6 dB in the standard
configuration. If there are problems concerning the range,
then the reduction is to be reduced (0 dB → highest trans-
mitting power, 6 dB → smallest transmitting power).

1. Press Service at the operating panel.

2. Press Network ....
3. Press WopController.

4‐128 MobileControl app (option) 2019-02-01 B813en

 20. Wireless operation point

20.1 Changing the settings on the wireless

operation point

Possible settings:
■ Country setting.
The country setting must be correctly set to adhere to the
statutory limit values and channel limitations.
■ Frequency band.
2.4 or 5 GHz. Notice: most mobile devices support only 2.4
GHz.
■ Channel.
The automatic channel selection is standard. However, spe-
cific channels can also be selected.
■ Transmission power reduction.
The transmission power is reduced by 6 dB in the standard
configuration. If there are problems concerning the range,
then the reduction is to be reduced (0 dB → highest trans-
mitting power, 6 dB → smallest transmitting power).

1. Press Service at the operating panel.

2. Press Network ....
3. Press WopController.

B813en 2019-02-01 Wireless operation point 4‐129

 21. Operating CoolLine

21.1 Select technology table

The following parameters for CoolLine are displayed in the tech-

nology table:
■ Piercing spot cooling time: Specification of the duration of
cooling for the piercing spot after piercing.
■ End of cut cooling time: Specification of the duration for
cooling the end of cut on the overshoot height.
■ Amount of water in ml/min: The parameter is currently not
evaluated.

1. After selecting the material and the material thickness, press

<Advanced>.
2. Select suitable nozzle.
3. Select a laser technology table with CoolLine in TruTops.

4‐130 Operating CoolLine 2019-02-01 B813en

 22. Smart Collision Prevention

22.1 Use in TruTops

Tip
More information on using TruTops is provided in the Help and in
the technical telegram.

Specifying distance between Smart Collision Prevention calculates how individual parts can tilt
slats based on the current slat configuration.
For a correct calculation and collision-free processing, it is there-
fore essential for smart collision prevention to have correct infor-
mation on the slat configuration.
The slats used must be correctly configured in TruTops for the
calculation to be correct.

Note
Only regular slat distances can be calculated.

Using microjoints In order to give the user the option of placing microjoints that
both can be automatically removed and are not removed by
smart collision prevention, machine microjoints are always
removed by smart collision prevention automatically.
Pre-programmed microjoints are kept or removed depending on
the selected settings.

Activation in TruTops Boost HERE2

Condition
■ TecZone Cut must be opened once.

1. Under "NC creation", select >Parameter "Parameter".

Activate "NC post-processing program" and select >SCP in
the drop-down menu.
2. In the machine rules, set the EnableNcSignature parameter
to a value of 1 under "File" >Modify machine >Rules
"Machine".

B813en 2019-02-01 Smart Collision Prevention 4‐131

 Activation in TruTops Laser

1. Unser "Create NC program", select "Parameter".

Activate "NC post-processing program" and select >SCP in
the drop-down menu or select SCP_PDM in PDM mode.
2. Set the EnableNcSignature parameter to a value of 1 in the
machine rules under "Extras" >Modify data... under >Rules
"Machine".

22.2 Configuring Smart Collision

Prevention

The behavior of Smart Collision Prevention can be configured

using the following options.

Keeping pre-programmed Default setting: off.

microjoints at outer
Pre-programmed microjoints on the outer geometries of parts are
geometries
kept.
This option can be useful for small parts that cannot be cut com-
pletely free so they do not fall onto the conveyor belt.

Note
The maximum permissible microjoint length is 2.5 mm.

Keeping pre-programmed Default setting: off.

microjoints at inner
Pre-programmed microjoints on the inner geometries of parts are
geometries
kept.
Microjoints are frequently set at inner geometries for collision
avoidance. This option should be disabled since smart collision
prevention avoids collisions automatically.
The option can be activated, however, if there are other reasons
for microjoints on inner geometries, such as optional sheet chip-
ping.

Note
The maximum permissible microjoint length is 2.5 mm.

Cut scrap Default setting: on.

Intelligent microjoints on inner geometries are replaced with auto-
matic scrap cutting.
Smart collision prevention automatically places what are called
intelligent microjoints. For inner geometries, these microjoints can
be replaced by the automatic separation of the scraps

4‐132 Smart Collision Prevention 2019-02-01 B813en

 Quality optimizations for Default setting: off.
cutting of small scrap pieces
With the Quality optimizations for cutting of small scrap pieces
function, the quality of the cutting edge is significantly improved.
Bit by bit, the contour and separating cut are processed together.
This means that the cutting edge is hardly damaged by the sep-
arating cut.
Due to the additional positioning motions, the processing time
increases compared to conventional scrap cutting.

Maximum cutting time per Default setting: 4 s.

cropping operation (s)
Input of the time in seconds (max. 15 s) that can be spent per
cropping operation.
Cutting scraps increases the machine uptime, compared to more
effort required for the manual post-processing of the microjoints.
The specified value is taken into account in the calculation
whether a microjoint is set or scraps are cut into pieces. The
processing time can thus be optimized.

Doming of the sheet Default setting: Weak.

Specification of the anticipated degree of arching or sheet distor-
tion.

22.3 Notes on use on the machine

Slats For the smart collision prevention to correctly calculate the tilt
height of the parts between the slats, the slat tips must be in
one plane and must not be too worn.

Reentering a program Due to the separation of contours, reentering a program that is

running is only possible with Last piercing or Interruption place.
Re-entry at a specific part is no longer possible, since process-
ing is no longer carried out part by part.

Note
The sheet must not be moved between program start and pro-
gram end since, with typical kerf widths of a just a few tenths of
a millimeter, this may lead to problems when cutting is contin-
ued, to damage to contours or skewed contours .

Editing and exporting The programs optimized with Smart Collision Prevention are
encrypted on the machine.
This is why it is not possible to edit or export these programs.

B813en 2019-02-01 Smart Collision Prevention 4‐133

 Post-production Post-production is not possible for parts optimized with smart
collision prevention. The original program created by TruTops is
available for this purpose.
The original program is also imported when selecting the pro-
gram optimized with smart collision prevention. "_" is attached to
the program name of the original program. Example: the smart
collision prevention program is called "trumpf123", the original
program is then called "trumpf123_".

Restrictions

Functions not supported The following functions are not supported by smart collision
prevention:
■ Common cuts (TwinLine)
■ FlyLine
■ Microweld
■ Machining of blanks.
■ Dot Matrix Code
■ Highspeed and Highspeed Eco cutting processes.
As smart collision prevention automatically crops scraps, no addi-
tional manual separating cuts may be used for cropping scraps.
The intricacy of the parts should not be less than the material
thickness of the component when scrap cropping is enabled.
Therefore, at a material thickness of s = 2 mm, the width of the
webs should not be less than s = 2 mm.

4‐134 Smart Collision Prevention 2019-02-01 B813en

 23. Operation of automatic nozzle
changers (option)

23.1 The replacement procedure

Prerequisites The sequence of a replacement cycle is described below:

■ The nozzle changer is loaded.
■ A nozzle is screwed into the cutting head.
■ ControlLine is calibrated.

Sequence ■ The "Brush nozzle" function is carried out (nozzle changer

retracted).
■ The nozzle changer moves to the change position.
■ The monitoring height of the nozzle is determined using the
calibration plate.
■ The new nozzle and the nozzle holder station of the previous
nozzle are blown out/cleaned.
■ The previous nozzle is screwed out the nozzle holder.
■ The new nozzle is screwed in.
■ The monitoring height of the new nozzle is measured and
checked using the calibration plate.
■ The nozzle changer moves to the parking position.

23.2 Translating axes

If the nozzle changer has been extended, the nozzle holders can
be manually rotated via the nozzle changer axis C1 using the <
+> or <-> buttons at Setup Traverse axes.

B813en 2019-02-01 Operation of automatic nozzle changers (option) 4‐135

 23.3 Manual functions

Fig. 57462

The following nozzle changer positions can be selected and

approached manually by selecting the "Setup – Manual func-
tions" operation:
■ Nozzle changer position: The nozzle changer station is
extended and retracted with this function.
■ Tooling position: The nozzle changer station is extended
and the nozzle changer axis is rotated to zero using this
function. Nozzles can be changed or checked in this position.

Note
Only screw nozzles in or out of the laser cutting head using the
nozzle tool.

4‐136 Operation of automatic nozzle changers (option) 2019-02-01 B813en

 Nozzle tool Fig. 57463

23.4 Nozzle management

Nozzles in the nozzle changer and the laser cutting head are
managed using the Technology, "Nozzle changer" function.

The mask offers the following functions:

■ Display of the magazine allocation (status, position, nozzle
types, remaining service life).
■ Manual intervention in allocation and service life.
■ Setting the status to "Nozzle changer active“.
■ Activation of the "Continue working during nozzle failure"
option.

B813en 2019-02-01 Operation of automatic nozzle changers (option) 4‐137

 The column next the "Nozzle type" indicates the remaining Fig. 57464
service life of the nozzle

Nozzles in the nozzle changer and the laser cutting head are
managed using the Technology, "Nozzle changer" function.

Nozzle holder allocation

If there is no symbol displayed in the status column, then the

nozzle holder station is free (the nozzle type column is empty) or
occupied (there is an entry in the nozzle type column).

Status symbols Nozzle in the laser cutting head

Nozzle holder station disabled

A nozzle cannot be allocated to this nozzle holder
station and queries regarding the nozzle allocation of
this station will be ignored.
Tool-change height
This symbol indicates to the operator that a nozzle
change is being performed. At the start of the screw-
ing in or out procedure, the status changes from "noz-
zle in the cutting head" to "tool-change height"; after
successful completion, it changes to "magazine station
occupied".
Tab. 4-48

4‐138 Operation of automatic nozzle changers (option) 2019-02-01 B813en

 Context buttons If a nozzle holder station (empty or occupied) is
selected in the table, the status can be changed
between disabled and enabled.

This button can be used to set the service life of the

nozzle of the selected magazine station to the default
value of four hours, regardless of the previous value.

The laser cutting head can be adjusted with this but-

ton.
A dialog box appears.

In case of a manual change of nozzle, information can be entered here

concerning which nozzle is located in the cutting head or, if the nozzle is
manually unscrewed, that the cutting head is empty. Only loaded maga-
zine stations are listed in the magazine station field.
By pressing this button, the nozzle changer is moved
to the tooling position so that the operator has better
access to the nozzle holders.
Note
If the tooling position was approached using the Tool-
ing position button, the End tool setup operation
button is active and, if it is actuated, the machine
moves back to the position that was current before
selecting the tooling position. If the tooling position
was not approached using this button, then the End
tool setup operation button is inactive.
The tool setup operation is concluded with this button.

This button deletes all the nozzles via the

Technology → Nozzle changer function except for
the magazine station with the Nozzle in the cutting
head status.

Tab. 4-49

B813en 2019-02-01 Operation of automatic nozzle changers (option) 4‐139

 23.5 Tooling dialog in the production plan

Fig. 57459

In this screen, the nozzles are shown that are required for the
selected program or for the production plan but are not yet avail-
able in the magazine.

Status Here it is not possible to modify the nozzle changer status

(check box is grayed out).
The check box “Continue working during nozzle failure“ can be
activated so that a program will run to the end even if the serv-
ice life has expired. If this check box has not been activated, the
machine will stop at the end of a contour and when the nozzle
service life has lapsed.
When the nozzle's service life has expired, a respective
message is displayed indicating the corresponding magazine
station in the message line.
This message will be displayed until the service life has been
accordingly changed.

4‐140 Operation of automatic nozzle changers (option) 2019-02-01 B813en

 Fig. 57460

23.6 Defining the service life of the

nozzles

The service life of the nozzles is dependent upon the respective

programs to be run and the corresponding operation periods.
Program run times are usually known. Approximate working lives
can be calculated on the basis of these known values according
the following formula:

Formula Service life = program run time x 80% x program repetitions

The value of "80%" is a result of the assumption that when a
program has run 100%, the average "beam on" time is 80%.

Example ■ Program run 1 hour

■ The program should run 5x.
■ Nozzle Ø 1.7 mm
This therefore results in the following according to the formula:
Service life 240 min = 60 min x 80% x 5 program repetitions.
The service life, which is indicated in this case in the tooling dia-
log, is 240 min = 4 h. If the service life has expired, the nozzle
is changed automatically if another identical nozzle is available in
the nozzle changer.

Tip
In everyday operation, the operator can define the service life at
his own discretion or based on his own experience, depending

B813en 2019-02-01 Operation of automatic nozzle changers (option) 4‐141

 on nozzle diameter, material, sheet thickness, gas and operating
mode (automatic or with operator).
If the operator enters a service life of 3 h for the nozzle in the
example in the tooling dialog, then a nozzle change will be car-
ried out after 3 h; in this case, one refers to a preventative noz-
zle change. In this way, the operator can himself define the num-
ber of nozzle changes or a preventative nozzle change via the
entered working life.

If the "Continue working during nozzle failure" function has been

selected, the machine continues cutting even when the entered
service life has expired.

If there are no further nozzles in the nozzle changer magazine,

that is, no nozzle changes can be carried out, then the machine
stops after the entered service life.

23.7 Loading nozzle changers

Inserting the nozzle ■ Insert the new nozzle so that it does not cant and so that it
lies horizontally with a little play in the nozzle holder.

Fig. 57453

Removing the nozzle Note

Nozzles can jam when being screwed in, should this be the
case, push the nozzle holder down and then release it, it should
spring back up and also release the nozzle.

■ Remove the nozzle from the nozzle holder.

4‐142 Operation of automatic nozzle changers (option) 2019-02-01 B813en

 Fig. 57454

23.8 Canceling an automatic nozzle

change

A nozzle change can be aborted as follows in automatic mode:

■ Press the RESET button .

■ Press the MACHINE OFF button .
■ PRESS THE EMERGENCY STOP push-button.

Case 1 A nozzle was not screwed in or out when the nozzle change
was canceled

■ The machine can then be moved back to the home position.

Case 2 ■ The operation of screwing a nozzle in or out was canceled,

the nozzle therefore does not have a clear status, or it has
the “tool-change height“ status.
■ Approaching the home position results in the machine and
mechanics of the nozzle changer returning to the home posi-
tion, but the "Home position reached" LED does not light up.
■ The message “The nozzle in the cutting head is at tool-
change height and needs to be checked“

■ Adapt the status in the nozzle management table (either "in

the cutting head“ or “in the magazine“).
The machine in back at the home position.

B813en 2019-02-01 Operation of automatic nozzle changers (option) 4‐143

 23.9 Minimizing and/or preventing
malfunctions and failures

When using the nozzle changer, always pay attention to the fol-
lowing points:

■ Use original TRUMPF nozzles and ceramic bodies.

■ Using the "technology – nozzle changer" function, nozzle
management must also be corrected in the following cases
to ensure that the nozzle space assignments match the
actual condition:
− After manual intervention.
− After replacement of the cutting unit.
− After canceling nozzle change.

■ There may not be any spatter on the nozzles (outer area of

the tapered surface), as they simultaneously form the support
areas in the nozzle chuck.
■ The following damage to the nozzle could lead to an abort of
the nozzle change:
− The hexagonal on the nozzle has been deformed or dam-
aged by being overtigthened manually or as a result of a
collision.
− The thread, and in particularly the start of thread, has
become damaged due to having been overtightened
manually or due to the nozzle having been dropped on a
hard surface.
− The thread or the sealing surface is not clean; this leads
to increased abrasion in the magazine stations and par-
ticularly in the ceramic insulator.
− The nozzle changer should, as a rule, be kept clean and
maintenance work should be performed according to the
maintenance plan.

4‐144 Operation of automatic nozzle changers (option) 2019-02-01 B813en

 Examples of damaged nozzles and ceramic
bodies

1 Cracked nozzle holder 3 Damaged nozzle surface 4 Rounded, crushed or broken off
2 Damaged thread hexagonal surfaces

Damaged nozzles and ceramic bodies Fig. 57465

Example of a damaged nozzle holder

Pressure point and crack in the nozzle holder Fig. 61719

The nozzle holders are subject to wear which varies depending

on use. If there is excessive wear and/or cracking, the corre-
sponding nozzle holders must be replaced. The transfer position
of the cutting unit must also be checked. Fig. 61719, (2) shows

B813en 2019-02-01 Operation of automatic nozzle changers (option) 4‐145

 the area which is most subject to wear (6 x per nozzle holder).
The macro photo (1) shows a possible damage pattern.

4‐146 Operation of automatic nozzle changers (option) 2019-02-01 B813en

 24. Diagnostics

24.1 Pending messages

All currently pending alarms, warnings and messages are dis-

played.

Displaying alarm and warning messages

1. Open Diagnostics, "Pending messages".

2. Select "Alarms", "Warnings" and/or "Acknowledgeable mes-
sages".
All pending messages of the previously check marked cate-
gory will be displayed with the following information:
− "Type": Warnings or alarm signal.
− "Message No.": Unique, non-language-dependent error
number from the TRUMPF error database.
− "Time": Date with time at which the error occurred.
− "Components": Component in the manufacturing cell at
which the error occurred.
3. If additional information concerning a message is to be dis-
played:
− Select message in the list.
− Press Message details.
Cause, effect, measure and error location are displayed.

24.2 History of messages

The last 1000 messages and information notices are displayed in

the History of messages.

Displaying message history

1. Open Diagnostics "History of messages".

2. Select "Alarms", "Warnings", "Acknowledgeable messages"
and/or "Informational messages".
The corresponding messages are displayed.
3. If additional information concerning a message is to be dis-
played:

B813en 2019-02-01 Diagnostics 4‐147

 − Select message in the list.
− Press Message details
Cause, effect, measure and error location are displayed.
4. Press Update messages if the message list is to be updated.

24.3 Condition Guide

Condition Guide monitors the cutting ability of the machine.

The overall state is indicated by signal lamps.

Showing signal lamps for monitored

properties

Next to the signal lamps for the overall state, there are signal
lamps for the respectively monitored property.

1. Open Diagnostics "Condition Guide".

A list of the monitored properties is displayed.
2. Display a monitored property:
Ø Enter the sought property in the field "Filter monitored
properties" and press Search.
or
Ø Activate "Status yellow/red" to display the properties with
a yellow or red signal lamp.

24.4 Displaying software versions

■ Open Diagnostics, "Version".

The software selection sheet with all of the installed software
versions is displayed.

4‐148 Diagnostics 2019-02-01 B813en

 25. Help when problems arise

25.1 Switch off the machine if

malfunctions occur

Ø Press the EMERGENCY STOP push-button on the control

panel.
or
Ø Turn the MAIN SWITCH to 0.

25.2 Activating remote support

Remote support is used to establish a connection between the

machine and a service employee at TRUMPF.
The service employee can access the machine's user interface
to localize problems and in some cases to eliminate them
directly.
Remote support can be activated when booting up the control
system via the TRUMPF Operating System (TOS) or via the user
interface, which is already open.

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

Activated remote support!

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

1. To start remote support via the machine user interface:

− Press Diagnosis, "Remote diagnostics", Run.

B813en 2019-02-01 Help when problems arise 4‐149

 Note
When using remote support for the first time, the machine ID
is queried. The machine ID is equivalent to the machine
number. The machine number is on the nameplate.
2. Enter the Machine number.
The "TRUMPF TelepresenceManager" screen appears.
3. Activate "Internet".
− Press Connect.
− To return to the user interface without ending the session:
Press MMC-HMI.
− To return to the user interface and end the session:
Press Quit.
4. To activate remote support via TOS:
Ø When booting the control system and the user interface,
wait until the "TRUMPF Operating System" screen is dis-
played.
− Press Start, Remote diagnostics .
or
Ø If the control and the user interface have already been
started up, use the change of application button to
change to the "Trumpf Operating System".
− Press Start, Remote diagnostics .
Remote support is active if the status of Program not in RAM
changes to Wait for call status at Remote diagnostics status.

25.3 Start Visual Online Support (option)

With Visual Online Support (VOS), a connection can be estab-

lished between a tablet PC or smartphone and Technical Serv-
ice. Here, VOS, like the MobileControl app, uses the Wireless
Operation Point (WOP) as well as the remote support Telepre-
sence Box. The most important function is image transmission.

Conditions
■ iPad tablet with camera or iPhone (minimum requirement:
iOS Version 7.0).
■ Android tablet with camera or smartphone (minimum require-
ment: Android version 4.0).
■ A remote support connection must be established between
the machine and the Telepresence Portal.
■ The VOS app must be installed on the tablet or smartphone
and must be open and connected with the WOP of the
machine.

1. Open Telepresence Manager.

4‐150 Help when problems arise 2019-02-01 B813en

 2. On the tablet, enter the network access data under "Set-
tings".
or
Ø In the main menu of VOS, press Change Wireless Net-
work.
Scan the QR code with the tablet.
3. Press Android Tablet: Change Wi-Fi.
4. Scan the QR code.
The connection will be set up automatically.
5. Press iPad: Change Network.

Fig. 90690
6. Scan the QR code.
The following dialog is opened:

Main menu VOS App Fig. 76022

B813en 2019-02-01 Help when problems arise 4‐151

 7. Press Copy password to clipboard to copy the WPA key.
8. Switch to the WLAN settings at the iPad.
9. Select the correct WLAN.
10. After the query, enter the WPA key once in the input field
and insert the WPA key from the clipboard.
11. Press Start Visual Online Support.
The application is started.
12. Take a photo of the problem.
Technical Service connects to the app and the images are auto-
matically synchronized.

VOS surface Fig. 69995

25.4 Measures after a collision detection

If there is a collision between the moving axes and interference

contours (e.g. with workpieces) all of the axes will be stopped
and the user interface will display the following message: "Drive-
based collision detection reports collision of the axis XX15". In
this case, proceed as follows:

Condition
■ EMERGENCY STOP is pending.

1. Eliminate the cause of the collision.

2. Acknowledge the error message.
An error message without a recognizable cause is dis-
played.

Ø Inform Technical Service.

15 The axis effected by the collision.

4‐152 Help when problems arise 2019-02-01 B813en

 25.5 Conversion software

The programs created with TRUMPF table names for laser proc-
essing machines with TruFlow can also be used on the laser
machines with TruDisk. To do this, conversion software is pro-
vided. This way, existing programs can still be used without hav-
ing to reprogram.

Notes
■ When using the converted programs, there might be minor
deviations from the maximum precision. The reason for these
deviations is the technology change (path correction/kerf). In
order to also achieve the maximum precision in such cases,
it might be necessary to reprogram with TruTops.
■ The programs created for laser machines with TruFlow for
machines with RotoLas cannot be converted on laser
machines with TruDisk due to the changed support protection
areas.
■ The conversion software only works with the cutting tables
provided by TRUMPF, whose names have not been changed.

1. After using the converted programs for the first time, check
the cutting results for precision.
2. If deviations from the maximum precision are too great,
reprogram the programs in TruTops.

25.6 Performing spot image

In the event of cutting problems with all materials, a spot image

can be made in the cutting unit to check the light path for con-
tamination.

Recording a spot image

Condition
■ The pallet changer is located outside the machine.

Means, Tools, Materials

■ Photo paper.

B813en 2019-02-01 Help when problems arise 4‐153

 1. Select Set up, "Manual functions", Cutting head, Cutting unit.
The dialog "Perform spot image" is opened.
2. In the event of a poor spot image, clean the protective glass
first or replace it, if necessary, and make a new spot image.
3. In the event of severe contamination: request Technical Serv-
ice.

4‐154 Help when problems arise 2019-02-01 B813en

 Chapter 5

Setting work

1 Safety notes 5‐3

2 Luminous displays on the cutting unit 5‐4

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

3 State of the protective glass 5‐6

3.1 Checking the state of the protective glass 5‐6

4 Center the beam to the nozzle 5‐10

4.1 Procedure with adhesive strips 5‐10

5 Determining the focal position 5‐13

5.1 Procedure 5‐13
5.2 CP_FOCUS_COMB focus search program 5‐13

B813en 2019-02-01 Setting work 5‐1

 6 Working with DetectLine 5‐14
6.1 Sheet position detection with DetectLine 5‐14
6.2 Calibrating DetectLine 5‐15
Calibrating DetectLine 5‐15

7 Calibrating the camera for the image-based 5‐16

post-production (option)
7.1 Calibrating the camera with a laser diode 5‐16
7.2 Calibrating the camera without a laser diode 5‐18

8 Setting work for the Highspeed Eco cutting 5‐21

process
8.1 Set cutting parametersHighspeed Eco 5‐21
8.2 Cut interruption with Highspeed Eco nozzle 5‐21

9 Setting work on the pallet conveyor 5‐22

9.1 Replace pallet conveyor chain 5‐22
Replace pallet conveyor chain 5‐22

10 Further utility programs and files 5‐25

10.1 CP_TRIM_OFF parting cut program 5‐25
Image-based separating cut with 5‐25
CP_TRIM_OFF
10.2 Cutting workpiece support consumables 5‐25
Loading files for tool cartridge slats 5‐26

5‐2 Setting work 2019-02-01 B813en

 1. Safety notes

The following information serves to ensure your safety when per-

forming setup work, especially if such work has to be carried out
with the laser beam ignited.

Adjustment work Max. laser output Execution

Power measurement 100 % Service personnel
Focus setting Setting work performed in normal Operator
mode (laser product class 1)
Centering the beam to the nozzle Setting work performed in normal Operator
mode (laser product class 1)
Setting work Tab. 5-1

Invisible, high-energy laser radiation!

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 portable barriers of
sheet steel).

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

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

B813en 2019-02-01 Safety notes 5‐3

 2. Luminous displays on the cutting unit

2.1 Luminous displays on the upper

cutting unit

Luminous displays on the upper cutting unit display the status of

the drives in the cutting unit.

1 Focal diameter adjustment drive 2 Focal position adjustment drive

Luminous display on the cutting unit Fig. 74132

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

Note
Inform Trumpf customer service when an error occurs.

5‐4 Luminous displays on the cutting unit 2019-02-01 B813en

 2.2 Luminous displays on the lower
cutting unit

Luminous displays for the sensor system electronics on the Fig. 74133
lower cutting unit

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

Light emitting diodes Description

Green, orange and The sensor system electronics is ready
yellow LEDs are on.
Green LED is lit up Power supply available
Orange LED is lit up Receiving CAN telegram
Red LED is lit up Bootloader active
Yellow LED is lit up Main program is active
Red LED is lit up and Main program update
yellow LED flashes
Yellow LED is lit up Bootloader update
and red LED flashes
Yellow and red LED Bootloader and main program defective. If this
flash is the case, contact TRUMPF customer service.
Tab. 5-2

B813en 2019-02-01 Luminous displays on the cutting unit 5‐5

 3. State of the protective glass

Dirt on the protective glass in the cutting unit can reduce the
quality of the cut. For this reason, the status of the protective
glass must be checked regularly. A measuring cycle is used to
determine the level of contamination of the protective glass. The
protective glass is also monitored online throughout the cutting
process.
After cleaning or replacing the protective glass, the status must
be measured again.

3.1 Checking the state of the protective

glass

Condition
■ Before measuring the protective glass status can take place,
the following conditions must be satisfied:
− The cutting unit is correctly adjusted.
− No objects may be present on the pallet between the
nozzle and the conveyor belt.
− "Test mode laser" may not be active and the feedrate
potentiometer is at 100 %.

Taking measurements 1. Press Set up, "Manual functions", Laser processing, Protec-
tive glass.
or
Ø Press Production, "Manual functions", General, Protective
glass.
The "Check protective glass" screen will open.
2. Press Set up, "Manual functions", Laser processing, Protec-
tive glass.
The "Check protective glass" dialog window opens.

Note
The measuring position is displayed in the dialog box. No
objects may be on the pallet in this area.

5‐6 State of the protective glass 2019-02-01 B813en

 1 Measuring position 2 Run button
Inspect protective glass Fig. 78596
3. Select "Adopt measured value".
or
Ø With a new protective glass, select "Adopt reference
value".
The reference value specifies the status of a clean pro-
tective glass for online measurement which is carried out
continuously throughout the cutting process.
4. Press Execute.

Result of the protective glass check Fig. 74211

Measurement is carried out and the protective glass status is

indicated graphically alongside the relevant recommenda-
tions.

B813en 2019-02-01 State of the protective glass 5‐7

 Tip
Press Change position so that the cutting unit travels to the
change position.

Settings for online

measurement

1 Settings
Inspecting protective glass - Online measurement Fig. 78597
5. The threshold values for warning and fault messages can be
modified in the settings.
or
Ø A fault message can also be deactivated.
When a fault message has been activated, the feed hold is
triggered first on the end of contour to ensure a clean cutting
edge. When the fault message is deactivated, no feed hold
is triggered.

Query following program If the protective glass cartridge has been removed or the
start machine switched off, the operator will be asked whether a new
protective glass has been inserted at the next program start.

Protective glass check query Fig. 78598

5‐8 State of the protective glass 2019-02-01 B813en

 6. Either
Ø Yes: adopt new reference value.
or
Ø No: carry out new measurement.

B813en 2019-02-01 State of the protective glass 5‐9

 4. Center the beam to the nozzle

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

4.1 Procedure with adhesive strips

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

Means, Tools, Materials

■ Measuring magnifier (10 to 20 times magnification) and adhe-
sive strips (Scotch Magic Tape).
■ Edding 400 felt-tip pen.
■ Allen key 4 mm AF.

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

menu-driven CP_TAPESHOT utility program.

1 Adjusting screw 1 2 Adjustind screw 2

Cutting unit Fig. 74134

5‐10 Center the beam to the nozzle 2019-02-01 B813en

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

1. Select the program 'CP_TAPESHOT'.

or
Ø Select Production, "Manual functions", General, Center
the beam to the nozzle.
2. Mark the position of the nozzle.
3. Stick adhesive strips without tension over the nozzle orifice.
Do not touch the adhesive strips in the scorching areas to
prevent impurities or traces of grease.
4. Close the safety doors.
5. Press Pulsing.
6. Open the safety door.

Note
A nozzle with larger diameter must be used if no hole can be
seen or only a hole at the very edge of the nozzle orifice can
be seen, despite the laser beam being ignited.
7. Screw out the nozzle.
8. If the hole in the adhesive strip is not centered relative to the
nozzle hole, the mark on the nozzle must be used to deter-
mine the direction in which it must be adjusted (see "Fig.
58809", pg. 5‐11).
9. The adjusting screws can be used to adjust the lens, and
hence the beam, diagonally in relation to the nozzle hole.
Note: One turn of the adjusting screw ≙ shifting the lens by
0.35 mm.

B813en 2019-02-01 Center the beam to the nozzle 5‐11

 10. Turn the adjusting screw with the Allen key to the desired
position.
11. Stick a new adhesive strip on the nozzle orifice and screw
the nozzle back in again each time after making adjustments.
12. Close the safety doors.
13. Press Pulsing again.
14. Open the safety door.
15. Check the centricity of the hole with a magnifier.
16. Repeat this procedure until the hole is centered to the nozzle
orifice.

5‐12 Center the beam to the nozzle 2019-02-01 B813en

 5. Determining the focal position

5.1 Procedure

This setting work performed with the machine in Normal opera-

tion.

Requirement
■ All openings of the beam guidance are closed. Safety devi-
ces are not bypassed.

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

To achieve good cut quality when processing workpieces, it is

necessary to set the laser beam focus at a precisely defined
position.

5.2 CP_FOCUS_COMB focus search

program

The dialog-driven focus search program CP_FOCUS_COMB is

stored in the control system (Programming, Program manage-
ment) and serves for detection of the actual focal position.

Integrated help The information necessary for operation has been integrated into
the program and can be retrieved using the Notes softkey.

B813en 2019-02-01 Determining the focal position 5‐13

 6. Working with DetectLine

With the aid of DetectLine, the workpiece position can be accu-

rately detected based on measurements on the inner contours or
on the outer sheet edges. Here an accuracy of up to ±0.1 mm is
achieved.
Standard gauge, rectangular sheets can also be detected with
DetectLine.

6.1 Sheet position detection with

DetectLine

Conditions
■ Sheet properties:
− Material: stainless steel, mild steel, aluminum.
− Flatness of approx. 0.2 mm within the measurement
range.
■ The minimum bore hole diameter is approx. 2 mm.
■ Full material must be available in a diameter of at least 30
mm around the measuring point.
■ Moreover, the following influencing factors can have limiting
effects on accuracy and/or lead to detection failure:
− working radii and/or round sheet edges, in particular if
they were cut using guillotine shears.
− limited straightness of edges or roundness of holes.
− flatness of the sheet.
− extraordinary surface properties of the material used (e.g.
strong mirroring, corrosion, film-coated).

Note
Using distance adapters (TruLaser 3030 (L20) in conjunction with
RotoLas) can mean that DetectLine cannot be used.

1. Insert workpiece or sheet.

2. Select a measuring program that contains the technology
table TC_SHEET_MEASURE.
3. Start the program.
The workpiece or sheet is measured and can be cut.

5‐14 Working with DetectLine 2019-02-01 B813en

 6.2 Calibrating DetectLine

CP_DETECTLINE_CALIB The camera must be calibrated before a measurement can be

calibration program carried out using DetectLine. For this, the
CP_DETECTLINE_CALIB program is defined in the control.

DetectLine must be calibrated in following cases:

■ Cleaning the DetectLine camera.
■ Centering the nozzle.
■ Replacement of cutting unit or the DetectLine camera.

Calibrating DetectLine

Conditions
■ Even sheet is inserted.
− Size: at least 200 x 200 mm
− Material: stainless steel
− Material thickness: 1 mm
■ The cutting unit is positioned above the inserted sheet.
■ The position of the cutting unit must be selected so that a
free surface of 50 x 50 mm can be machined.

1. Select the program CP_DETECTLINE_CALIB.

2. Select the laser technology table for nitrogen.
3. Start the program.
The contour is cut.
The cut contour is measured and DetectLine is automatically
calibrated according to the measurement result.

B813en 2019-02-01 Working with DetectLine 5‐15

 7. Calibrating the camera for the image-
based post-production (option)

7.1 Calibrating the camera with a laser

diode

Condition
■ The laser diode is calibrated.

Means, Tools, Materials

■ 4 calibration plates 200 x 200 mm, mild steel 1 mm, surface
matt black, if possible.

1. Press Production, "Current program", Select program.

Note
Every camera must be calibrated individually on machines
with several cameras.
2. Open the program 'Service.prg\Customer\cp_3d_calib_wiz-
ard.lst\'.
A dialog-driven utility program to calibrate the camera will be
displayed.
3. Select "Use position of laser diode".
4. Position the calibrating plate in the machine so that the
sheets are as far from each other as possible, but the cutting
head is still visible at each position in the camera image.
5. Press Continue.
6. Position the laser diode on the first sheet (front right).
7. Use the mouse to move the cross-hairs to the center of the
laser diode on the sheet.
8. Press Continue.
9. Position the laser diode on the second sheet (back right).

5‐16 Calibrating the camera for the image-based post- 2019-02-01 B813en
production (option)
 Example of camera calibration: Laser diode position Fig. 74267

10. Use the mouse to move the cross-hairs to the center of the
laser diode on the sheet.
11. Press Continue.
12. Position the laser diode on the third sheet (back left).
13. Use the mouse to move the cross-hairs to the center of the
laser diode on the sheet.
14. Press Continue.
15. Position the laser diode on the fourth sheet (front left).
16. Use the mouse to move the cross-hairs to the center of the
laser diode on the sheet.
17. Press Continue.
The result of the calibration is displayed.

Example for camera calibration: Fine adjustment Fig. 74271

18. Check whether the frame displayed fits in the machine's

working range and runs parallel the the pallet frame. Slight
deviations can be accepted.

B813en 2019-02-01 Calibrating the camera for the image-based post- 5‐17
production (option)
 19. Press Apply.
Calibration is ended, Drop&Cut is available.

7.2 Calibrating the camera without a

laser diode

Calibration of the camera without a laser diode requires subse-

quent fine calibration using cut circles.

Condition
■ Use position of laser diode is deactivated.

Coarse calibration 1. Move the cutting unit to the first calibration position (see
"Calibrating the camera with a laser diode", pg. 5‐16).

Note
If the center of the cutting nozzle cannot be detected in the
live image, position the cross-hairs in the approximate posi-
tion, front right.
2. Use the mouse to position the cross-hairs at the lowest point
of the cutting head in the center of the cutting nozzle.

Example Fig. 74272

3. Press Continue.
4. Repeat the procedure with the three other calibration posi-
tions (see "Calibrating the camera with a laser diode",
pg. 5‐16).
The calibration result will be shown.

5‐18 Calibrating the camera for the image-based post- 2019-02-01 B813en
production (option)
 5. Press Apply.
The message Calibration succeeded will be displayed.
6. Check whether the frame displayed fits in the machine's
working range. Slight deviations can be accepted.
7. If the calibration frame shows large deviations from the
machine's working range, repeat the calibration.
8. Press Continue.

Fine calibration The four calibration circles should cover as large an area as
possible. The circles may only, however, be positioned in an
easily visible location. They must be easily visible on the camera
image. The following approximate positions are recommended
for cutting the calibration circles:
■ Position 1: X150, Y300
■ Position 2: X1000, Y300
■ Position 3: X1000, Y1250
■ Position 4: X150, Y1250
9. Position the cutting unit and cross-hairs for the first calibra-
tion circle. Ensure that there is sufficient safety distance to
the surrounding sheet edges, since coarse calibration could
be imprecise.
10. Press Continue.
The machine cuts the first calibration circle into the sheet.

Note
The calibrated points can be moved subsequently with the
(up /down) arrow key. The result of the calibration is recalcu-
lated immediately and shown as a red frame.
11. Repeat the procedure with the other three positions.

B813en 2019-02-01 Calibrating the camera for the image-based post- 5‐19
production (option)
 After the fourth calibration circle, the calibration result is dis-
played as a red frame. The message Calibration succeeded!
will be displayed.

1 Calibration circle 2 Calibration frame

Example Fig. 74273

12. Check whether the frame displayed runs parallel the the pal-
let frame.
13. If the frame displayed deviates from the pallet frame, the cal-
ibration crosses can be re-optimized:
− Position the calibration cross with the (up /down) arrow
keys in the center of the previously cut calibration circle.
14. Press Apply.
Drop&Cut is now available.

5‐20 Calibrating the camera for the image-based post- 2019-02-01 B813en
production (option)
 8. Setting work for the Highspeed Eco
cutting process

8.1 Set cutting parametersHighspeed Eco

When cutting with Highspeed Eco the following limitations are in

place for the cutting parameters:
■ The nozzle distance should not be changed.
■ The nozzle distance at reduced approach speed must not be
modified, since otherwise, there is a risk of collision during
the separating cut.
■ The cutting gas pressure must not exceed 6 bar.

8.2 Cut interruption with Highspeed Eco

nozzle

Checking, cleaning or After every interruption in the production operation caused by a

replacing the nozzle cut interruption, the following work must be carried out:

1. Start visual inspection of the nozzle of nozzle inspection.

2. Clean dirty nozzle (sleeve or inner part) or replace in the
case of severe damage.

B813en 2019-02-01 Setting work for the Highspeed Eco cutting process 5‐21
 9. Setting work on the pallet conveyor

Note
To be able to replace the cam assembly and/or the infeed chain,
technical personnel must have completed a maintenance course
at TRUMPF.

The repair must be performed:

■ if there is a cam defect, chain break or replacement of a
worn chain.
■ Arrangement of the pallet changer - automation components
are lost by chain elongation.

Notes
■ If the chain has to be removed completely, be sure to mark
the position of the cam on the driving chain wheel with a felt-
tip pen beforehand.
■ Do not twist the driving chain wheel.
■ We recommend that two persons be assigned to perform all
of the tasks listed below.

9.1 Replace pallet conveyor chain

Use ■ If the chain breaks or if a worn chain is to be replaced.

■ Arrangement of the pallet changer - automation components
are lost by chain elongation.

Replace pallet conveyor chain

To ensure the correct arrangement of the chain and drive of the

pallet infeed, the chain must be placed in an exactly defined
position on the driven chain wheel.

5‐22 Setting work on the pallet conveyor 2019-02-01 B813en

 When the chain is laid, there are two possible initial situations
that must be distinguished for the following procedure:
■ Case 1: The driven chain wheel was not displaced and is
located in the same position as when the chain was
removed.
■ Case 2: The driven chain wheel was moved for some reason
and is not located in the same position as when the chain
was removed.
Please note: In this case, the chain exchange can only be
prepared by the customer. Technical Service must be con-
tacted for the subsequent commissioning.

Procedure 1. Release the brake (refer to chapter "Operation").

2. Loosen or screw back the screw (3) until the pressure on the
clamping lever (2) has been relieved .

Note
Before the chain is removed, mark the position of the cam
on the driven chain wheel with a felt-tip pen.
3. Take the chain off the chain wheel (1)(see "Fig. 25042",
pg. 5‐23).

Procedure in case 1 Note

When installing the chain, make sure the cam on the chain is
at the lower chain strand. The cam on the chain can be
"aligned" into the guide rails on the pallet only from below.

1 Chain wheel 2 Chain joints

Rear deflection point of the chain Fig. 25042

B813en 2019-02-01 Setting work on the pallet conveyor 5‐23

 4. Lay the new chain on the chain wheel; make sure that both
chain joints are located on the back chain wheel and that the
chain is positioned in such a way that the cam sits on the
marked position on the driven chain wheel.
5. Retighten the screw (3) until the setting value of 65 mm has
been achieved .
6. Push the chain in infeed direction to the home position by
hand, in doing so "align" the pallet.
7. Replace damaged guide rails on the pallet if necessary.

Procedure in case 2 8. Select Setup, "Manual functions", PaCh man..

9. Press Pallet in changer.
10. Lay the new chain in such a way that the cam bolt (next to
the chain lock) and the indexing pin are horizontal or on the
vertex of the chain.
11. Lay the indexing pin on the front wheel.
12. Retighten the screw (3) until the setting value of 65 mm has
been achieved .
13. Push the chain in infeed direction to the home position by
hand, in doing so "align" the pallet.

5‐24 Setting work on the pallet conveyor 2019-02-01 B813en

 10. Further utility programs and files

For support in day-to-day operations, a series of dialog-driven

utility programs and files are supplied with the machine. The
most important utility programs (apart from those already descri-
bed in this chapter) and files are listed and described in the fol-
lowing section.

10.1 CP_TRIM_OFF parting cut program

Use After processing a sheet completely or partially, the scrap skele-

ton should be separated in order to reduce the required storage
space.
The sheet can be separated in the X or Y direction using the
separating cut program.

Image-based separating cut with

CP_TRIM_OFF

Use Note
This function can only be used in connection with the image-
based post-production Drop&Cut.

If the CP_TRIM_OFF program is started, the teach points can be

set with the finger or click with the mouse.

10.2 Cutting workpiece support

consumables

The machine comes with drawings that the customer can use to
cut the wearing parts for the workpiece support (pallet).

The files for cutting the slats can be found at the following paths:
■ 'C:\dh\topsmanu.dir\Pallet'
■ 'C:\dh\topsmanu.dir\Shopfloorprogramming\Partsfolder\Pallet'

B813en 2019-02-01 Further utility programs and files 5‐25

 The files for cutting the guard plates can be found at the follow-
ing paths:
■ 'C:\dh\topsmanu.dir\Shopfloorprogramming\Partsfolder
\exhaust_flap_protection_10mm.GEO'
■ 'C:\dh\topsmanu.dir\Shopfloorprogramming\Partsfolder
\exhaust_flap_protection_10mm.DXF'

Loading files for tool cartridge slats

The drawings of the machine-specific support slats are copied to

the machine controller at the factory. Support slats can be
loaded as a program and cut on the machine.

1. Press Programming, "Program management".

2. Press Drive and select 'topsmanu.dir'.
3. Switch to the directory from which the drawing is to be
imported.
4. Select file and press Import.
The support slat can now be cut.

Tip
The drawings can also be loaded and edited in TruTops. You will
find further information in the TruTops Help area.

5‐26 Further utility programs and files 2019-02-01 B813en

 Chapter 6

Maintenance

1 General guidelines 6‐8

2 Maintenance Overview 6‐10

3 Lubrication 6‐15
3.1 Overview 6‐15
3.2 Central lubrication 6‐17
Checking and refilling the lubricant level 6‐17
[101]
Checking lubrication lines for air pockets 6‐20
and bleeding them if necessary
3.3 Guide rails on the pallet 6‐21
Lubricating the guide rail [41] 6‐21
3.4 Longitudinal and transverse conveyor belt 6‐22
brush lubrication
Refilling lubricant [46] 6‐22
Check brush lubrication and brushes and 6‐23
replace if necessary

B813en 2019-02-01 Maintenance 6‐1

 3.5 Chain and cam assembly of pallet transport 6‐24
unitChain, cam and guide rail of pallet trans-
port unit
Cleaning and lubricating the chain and cam 6‐24
assembly of the pallet transport unit

4 Hydraulics 6‐25
4.1 Overview 6‐25
4.2 Hydraulic unit 6‐25
Check oil level, top up as required [85] 6‐25
Change the oil and oil filter 6‐25
4.3 Hydraulic hoses 6‐27
Check the hydraulic hoses 6‐27

5 Mechanics 6‐29
5.1 Overview 6‐29
5.2 Safety cabin 6‐29
Check the safety cabin [04] 6‐29
Check the laser protection window [04] 6‐30
Cleaning the laser protection window [04] 6‐30
5.3 Work area illumination 6‐31
Check the work area illumination [03] 6‐31
5.4 Support slats - Pallets 6‐33
Clean the slats and slat supports; 6‐33
exchange, if necessary [25]
5.5 Compact dust extractor 6‐34
Checking or replacing the disposable con- 6‐34
tainer [02]
5.6 Dust chamber in the compact dust extractor 6‐36
Cleaning the dust chamber [22] 6‐36
5.7 The differential pressure indicator on the 6‐37
compact dust extractor
Check differential pressure indicator [23] 6‐37
5.8 Compact dust extractor purging valves 6‐37
Check the purging valves [44] 6‐37
5.9 Compact dust extractor: extinguisher system 6‐38
(option)
Maintain extinguisher system 6‐38
5.10 Tube bend and suction tube of the suction sys- 6‐38
tem
Dismantling and cleaning the pipe elbow 6‐38
and suction tube [45]
5.11 Storage bin for slag and dust 6‐39

6‐2 Maintenance 2019-02-01 B813en

 Emptying the storage bin [26] 6‐39
5.12 Y measurement system, guideways, covers 6‐40
and track strippers
Cleaning the Y scale [06] 6‐40
5.13 X and Y axis racks and guideways 6‐43
Cleaning the X and Y axis racks and guide- 6‐43
ways
5.14 Z axis bellows 6‐45
Checking and cleaning the Z axis bellows 6‐45
5.15 Cable carriers 6‐46
Checking the Y and Z cable carriers [07] 6‐46
5.16 Motion unit 6‐46
Clean the grease collecting tray 6‐46
Cleaning the spray shield 6‐47
5.17 Pallet conveyor cam assembly 6‐48
Replacing the cam assembly of the pallet 6‐48
transport
5.18 Longitudinal conveyor belt 6‐49
Checking the hinge conveyor belt [20] 6‐49
Tightening the hinge conveyor belt 6‐49
5.19 Cover sheets of the longitudinal and transverse 6‐51
conveyor belt
Cleaning the cover sheets 6‐51
5.20 Exhaust module 6‐52
Checking, cleaning and if necessary replac- 6‐52
ing components of the exhaust module [24]
5.21 Pallet changer 6‐54
Check and clean the calibration plate and 6‐54
nozzle-cleaning brushes; replace, if neces-
sary [42]
5.22 Camera for process monitoring 6‐55
Check the protective glass on the camera; 6‐55
clean, if necessary [66]
5.23 Automatic nozzle changer (option) 6‐56
Check nozzles, ceramic body and nozzle 6‐56
threads
Check and clean the nozzle holders 6‐56
Clean or replace the sleeve and internal 6‐57
part of the nozzle (Highspeed Eco)
Check and clean the calibration plate and 6‐59
nozzle-cleaning brushes [42]
Cleaning the drive unit's cover sheet 6‐59
Lubricating the linear guides 6‐60

B813en 2019-02-01 Maintenance 6‐3

 6 Pneumatics 6‐61
6.1 Overview 6‐61
6.2 Input controller operating pressure 6‐62
Check the operating pressure 6‐62
6.3 40 μm filter for compressed air supply 6‐62
Replace the filter cartridge 6‐62
6.4 Filter B compressed air supply 6‐63
Replace the filter cartridge 6‐63
6.5 Filter A compressed air supply 6‐63
Replace the filter cartridge 6‐63
6.6 Activated carbon filter compressed air supply 6‐64
Replace the filter cartridge 6‐64
6.7 Condensation water container for compressed 6‐64
air supply
Emptying the condensed water container 6‐64
[94]
6.8 Cutting gas filter for oxygen nitrogen and argon 6‐65
Replacing filter elements 6‐65
6.9 Filter elements in the compact dust extractor 6‐68
Checking and replacing filter elements 6‐68
6.10 Maintenance unit on compact dust extractor 6‐69
Check the pressure reducer and the com- 6‐69
pressed air supply
Checking and, if necessary, replacing the fil- 6‐70
ter elements
6.11 Filter (only with the compressed-air cutting 6‐70
option)
Replace the filter element [52] 6‐70
6.12 Microfilter (only with the compressed-air cutting 6‐71
option)
Replace the filter element [52] 6‐71
6.13 Activated carbon filter 1 (only for the com- 6‐71
pressed-air cutting option)
Check activated carbon filter 1, replace if 6‐71
necessary[47]
6.14 Activated carbon filter 2 (only for the com- 6‐72
pressed-air cutting option)
Check activated carbon filter 2, replace if 6‐72
necessary[48]
6.15 Spraying equipment 6‐73
Refilling spraying agent [92] 6‐73

6‐4 Maintenance 2019-02-01 B813en

 7 Machine cooling circuit 6‐76
7.1 Overview 6‐76
7.2 Machine cooler , water-air chiller 6‐79
Checking and refilling the level 6‐79
Checking filter mat; replacing, if necessary 6‐80
Change cooling water 6‐82

8 External laser cooling circuit 6‐86

(TruDisk 3001 / 4001, standard version)
8.1 Overview 6‐86
8.2 Process cooler: Laser (water-air) 6‐87
Replacing the filter mat 6‐87
Checking and refilling the level 6‐88
Check the ventilation fan and clean, if nec- 6‐88
essary.
Change cooling water 6‐88

9 Cooling circuit of the machine 6‐93

(TruDisk 6001)
9.1 Overview 6‐93
9.2 Process cooler for machine 6‐93
Exchange filter mat 6‐93
Checking the filling level 6‐94
Replace cooling water 6‐96

10 External laser cooling circuit (TruDisk 6001) 6‐100

10.1 Overview 6‐100
10.2 Laser process cooler 6‐100
Replacing the filter mat [91] 6‐100
Checking the filling level [81] 6‐101
Replace cooling water 6‐102

11 TruDisk 6‐105
11.1 Overview 6‐105
11.2 TruDisk cooling circuit 6‐106
Changing the cooling water and tank 6‐106
Checking the cooling for tightness 6‐106
Cleaning or replacing the contamination fil- 6‐106
ter
Replacing the water microfilter 6‐107

B813en 2019-02-01 Maintenance 6‐5

 12 Laser cooling circuit with Easy Filter 6‐108
12.1 Overview 6‐108
12.2 Cooling circuit with Easy Filter 6‐109
Reconditioning cooling water 6‐109

13 Electrics 6‐112
13.1 Overview 6‐112
13.2 Electrical cabinet 6‐112
Checking and, if necessary, cleaning the 6‐112
electrical cabinet
Checking the door monitoring 6‐113
Checking the power supply 6‐113
Checking the function of the fan on the 6‐113
electrical cabinet
Cleaning the fan [64] 6‐114
Replacing the BIOS battery 6‐115
Replacing the NCU fan unit 6‐116
Replacing the NCU fan battery 6‐117
Replacing the UPS rechargeable battery 6‐119
pack
Replace the buffer battery for the real time 6‐122
clock
13.3 Safety light barriers 6‐124
Cleaning the safety light barrier [51] 6‐124

14 Optics 6‐125
14.1 Overview 6‐125
14.2 Cutting unit 6‐126
Check the nozzle and blowing nozzle, and 6‐126
clean if necessary [93]
14.3 Cartridge in the cutting unit 6‐127
Cleaning the protective glass [08] 6‐127

15 RotoLas 6‐131
15.1 Support housing, outside 6‐131
Cleaning the support housing 6‐131
15.2 Four-jaw collet chuck 6‐131
Checking and cleaning the collet chuck 6‐131
15.3 RotoLas spatter guard 6‐132
Check the buffer and exchange, if neces- 6‐132
sary.

6‐6 Maintenance 2019-02-01 B813en

 16 CoolLine 6‐133
16.1 CoolLine water container 6‐133
Refilling the water container 6‐133
Check the water filter and replace if neces- 6‐134
sary

B813en 2019-02-01 Maintenance 6‐7

 1. General guidelines

Correct maintenance is essential for maintaining the quality of

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

Risk of fatal injury during maintenance work with the

DANGER machine switched on!
Ø Unless expressly stated otherwise, switch off the MAIN
SWITCH, lock the MAIN SWITCH and pull out the key.
Ø Strictly observe the safety regulations.

Before commissioning the The machine must be lubricated carefully in accordance with the
machine lubrication chart before being put into service. The entire lubrica-
tion of the machine has to be checked if the machine has not
been used for a long time (e.g. overseas transport). If required,
the gummy oil must be completely removed from all lubrication
points and supply lines.

Maintenance personnel The user must authorize the maintenance personnel to perform
maintenance work on the machine.

Depending upon the labeling, the maintenance work must be

done by the persons as specified in the following table:

Symbol Maintenance personnel

Machine operator

Trained maintenance personnel:

■ To train maintenance personnel, TRUMPF recommends that they participate in the mainte-
nance course for customers.
■ Work on the following assemblies requires specialist knowledge in the relevant area:
− Electrics.
− Hydraulics.
− Pneumatics.
− Mechanics.
− Laser.
■ The regulations of the relevant country are also applicable.
Technical Service:
The user is obliged to have this maintenance work done by TRUMPF Technical Service.
Maintenance personnel identification Tab. 6-1

Notes on cleaning ■ The entire system should be cleaned at regular intervals.

■ Brush off large elements of dirt and dust or remove them
using an industrial vacuum cleaner.

6‐8 General guidelines 2019-02-01 B813en

 Notes on lubrication Refer to the lubrication schematic and maintenance instructions
for lubrication of the machine. The following points should also
be observed:
■ Do not leave filler and drainage caps open for longer than
necessary and keep them clean.
■ Drain the waste oil only at operating temperature.
■ Use only lint-free cleaning cloths and low-viscosity spindle oil
("scavenge oil") to clean oil chambers and lubricating points.
Do not use cleaning wool, kerosene or benzene.
■ Do not mix synthetic lubricating oils with mineral oils or syn-
thetic oils from other manufacturers, even if the synthetic oil
in question has equivalent properties.
■ Dispose of waste oil appropriately.

Maintenance numbers with Signs with maintenance numbers and symbols have been
symbol attached to the machine at those maintenance points which have
to be serviced at an interval of <2000 h.
Maintenance work steps in this chapter are assigned a 6-digit
maintenance ID (unique internal ID) and a maintenance number
of the sign in square brackets.

Identification of the maintenance point Activity Representation of the maintenance work

on the machine in the document
Check 105410: Check filling level [91].

Cleaning -

Lubricate -

Empty -

Replacement -

Examples for identification of maintenance points and maintenance tasks Tab. 6-2

B813en 2019-02-01 General guidelines 6‐9

 2. Maintenance Overview

Interval/ operating Maintenance Maintenance point Page

hours personnel
Ø Maintenance work
8 Safety cabin 6‐30
Ø Cleaning the laser protection window [04]
8 Work area illumination 6‐31
Ø Check the work area illumination [03]
8 Compact dust extractor 6‐34
Ø Checking or replacing the disposable container [02]
8 Storage bin for slag and dust 6‐39
Ø Emptying the storage bin [26]
8 Cover sheets of the longitudinal and transverse conveyor belt 6‐51
Ø Cleaning the cover sheets
8 Automatic nozzle changer (option) 6‐56
Ø Check nozzles, ceramic body and nozzle threads
8 Cutting unit 6‐126
Ø Check the nozzle and blowing nozzle, and clean if neces-
sary [93]
40 Support slats - Pallets 6‐33
Ø Clean the slats and slat supports; exchange, if necessary
[25]
40 The differential pressure indicator on the compact dust extrac- 6‐37
tor
Ø Check differential pressure indicator [23]
40 Longitudinal conveyor belt 6‐49
Ø Checking the hinge conveyor belt [20]
40 Longitudinal conveyor belt 6‐49
Ø Tightening the hinge conveyor belt
40 Exhaust module 6‐52
Ø Checking, cleaning and if necessary replacing components
of the exhaust module [24]
40 Automatic nozzle changer (option) 6‐56
Ø Check and clean the nozzle holders
100 Process cooler for machine 6‐93
Ø Exchange filter mat
100 Laser process cooler 6‐100
Ø Replacing the filter mat [91]
500 Guide rails on the pallet 6‐21
Ø Lubricating the guide rail [41]
500 Dust chamber in the compact dust extractor 6‐36
Ø Cleaning the dust chamber [22]
500 Compact dust extractor purging valves 6‐37
Ø Check the purging valves [44]

6‐10 Maintenance Overview 2019-02-01 B813en

Interval/ operating Maintenance Maintenance point Page
hours personnel
Ø Maintenance work
500 Tube bend and suction tube of the suction system 6‐38
Ø Dismantling and cleaning the pipe elbow and suction tube
[45]
500 Pallet changer 6‐54
Ø Check and clean the calibration plate and nozzle-cleaning
brushes; replace, if necessary [42]
500 Automatic nozzle changer (option) 6‐59
Ø Check and clean the calibration plate and nozzle-cleaning
brushes [42]
500 Filter elements in the compact dust extractor 6‐68
Ø Checking and replacing filter elements
500 Filter (only with the compressed-air cutting option) 6‐70
Ø Replace the filter element [52]
500 Activated carbon filter 1 (only for the compressed-air cutting 6‐71
option)
Ø Check activated carbon filter 1, replace if necessary[47]
500 Activated carbon filter 2 (only for the compressed-air cutting 6‐72
option)
Ø Check activated carbon filter 2, replace if necessary[48]
1000 Y measurement system, guideways, covers and track strippers 6‐40
Ø Cleaning the Y scale [06]
1000 Cable carriers 6‐46
Ø Checking the Y and Z cable carriers [07]
1000 Camera for process monitoring 6‐55
Ø Check the protective glass on the camera; clean, if neces-
sary [66]
1000 Electrical cabinet 6‐114
Ø Cleaning the fan [64]
2000 Chain and cam assembly of pallet transport unitChain, cam 6‐24
and guide rail of pallet transport unit
Ø Cleaning and lubricating the chain and cam assembly of the
pallet transport unit
2000 Hydraulic hoses 6‐27
Ø Check the hydraulic hoses
2000 X and Y axis racks and guideways 6‐43
Ø Cleaning the X and Y axis racks and guideways
2000 Z axis bellows 6‐45
Ø Checking and cleaning the Z axis bellows
2000 Motion unit 6‐46
Ø Clean the grease collecting tray
2000 Motion unit 6‐47
Ø Cleaning the spray shield
2000 Automatic nozzle changer (option) 6‐59
Ø Cleaning the drive unit's cover sheet

B813en 2019-02-01 Maintenance Overview 6‐11

Interval/ operating Maintenance Maintenance point Page
hours personnel
Ø Maintenance work
2000 Input controller operating pressure 6‐62
Ø Check the operating pressure
2000 40 μm filter for compressed air supply 6‐62
Ø Replace the filter cartridge
2000 Filter B compressed air supply 6‐63
Ø Replace the filter cartridge
2000 Filter A compressed air supply 6‐63
Ø Replace the filter cartridge
2000 Activated carbon filter compressed air supply 6‐64
Ø Replace the filter cartridge
2000 Maintenance unit on compact dust extractor 6‐69
Ø Check the pressure reducer and the compressed air supply
2000 Maintenance unit on compact dust extractor 6‐70
Ø Checking and, if necessary, replacing the filter elements
2000 Microfilter (only with the compressed-air cutting option) 6‐71
Ø Replace the filter element [52]
2000 RotoLas spatter guard 6‐132
Ø Check the buffer and exchange, if necessary.
2000 CoolLine water container 6‐134
Ø Check the water filter and replace if necessary
5000 Longitudinal and transverse conveyor belt brush lubrication 6‐23
Ø Check brush lubrication and brushes and replace if neces-
sary
5000 Pallet conveyor cam assembly 6‐48
Ø Replacing the cam assembly of the pallet transport
5000 Cutting gas filter for oxygen nitrogen and argon 6‐65
Ø Replacing filter elements
Daily Safety cabin 6‐29
Ø Check the safety cabin [04]
Daily Safety cabin 6‐30
Ø Check the laser protection window [04]
Annually Machine cooler , water-air chiller 6‐82
Ø Change cooling water
Annually Process cooler: Laser (water-air) 6‐87
Ø Replacing the filter mat
Annually Process cooler: Laser (water-air) 6‐88
Ø Check the ventilation fan and clean, if necessary.
Annually Process cooler: Laser (water-air) 6‐88
Ø Change cooling water
Annually Process cooler for machine 6‐96
Ø Replace cooling water

6‐12 Maintenance Overview 2019-02-01 B813en

Interval/ operating Maintenance Maintenance point Page
hours personnel
Ø Maintenance work
Annually Laser process cooler 6‐102
Ø Replace cooling water
Annually TruDisk cooling circuit 6‐106
Ø Changing the cooling water and tank
Annually Cooling circuit with Easy Filter 6‐109
Ø Reconditioning cooling water
Annually Electrical cabinet 6‐112
Ø Checking and, if necessary, cleaning the electrical cabinet
Annually Electrical cabinet 6‐113
Ø Checking the door monitoring
Annually Electrical cabinet 6‐113
Ø Checking the power supply
Annually Cartridge in the cutting unit 6‐127
Ø Cleaning the protective glass [08]
Every 3 years Automatic nozzle changer (option) 6‐60
Ø Lubricating the linear guides
Every 3 years Electrical cabinet 6‐117
Ø Replacing the NCU fan battery
Every 3 years Electrical cabinet 6‐122
Ø Replace the buffer battery for the real time clock
Every 5 years Hydraulic unit 6‐25
Ø Change the oil and oil filter
Every 5 years Electrical cabinet 6‐113
Ø Checking the function of the fan on the electrical cabinet
Every 5 years Electrical cabinet 6‐115
Ø Replacing the BIOS battery
Every 5 years Electrical cabinet 6‐116
Ø Replacing the NCU fan unit
Every 5 years Electrical cabinet 6‐119
Ø Replacing the UPS rechargeable battery pack
As needed Compact dust extractor: extinguisher system (option) 6‐38
Ø Maintain extinguisher system
As needed Automatic nozzle changer (option) 6‐57
Ø Clean or replace the sleeve and internal part of the nozzle
(Highspeed Eco)
As needed Condensation water container for compressed air supply 6‐64
Ø Emptying the condensed water container [94]
As needed Spraying equipment 6‐73
Ø Refilling spraying agent [92]
As needed TruDisk cooling circuit 6‐106
Ø Checking the cooling for tightness

B813en 2019-02-01 Maintenance Overview 6‐13

Interval/ operating Maintenance Maintenance point Page
hours personnel
Ø Maintenance work
As needed Safety light barriers 6‐124
Ø Cleaning the safety light barrier [51]
As needed Support housing, outside 6‐131
Ø Cleaning the support housing
As needed Four-jaw collet chuck 6‐131
Ø Checking and cleaning the collet chuck
When indicated by Central lubrication 6‐17
the control system
Ø Checking and refilling the lubricant level [101]
When indicated by Central lubrication 6‐20
the control system
Ø Checking lubrication lines for air pockets and bleeding them
if necessary
When indicated by Longitudinal and transverse conveyor belt brush lubrication 6‐22
the control system
Ø Refilling lubricant [46]
When indicated by Hydraulic unit 6‐25
the control system
Ø Check oil level, top up as required [85]
When indicated by Machine cooler , water-air chiller 6‐79
the control system
Ø Checking and refilling the level
When indicated by Machine cooler , water-air chiller 6‐80
the control system
Ø Checking filter mat; replacing, if necessary
When indicated by Process cooler: Laser (water-air) 6‐88
the control system
Ø Checking and refilling the level
When indicated by Process cooler for machine 6‐94
the control system
Ø Checking the filling level
When indicated by Laser process cooler 6‐101
the control system
Ø Checking the filling level [81]
When indicated by TruDisk cooling circuit 6‐106
the control system
Ø Cleaning or replacing the contamination filter
When indicated by TruDisk cooling circuit 6‐107
the control system
Ø Replacing the water microfilter
When indicated by CoolLine water container 6‐133
the control system
Ø Refilling the water container

6‐14 Maintenance Overview 2019-02-01 B813en

 3.  Lubrication

3.1 Overview

1 Longitudinal conveyor belt brush 3 Pallet conveyor chain 5 Hydraulic unit

lubrication 4 Guide rails on the pallet
2 Central lubrication lubricant con-
tainer
Fig. 64834

Icon Definition Icon Definition

Indication of Monitor oil level, refill
lubrication intervals in to correct level if nec-
operating hours essary
Read the maintenance Check the oil level
instructions
Lubrication with a Empty the container
grease gun

Lubricate with grease Replace the contents

of the container

B813en 2019-02-01 Lubrication 6‐15

 Icon Definition Icon Definition
Lubricating with the oil Lubricating with spray
can can

Check

Symbols in the lubrication plan Tab. 6-3

Lubrication Quantity [l] Recommended lubricants Identification Viscosity, TRUMPF

point consistency order no.
Lubricant 0.12 - 0.36 KLÜBER Microlube GB 00 GP00 G-10 NLGI Nr. 00 1 l: 111780
container, (consult the manufacturer for
central lubri- details on miscibility with other
cation lubricants)
Guide rails
on the pallet
Pallet con-
veyor chain
Longitudinal 0.20 MOBIL Vactra Oil No. 1 Max. ISO VG 5 l: 0368910
conveyor belt 32
SHELL Tonna S-32
brush lubrica-
tion
Hydraulic unit 20 ARAL Vitam DE 32 ISO VG 32
ARAL Vitam GF 32
BP Energol HLP-HM 32
CASTROL Hyspin AWS 32
TOTAL AZOLLA ZS 32 1 l: 125503
TOTAL AZOLLA DZF 32 18 kg:
037805
ESSO TERESSO 32
ESSO NUTO H 32
FUCHS RENOLIN MR 10 VG
32
MOBIL DTE 24
SHELL Tellus Oil C 32
SHELL Tellus OL DO 32
Lubricants Tab. 6-4

Note
The lubricant table contains a list of approved lubricants. We rec-
ommend using the listed lubricants or verifiable equivalents from
other mineral oil companies.
Pay attention to the expiration date of the respective lubricant.

6‐16 Lubrication 2019-02-01 B813en

 3.2 Central lubrication

(see "Overview", pg. 6‐15)

Checking and refilling the lubricant level

[101]

Maintenance interval: When indicated by the control sys-

tem

The central lubrication supplies the following components with a

lubricant:
■ X and Y drive pinions.
■ Ballscrew bearings of the X and Y axes.
■ Bearings of the X and Y rails.

B813en 2019-02-01 Lubrication 6‐17

1 Single-piston pump and central 6 40 μm filter for compressed air 11 3/2 directional valve
lubrication lubricant container supply 12 Filter16
2 Electrical lubricator for chain on 7 Filter B compressed air supply
13 Microfilter16
the longitudinal conveyor belt 8 Filter A compressed air supply
14 Activated carbon filter 116
3 Spraying equipment 9 Activated carbon filter com-
4 Cutting unit ventilation pressure pressed air supply 15 Activated carbon filter 216
reducer 10 Gas filter for oxygen and nitro-
5 Operating pressure reducer gen
Instrument panel Fig. 64567

One-shift operation 100 cm3

Two-shift operation 200 cm3
Three-shift operation 300 cm3
Yearly refilling requirements (250 days) Tab. 6-5

Checking the lubricant level Note

The grease and air apportionment is determined at the fac-
tory.
The lubrication cycle is activated every eight hours by the
control system.

16 For compressed-air cutting only

6‐18 Lubrication 2019-02-01 B813en

 The next time a program is started, a lubrication cycle will be
run automatically.
The "Check lubricant level" message appears on the screen
every three months.
The lubricant container must not be emptied; otherwise the
entire system must be bled.
Since the lubricant loses its optimal lubrication qualities after
three years, it is recommended to store only small quantities.
The refill quantity should always be enough to make it nec-
essary to refill once a year. The values above can be used
to calculate the amount of top-up oil.
1. Check the lubricant level.
2. Acknowledge the fill level check on the control system.

Refilling the lubricant

1 Central lubrication lubricant 3 Spray lubrication container

container 4 Holding sheet
2 Lubricant container, brush lubri-
cation, longitudinal conveyor
belt
Fig. 65031

3. Pull out the drawer.

4. Take off the cover.
5. Pour the lubricant slowly to avoid bubbles.
6. Put the lid back on.
7. Push the drawer back in.

B813en 2019-02-01 Lubrication 6‐19

 Checking lubrication lines for air pockets
and bleeding them if necessary

Maintenance interval: When indicated by the control sys-

tem

The central lubrication supplies the following components with

lubricant:

1 Lubricant distributor 2 Supply line

Lubricant distributor Fig. 96611

Checking lubrication lines 1. Check lubrication lines for air pockets.

If air pockets are visible, the lubrication lines must be bled.

Bleeding lubrication lines 2. Place a cleaning cloth below the lubrication lines.
3. Remove lubrication lines.
4. Run the lubrication cycle.
5. If there are no more air pockets, connect the lines.

6‐20 Lubrication 2019-02-01 B813en

 3.3 Guide rails on the pallet

(see "Overview", pg. 6‐15)

Lubricating the guide rail [41]

Maintenance interval: 500 operating hours

1 Guide rail 2 Pallet frame

Guide rail for longitudinal layout Fig. 55766

Ø Lubricate the guide rails with the lubricating grease and

check it for fixed seat.

B813en 2019-02-01 Lubrication 6‐21

 3.4 Longitudinal and transverse conveyor
belt brush lubrication

(see "Overview", pg. 6‐15)

Refilling lubricant [46]

Maintenance interval: When indicated by the control sys-

tem

Side board chains are lubricated using brush lubrication.

1 Central lubrication lubricant 3 Spray lubrication container

container 4 Holding sheet
2 Lubricant container, brush lubri-
cation, longitudinal conveyor
belt
Fig. 65031

1. Fill the lubricant container when the message "Filling level in

the container of the metering pump too low" is output.
2. Pull out the drawer.
3. Open the lubricant container and refill oil (brush lubrication)
or grease (longitudinal and transverse conveyor belt).
4. Seal the lubricant container.
5. Push the drawer back in.
6. Check level switch.

6‐22 Lubrication 2019-02-01 B813en

 Check brush lubrication and brushes and
replace if necessary

Maintenance interval: 5000 operating hours

Note
Transverse conveyor belt is an option.
Ø Request Technical Service.

B813en 2019-02-01 Lubrication 6‐23

 3.5 Chain and cam assembly of pallet
transport unitChain, cam and guide
rail of pallet transport unit

(see "Overview", pg. 6‐15)

Cleaning and lubricating the chain and cam

assembly of the pallet transport unit

Maintenance interval: 2000 operating hours

1 Guide rail 2 Pallet frame

Guide rail for longitudinal layout Fig. 55766

1. Clean and lubricate the chain, cam and guide rail using the
brush.
2. Inspect visually for damage and check the parts are securely
fixed in place.
3. Check the chain tension (see chapter “Setting work“).

6‐24 Lubrication 2019-02-01 B813en

 4.  Hydraulics

4.1 Overview

4.2 Hydraulic unit

(see "Overview", pg. 6‐25)

Check oil level, top up as required [85]

Maintenance interval: When indicated by the control sys-

tem

The hydraulic unit has an automatic level check. A message is

issued if the oil level drops below a certain level.

Note
The lifting frame of the pallet changer must be in the bottom
position so that the oil level can be checked.
1. Check the oil level (3/4 to full).
2. If necessary, refill with hydraulic oil.

Change the oil and oil filter

Maintenance interval: Every 5 years

Note
Only use the same type of oil as before for topping up.

B813en 2019-02-01 Hydraulics 6‐25

 1 Protective cover 4 Cover
2 Inspection glass 5 Oil filter
3 Oil drain plug
Example, hydraulic unit for TruLaser 1030/3030/5030 Fig. 89801

1. Switch off and lock the MAIN SWITCH. Remove the key.
2. Remove the protective cover (1) of the hydraulic unit.
3. Stake all hose couplings on the hydraulic unit.
4. Lift hydraulic unit.
5. Open the cover (4) on the hydraulic unit and remove any
contamination on the edge of the filler neck with a lint-free
cloth.
6. Open oil drain plug (3) and drain off oil.
7. Replace seal on the oil drain plug and close oil drain plug.
8. Fill the new hydraulic oil filtered (filter unit: 25 µm), check
cover seal and, if necessary, replace.
9. Observe the oil filling height at the level indicator (2).
10. Replace the oil filter (5).
11. Close the cover (4).
12. Assemble all hose couplings.
13. Fasten the protective cover (1) of the hydraulic unit.
14. Initiate a start of the hydraulic unit at the control panel to
check it for proper working order (to do this, raise and lower
the pallet changer control).

6‐26 Hydraulics 2019-02-01 B813en

 4.3 Hydraulic hoses

(see "Overview", pg. 6‐25)

Check the hydraulic hoses

Maintenance interval: 2000 operating hours

Possible defect at the hydraulic system hoses:

■ Damage in the outer layer extending to the inner lining
(chafe marks, cuts, cracks).
■ Brittle outer layer (cracks in the hose).
■ Deformations that do not correspond to the natural form of
the hydraulic system hoses; in the depressurized or pressur-
ized status or when bending (layer separation, bubble forma-
tion, crush areas, kinks).
■ Leaks.
■ Installation requirements not adhered to.
■ The hydraulic system hose moving out of the fittings.
■ Damage or distortion of the fittings which diminishes the
function and tensile strength of the fitting or impairs the con-
nection between hydraulic system hose and fittings.
■ Corrosion of the fittings that impairs the function and tensile
strength.

Note
The safety rules for hydraulic system hoses (for Germany,
see DGUV, rule 113-015, former number was BGR 237) and
the national safety regulations must be complied with.

Injury due to a hydraulic system hose bursting and

DANGER thrashing around!
Ø Check all hydraulic system hoses in accordance with these
maintenance instructions.
Ø In case of doubt, replace the hydraulic system hoses.

1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Remove the cover plate.

B813en 2019-02-01 Hydraulics 6‐27

 Hydraulic system hoses Fig. 74202

3. Have the hydraulic hoses inspected by an expert to assure

safe operating standards. An expert is a person who has
completed the appropriate course of studies.
Check the hydraulic hoses before the initial commissioning of
the machine.
4. Install the cover plate again.

6‐28 Hydraulics 2019-02-01 B813en

 5.  Mechanics

5.1 Overview

1 Z axis bellows 5 Dust chamber (spark arrester), 9 Scrap carriage (2×)

2 X and Z energy chain compact dust extractor 10 Longitudinal conveyor belt
3 Purging valves for compact dust 6 CO2 fire extinguishing system in 11 Bulkheads in suction chambers,
extractor the compact dust extractor grid sheets and flaps
(option)
4 Disposable container for
compact dust extractor 7 Pallet track rollers and brass
brushes
8 Pallet changer and ground area
Fig. 64833

5.2 Safety cabin

(see "Overview", pg. 6‐29)

Check the safety cabin [04]

Maintenance interval: Daily

A visual inspection is carried out.

1. Check that the safety cabin is undamaged especially in the

area of the scrap conveyor.
2. Do not put the machine into operation if a safety device is
damaged (deep scorching, hole, crack, etc.). Replace dam-
aged parts immediately.

B813en 2019-02-01 Mechanics 6‐29

 Check the laser protection window [04]

Maintenance interval: Daily

Note
To replace the laser protection window, make a request to
TRUMPF Technical Service.

Invisible, high-energy laser radiation!

DANGER
Severe skin burns and eye injuries may occur.
Ø Replace the laser protection window if 1 mm scorched mark-
ings or holes are discovered during inspection.
Ø Only put the machine back into operation once the defective
laser protection window has been replaced.

Ø Check the laser protection window for scorched areas, holes

or damage.

Cleaning the laser protection window [04]

Maintenance interval: 8 operating hours

The following cleaning agents are recommended for cleaning the

laser protection windows:
■ Anti-static plastic cleaner and polish UBA 0197 0057, Burnus
GmbH (mat. no. 1672922).
■ Intensive plastic cleaner UBA 0197 0062, Burnus GmbH
(mat.no. 1672919)

Means, Tools, Materials

■ Clean, lint-free cloth.
■ Suitable cleaning agent.

6‐30 Mechanics 2019-02-01 B813en

 Destruction of the laser protection window caused by
NOTICE cleaning with unsuitable cleaning agents.
Ø Laser protection window Do not clean the viewing window
with glass cleaner.
Ø Use only cleaning agents which are suitable for polycarbon-
ate.
Ø When cleaning the laser protection window, do not use any
abrasive or highly alkaline cleaning agents or solvents such
as acetone, gasoline, benzene, or carbon tetrachloride.

Ø Clean the laser protection windows using a soft cloth and a

suitable cleaning agent.

5.3 Work area illumination

(see "Overview", pg. 6‐29)

Check the work area illumination [03]

Maintenance interval: 8 operating hours

1 Work area illumination

Fig. 74203

1. Via Production, "Manual functions", General, switch on Work

area illumination.
2. Visually check whether all of the lamps light up.
3. Replace illuminants if necessary.

B813en 2019-02-01 Mechanics 6‐31

 4. Shut down the machine properly, secure the MAIN SWITCH
and secure with a padlock.

1 Work area illumination 2 Screws (6x)

Fig. 74215
5. Undo the screws on the work area illumination mounting
device.
6. Take the work area illumination out and replace the fluores-
cent tubes.
7. Re-install the work area illumination and fix the screws on
the mounting device.

6‐32 Mechanics 2019-02-01 B813en

 5.4 Support slats - Pallets

(see "Overview", pg. 6‐29)

Clean the slats and slat supports;

exchange, if necessary [25]

Maintenance interval: 40 operating hours

For cleaning of the slats, TRUMPF offers TruTool TSC 100, a

specially developed slat cleaner, with the following characteris-
tics:
■ Good cleaning performance regardless of cut material.
■ Simple handling.
■ For 1-man operation, it is not necessary to remove the slats.
■ High parts quality by clean slats.
■ Cost reduction by up to 4 times longer use of the slats.
For more information: www.trumpf-powertools.com

TruTool TSC 100 Fig. 64744

1. Shut down the machine properly, secure MAIN SWITCH with

padlock and remove the key.
2. Release and remove slag.
3. If there is a lot of contamination or damage, clean or replace
the carrier slats. During replacement, make sure that the
slats inserted between the slat supports have rounded cor-
ners.

B813en 2019-02-01 Mechanics 6‐33

 Fig. 95390

5.5 Compact dust extractor

(see "Overview", pg. 6‐29)

Checking or replacing the disposable

container [02]

Maintenance interval: 8 operating hours

Means, Tools, Materials

■ Disposable containers.
■ Breathing mask of the safety class FFP3.

Notes
■ This involves extremely fine metal dust particles which must
not be brought into contact with burning objects due to the
risk of combustion.
When working on the compact dust extractor, always wear a
tightly-fit dust mask (e.g. breathing mask of the safety class
FFP3) as personal safety equipment.
■ Disposal as hazardous waste is not necessary. However, it is
vital to find out the relevant national, regional, and local reg-
ulations and follow them closely.
If the machine is used as intended, the filtered dust can be
supplied for metal recycling.

According to German national regulations, the containers must

be marked as follows according to the dust they contain:

6‐34 Mechanics 2019-02-01 B813en

Metal dust Identification
Dust from steel machining ■ LAGA key 35101 (ferrous dust without harmful impurities).
■ EAK code 120102 (ferrous particles);
EAK group: waste from mechanical shaping (incl. welding, cutting)
Dust from aluminum machining ■ LAGA key 35304 (aluminum scraps)
■ EAK code 120103 (chips and waste containing non-iron metal)
EAK group: waste from mechanical shaping (incl. welding, cutting)
Tab. 6-6

1. Before changing the container, switch off the dust extractor.

2. Open the lower doors of the compact dust extractor.

1 Disposable container (30 l) 2 Disposable container (213 l)

Fig. 81032
3. Check the level of the two disposable containers (1 and 2).
4. If a smoldering fire occurs, immediately exchange the dispos-
able containers.
or
Ø Exchange the disposable containers when they are 75%
full.
5. Securely seal the cover of the old disposable containers and
completely dispose of the containers.
6. Install the new containers.
7. Open the lower doors of the compact dust extractor.

B813en 2019-02-01 Mechanics 6‐35

 5.6 Dust chamber in the compact dust
extractor

(see "Overview", pg. 6‐29)

Cleaning the dust chamber [22]

Maintenance interval: 500 operating hours

Dust chamber cover at the compact dust extractor Fig. 65799

1. Remove the screws on the cover and remove the cover.

2. Check the dust chamber for dust accumulation, contamina-
tion or damage.
3. Clean the dust chamber and repair if necessary.
4. Refit the cover and tighten the screws.

6‐36 Mechanics 2019-02-01 B813en

 5.7 The differential pressure indicator on
the compact dust extractor

(see "Overview", pg. 6‐29)

Check differential pressure indicator [23]

Maintenance interval: 40 operating hours

1. Read the differential pressure.

Fig. 85153
2. If the indicated value is in the red range (1), proceed as
described in the manufacturer's documentation.

5.8 Compact dust extractor purging

valves

(see "Overview", pg. 6‐29)

Check the purging valves [44]

Maintenance interval: 500 operating hours

1. Check the purging valve acoustically and clean if necessary.

Note
See "Subcontractor_documents" on the DVD "Documents".
2. Remedy malfunctions according to the information in the sup-
plier documentation.

B813en 2019-02-01 Mechanics 6‐37

 5.9 Compact dust extractor: extinguisher
system (option)

(see "Overview", pg. 6‐29)

Maintain extinguisher system

Maintenance interval: As needed

Note
See "Subcontractor_documents" on the DVD "Documents".
Ø Perform maintenance work in accordance with the delivery
documentation.

5.10 Tube bend and suction tube of the

suction system

(see "Overview", pg. 6‐29)

Dismantling and cleaning the pipe elbow

and suction tube [45]

Maintenance interval: 500 operating hours

Note
See "Subcontractor_documents" on the DVD "Documents".
Ø Perform maintenance work in accordance with the delivery
documentation.

6‐38 Mechanics 2019-02-01 B813en

 5.11 Storage bin for slag and dust

(see "Overview", pg. 6‐29)

Emptying the storage bin [26]

Maintenance interval: 8 operating hours

Condition
■ EMERGENCY STOP is pending.

Note
The storage bins under the front and rear conveyor belt deflec-
tion shaft should always be cleaned before changing the material
from aluminum/aluminum alloys to ferrous materials or vice
versa.

Side view of the machine (left installation) with the Fig. 62975
storage bins pulled out

1. Pull the storage bin under the front and rear conveyor belt
deflection shaft out completely in Y direction.
2. Empty the entire storage bin or vacuum with an industrial
vacuum cleaner. When emptying a segmented storage bin
(option) be careful to empty all of the 3 segments.
3. Clean the loading area of the storage bin carefully.
4. Push the storage bins under the machine up to the back
stop; they must not protrude.

B813en 2019-02-01 Mechanics 6‐39

 Risk of crushing due to movement of the conveyor belt!
WARNING
If the transverse conveyor is started while the storage bin
is being cleaned, hands or fingers might be clamped
between the conveyor belt and the bottom plate.
Ø Before cleaning and removing the clamped parts, stop the
transverse conveyor.
Ø Do not clean the dust drawer of the transverse conveyor or
the dust accumulation on the conveyor belt with your hands.
Use suitable auxiliary tools for cleaning (e.g. industrial vac-
uum cleaner).

5. Empty the storage bin for the transverse conveyor (option) or

vacuum it with an industrial vacuum cleaner.

5.12 Y measurement system, guideways,

covers and track strippers

(see "Overview", pg. 6‐29)

Cleaning the Y scale [06]

Maintenance interval: 1000 operating hours

The Y measurement system must be cleaned at regular inter-

vals. Contamination can cause failure of the Y measuring sys-
tem. In the event of failure, the machine can be damaged by
axes moving at uncontrolled speed against the fixed stops.

Condition
■ Switch off the machine in the correct way, switch off the
MAIN SWITCH, lock it, and remove the key.

Means, Tools, Materials

■ Cleaning cloths from the 1850436 cleaning kit.
■ Isopropyl alcohol from the 1850436 cleaning kit.

Notes
■ Only use the above-mentioned materials to avoid consequen-
tial damage to the measurement system during cleaning.
■ A contaminated rag (e.g. due to chips, slag or dust residues)
must not be used for cleaning to prevent scratches from
appearing on the Y scale.

6‐40 Mechanics 2019-02-01 B813en

 Strong magnetic fields can cause risk of fatal injury to
DANGER persons with pacemakers!
Ø Persons with pacemakers must maintain a distance of at
least 30 cm from the linear motors.
Ø Please pay attention to the safety information in the chapter
on safety in the operator's manual.

Risk of injury caused by axes moving at uncontrolled

DANGER speed!
In the event of an error, the linear axes may move at
uncontrolled speeds against the fixed stops.
Ø Switch off the machine during the cleaning work.

Risk of injury due to high force of attraction!

WARNING
Ø Do not bring any magnetic tools or workpieces near the
linear motors.
Ø Do not bring any clocks or magnetic storage media (floppy
disks, credit cards) near the linear motors.
Ø Please pay attention to the safety information in the chapter
on safety in the operator's manual.

Procedure for machines with 1. Move the Y/Z slides to the left.
TruDisk

1 Bellows of the right Y guide 2 Cover of the Y scale

Fig. 67728
2. Remove the bellows of the right Y guide (1).

B813en 2019-02-01 Mechanics 6‐41

 3. Move the bellows to the left to expose the cover of the Y
guide (2).
4. Wet the cleaning cloth with isopropyl alcohol and completely
clean the cover of the Y scale (2) in the opened section of
the bellows using light pressure.
5. Ensure that the Y scale is no longer moist before installing
the bellows. Reinstall the right bellows.

1 Cover of the Y scale 2 Bellows of the left Y guide

Fig. 67729
6. Move the Y/Z slides to the right.
7. Remove the bellows of the left Y guide (2).
8. Move the bellows to the right to expose the cover of the Y
guide (1).
9. Wet the cleaning cloth with isopropyl alcohol and completely
clean the cover of the Y scale (1) in the opened section of
the bellows using light pressure.
Cleaning is complete after the Y scale has been cleaned
along its entire length.
10. Ensure that the Y scale is no longer moist before installing
the bellows. Reinstall the left bellows.

6‐42 Mechanics 2019-02-01 B813en

 5.13 X and Y axis racks and guideways

(see "Overview", pg. 6‐29)

Cleaning the X and Y axis racks and

guideways

Maintenance interval: 2000 operating hours

Chips, slag and dust have to be cleaned from the X and Y axis
racks and guideways at regular intervals.

Condition
■ Switch off the machine in the correct way, switch off the
MAIN SWITCH, lock it, and remove the key.

Means, Tools, Materials

■ Clean cloth for racks.
■ Slightly oiled cloth for the guideways.
■ Kerosene or thin spindle oil (spray oil).

Cleaning the guideway of

the Y axis

1 Y axis guideway, right 3 X axis rack, right

2 X axis guideway, right
Fig. 76879

1. Remove the bellows of the right Y guide.

2. Push the bellows to the left, in order to expose the guide.
3. Clean guideway (1) with a slightly oiled cloth. Reinstall the
right bellows.

B813en 2019-02-01 Mechanics 6‐43

 4. Move the Y/Z slides to the right.
5. Remove the bellows of the left Y guide. Repeat the cleaning
of the guideway on the left side.

Cleaning the guideway and

X axis rack

1 Y axis guideway, right 3 X axis rack, right

2 X axis guideway, right
Fig. 76879
6. Loosen the bellows of the right X guide and push to the side.
7. Spray or coat rack (3) with kerosene or light spindle oil.
8. Remove the dirt from the tooth flanks with a clean cloth.
9. Repeat the cleaning procedure twice.
10. Clean old oil and dirt from the guideway (2) with a slightly
oiled cloth. Reinstall the right bellows.
11. Loosen the left X axis bellows and push to the side.
12. Repeat steps 7 to 10 for the left machine side.
13. In order to continue the cleaning procedure at the rear of the
machine: push the motion unit forwards and loosen the rear
bellows.
14. Repeat steps 7 to 10 at the rear of the machine.

6‐44 Mechanics 2019-02-01 B813en

 5.14 Z axis bellows

(see "Overview", pg. 6‐29)

Checking and cleaning the Z axis bellows

Maintenance interval: 2000 operating hours

1 Z axis bellows
Example Fig. 78435

1. Check the bellows for damage such as cracks or holes as

well as for fixed seat.
2. Clean the bellows.

B813en 2019-02-01 Mechanics 6‐45

 5.15 Cable carriers

(see "Overview", pg. 6‐29)

Checking the Y and Z cable carriers [07]

Maintenance interval: 1000 operating hours

1 Y axis cable carrier 3 Z axis cable carrier

2 Cutting unit cable carrier
Example Fig. 73292

Ø Check the joints, cables and hoses for damage and wear.

5.16 Motion unit

(see "Overview", pg. 6‐29)

Clean the grease collecting tray

Maintenance interval: 2000 operating hours

Means, Tools, Materials

■ Cleaning cloth.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.

6‐46 Mechanics 2019-02-01 B813en

 2. Remove the left and right bellows of the Y guide.
3. Open the cover of the cutting unit.

1 Screws (2x) 2 Grease collecting tray

Fig. 74216
4. Undo the screws on the grease collecting trays to the left
and right of the cutting unit.
5. Clean the grease collecting tray with a cloth.

Cleaning the spray shield

Maintenance interval: 2000 operating hours

Means, Tools, Materials

■ Cleaning cloth.

1. Shut down the machine properly, secure the MAIN SWITCH

and secure with a padlock.
2. Remove the left and right bellows of the Y guide.
3. Open the cover of the cutting unit.

B813en 2019-02-01 Mechanics 6‐47

 1 Lower spatter guard 4 Screws (2x)
2 Bottom plate 5 Screws (4x)
3 Screws (3x)
Spatter guard Fig. 70416
4. Undo the screws on the spray shield beneath the cutting
unit.
5. Clean the spray shield with a cloth.

5.17 Pallet conveyor cam assembly

(see "Overview", pg. 6‐29)

Replacing the cam assembly of the pallet

transport

Maintenance interval: 5000 operating hours

Note
Wear appears on the cam assembly after approx. 5000
operating hours.

Ø Replace the cam assembly in case of wear (see chapter

“Setting work”).

6‐48 Mechanics 2019-02-01 B813en

 5.18 Longitudinal conveyor belt

(see "Overview", pg. 6‐29)

Checking the hinge conveyor belt [20]

Maintenance interval: 40 operating hours

1. With Set up"Manual functions"PaCh man. , move the pallet

changer out.
2. Move the hinge conveyor belt using Set up"Manual func-
tions"General"Conveyor forwards".
3. Check the hinge conveyor belt for scorching, holes and or
other damage.
4. If required: request Technical Service.

Tightening the hinge conveyor belt

Maintenance interval: 40 operating hours

Notes
■ Since the side chains of the hinge conveyor belt are elon-
gated in operation by the tensile forces absorbed, they need
to be regularly retensioned.
■ The hinge conveyor belt must be retensioned following each
change.
■ The following work must be performed on both sides of the
conveyor housing.

Heavy wear due to strong tension!

NOTICE
Ø The torque may not exceed 15 Nm.

B813en 2019-02-01 Mechanics 6‐49

 Fig. 96624

1. Loosen the lock nut (1).

Fig. 96610
2. Tighten the clamping screw (2) with a tightening torque of
15 Nm.
3. Ensure that the clamping screw and lock nut cannot be
warped.
4. Check whether the dimension x (see "Fig. 96610", pg. 6‐50)
is identical on both sides. If this is not the case, release the
clamping screw tension on the side with the smaller clear-
ance measurement.
5. If required: request Technical Service.

6‐50 Mechanics 2019-02-01 B813en

 5.19 Cover sheets of the longitudinal and
transverse conveyor belt

(see "Overview", pg. 6‐29)

Cleaning the cover sheets

Maintenance interval: 8 operating hours

Health hazard from metal dust!

WARNING
Irritation, poisoning or caustic injury to the skin and the
eyes could occur, depending on the type of dust (e.g. from
chrome/nickel compounds).
Ø Use vacuum cleaner with activated carbon filter.
Ø Do not stir up dust when cleaning.

The cover sheets above the longitudinal and transverse conveyor

belts in the rear part of the machine must be cleaned depending
on the degree of contamination.

1. Move the pallets into the pallet changer.

2. Remove slag residues from the cover sheets.
3. Sweep or vacuum the cover sheets.

B813en 2019-02-01 Mechanics 6‐51

 5.20 Exhaust module

(see "Overview", pg. 6‐29)

Checking, cleaning and if necessary

replacing components of the exhaust
module [24]

Maintenance interval: 40 operating hours

1 Bulkhead 3 Grid sheet

2 Protective plate 4 Vacuum flap
Fig. 71227

1. Move the pallets into the pallet changer.

2. Remove slag remnants from the side walls.
3. Clean protective plates, grids and bulkheads.
4. Check the suction channel and vacuum flaps for contamina-
tion and clean if necessary.

Damage to the machine due to reflections!

NOTICE
Ø Use S235 (mild steel) as material for the protective plates.

6‐52 Mechanics 2019-02-01 B813en

 1 Protective plate
Fig. 71224
5. Clean the protective plates, grids and bulkheads and replace
them if they are badly deformed. The files for cutting are on
the machine under the following path:
− 'C:\dh\Topsmanu.dir\ShopFloorProgramming\PartsFolder
\exhaust_flap_protection_10mm.GEO'
− 'C:\dh\Topsmanu.dir\ShopFloorProgramming\PartsFolder
\exhaust_flap_protection_10mm.DXF'

Note
The vacuum flaps can get stuck in the case of deposit build-
up on the front side. Then the vacuum flaps cannot be
opened anymore, even if the cutting unit is above the
respective suction chamber.
6. Move the motion unit back in jog mode.

B813en 2019-02-01 Mechanics 6‐53

 5.21 Pallet changer

(see "Overview", pg. 6‐29)

Check and clean the calibration plate and

nozzle-cleaning brushes; replace, if
necessary [42]

Maintenance interval: 500 operating hours

1 Nozzle-cleaning brush 3 Pallet frame

2 Calibration plate
Position on the pallet changer in longitudinal layout Fig. 55768

Ø Clean the calibration plate and nozzle-cleaning brushes on

the two pallets. Check the nozzle-cleaning brushes and
replace if necessary.

6‐54 Mechanics 2019-02-01 B813en

 5.22 Camera for process monitoring

(see "Overview", pg. 6‐29)

Check the protective glass on the camera;

clean, if necessary [66]

Maintenance interval: 1000 operating hours

Means, Tools, Materials

■ Lint-free cloth (e.g. microfiber cloth)

1 Protective glass
Protective glass on the camera Fig. 87691

1. Check the protective glass for dirt and clean it with a lint-free
cloth (e.g. microfiber cloth).
2. If the protective glass is damaged or can no longer be
cleaned, exchange the protective glass.

B813en 2019-02-01 Mechanics 6‐55

 5.23 Automatic nozzle changer (option)

(see "Overview", pg. 6‐29)

Check nozzles, ceramic body and nozzle

threads

Maintenance interval: 8 operating hours

1. Press Technology, "Laser", "Nozzle changer", Tooling posi-

tion.
The axes of the machine move into a position in which the
nozzle changer is easily accessible.
2. Check ceramic parts and nozzle threads for abrasion.
3. Check the condition of all of the nozzles.
4. If necessary, replace the nozzles and enter the desired noz-
zle distance or default value in the control.

Check and clean the nozzle holders

Maintenance interval: 40 operating hours

1. Press Technology, "Laser", "Nozzle changer", Tooling posi-

tion.
The axes of the machine move into a position in which the
nozzle changer is easily accessible.
2. Check the nozzle holders for damage.
3. Check whether all of the nozzle holders can be pushed down
equally. If this is not so, replace the respective nozzle
holder(s).
4. Clean the nozzle holders.
5. Clean the upper side of the cover sheet.

6‐56 Mechanics 2019-02-01 B813en

 Clean or replace the sleeve and internal
part of the nozzle (Highspeed Eco)

Maintenance interval: As needed

During a nozzle inspection, a leak test is performed on the

sleeve and mechanical wear is checked. If the sleeve is faulty,
the nozzle from the nozzle changer is replaced.
For machines without a nozzle changer, the operator must check
the sleeve (characteristic curve recording) and if necessary clean
or completely replace the sleeve or the internal part.

Note
Before checking the sleeve condition without a nozzle changer, a
Highspeed Eco processing program must be started and an
EAV 3.0 nozzle selected, so as to record the correct characteris-
tic curve.

Replacing a worn sleeve

1 Inner part 3 Base tube 4 Assembly tool

2 Bushing
Fig. 88041

1. Insert the assembly tool through the base body until it pro-
trudes approximately 1 mm out of the internal part of the
sleeve.
2. Rotate the assembly tool in the open direction and unscrew
the internal part.
The sleeve and internal part can now be replaced.

Replacing the internal part 3. Either

Ø Check the internal part and clean if necessary.

B813en 2019-02-01 Mechanics 6‐57

 or
Ø Replace internal parts which can no longer be cleaned.

1 Inner part 3 Base tube 4 Assembly tool

2 Bushing
Fig. 88041
4. Insert the base body, sleeve and internal part into each other.
Insert the assembly tool through the base body until it pro-
trudes approximately 1 mm out of the internal part.

Note
Do not use any other tools. Other tools can damage the
internal part.
5. Rotate the assembly tool in the direction of close and screw
the inner part in tightly (the assembly tool may turn slightly in
the process).

6‐58 Mechanics 2019-02-01 B813en

 Check and clean the calibration plate and
nozzle-cleaning brushes [42]

Maintenance interval: 500 operating hours

1 Nozzle-cleaning brush 3 Nozzle holder

2 Calibration plate 4 Nozzle changer extension
Fig. 61830

1. Press Technology, "Laser", "Nozzle changer", Tooling posi-

tion.
The axes of the machine move into a position in which the
nozzle changer is easily accessible.
2. Clean the calibration plate.
3. Check the nozzle-cleaning brush, clean it and replace it if
necessary.

Cleaning the drive unit's cover sheet

Maintenance interval: 2000 operating hours

1. Press Technology, "Laser", "Nozzle changer", Tooling posi-

tion.
The axes of the machine move into a position in which the
nozzle changer is easily accessible.

B813en 2019-02-01 Mechanics 6‐59

 1 Drive unit area
Fig. 57676
2. Remove the cover sheet and clean the drive unit area (1)
under the cover sheet.

Lubricating the linear guides

Maintenance interval: Every 3 years

Ø Request Technical Service.

6‐60 Mechanics 2019-02-01 B813en

 6.  Pneumatics

6.1 Overview

1 Single-piston pump and central 6 40 μm filter for compressed air 11 3/2 directional valve
lubrication lubricant container supply 12 Filter17
2 Electrical lubricator for chain on 7 Filter B compressed air supply
13 Microfilter17
the longitudinal conveyor belt 8 Filter A compressed air supply
14 Activated carbon filter 117
3 Spraying equipment 9 Activated carbon filter com-
4 Cutting unit ventilation pressure pressed air supply 15 Activated carbon filter 217
reducer 10 Gas filter for oxygen and nitro-
5 Operating pressure reducer gen
Instrument panel Fig. 64567

17 For compressed-air cutting only

B813en 2019-02-01 Pneumatics 6‐61

 6.2 Input controller operating pressure

(see "Overview", pg. 6‐61)

Check the operating pressure

Maintenance interval: 2000 operating hours

1. Check whether the setting is 5 ±0.5 bar.

2. Check the condensate status.

6.3 40 μm filter for compressed air

supply

(see "Overview", pg. 6‐61)

Replace the filter cartridge

Maintenance interval: 2000 operating hours

1. Shut down the machine in the correct way, switch off the
MAIN SWITCH, lock it and remove the key.
2. Push the release downwards.
3. Rotate the filter bowl to the left and pull it off downwards
(bayonet lock).
4. Replace the filter element.
5. To re-install the filter bowl, perform the above steps in
reverse order.
6. Turn the MAIN SWITCH to I.
7. Switch on the machine.

6‐62 Pneumatics 2019-02-01 B813en

 6.4 Filter B compressed air supply

(see "Overview", pg. 6‐61)

Replace the filter cartridge

Maintenance interval: 2000 operating hours

1. Shut down the machine in the correct way, switch off the
MAIN SWITCH, lock it and remove the key.
2. Push the release downwards.
3. Rotate the filter bowl to the left and pull it off downwards
(bayonet lock).
4. Replace the filter element.
5. To re-install the filter bowl, perform the above steps in
reverse order.
6. Turn the MAIN SWITCH to I.
7. Switch on the machine.

6.5 Filter A compressed air supply

(see "Overview", pg. 6‐61)

Replace the filter cartridge

Maintenance interval: 2000 operating hours

1. Shut down the machine in the correct way, switch off the
MAIN SWITCH, lock it and remove the key.
2. Push the release downwards.
3. Rotate the filter bowl to the left and pull it off downwards
(bayonet lock).
4. Replace the filter element.
5. To re-install the filter bowl, perform the above steps in
reverse order.
6. Turn the MAIN SWITCH to I.
7. Switch on the machine.

B813en 2019-02-01 Pneumatics 6‐63

 6.6 Activated carbon filter compressed
air supply

(see "Overview", pg. 6‐61)

Replace the filter cartridge

Maintenance interval: 2000 operating hours

1. Shut down the machine in the correct way, switch off the
MAIN SWITCH, lock it and remove the key.
2. Push the release downwards.
3. Rotate the filter bowl to the left and pull it off downwards
(bayonet lock).
4. Replace the filter element.
5. To re-install the filter bowl, perform the above steps in
reverse order.
6. Turn the MAIN SWITCH to I.
7. Switch on the machine.

6.7 Condensation water container for

compressed air supply

(see "Overview", pg. 6‐61)

Emptying the condensed water container

[94]

Maintenance interval: As needed

Note
For the tropical option of this machine, the condensed water
container must be checked and emptied at shorter intervals.

6‐64 Pneumatics 2019-02-01 B813en

1 Condensed water container
Example Fig. 68663
1. Regularly check the condensed water container (1) at the
device panel and empty if need be.
2. Reinstall the empty container.

6.8 Cutting gas filter for oxygen nitrogen

and argon

(see "Overview", pg. 6‐61)

Replacing filter elements

Maintenance interval: 5000 operating hours

1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Cut off the pressure at the stop valve.

B813en 2019-02-01 Pneumatics 6‐65

 1 Purge valve
Fig. 94894
3. Let off pressure via the purge valve.
4. Undo the screw joint on the hose.

1 Filter casing
Fig. 85125
5. Screw out the filter housing (1).

6‐66 Pneumatics 2019-02-01 B813en

 1 Filter screw 3 Sintered filter
2 Seal 4 Filter element
Fig. 85168
6. Replace the filter element:
− Assemble the filter screw (1), seal (2), sintered filter (3)
and the new filter element (4).

1 Filter casing 3 Auxiliary bore hole

2 Filter screw
Fig. 85124
7. Insert the filter screw (2) in the filter housing (1):
− First tighten the filter housing by hand.
− Using a ruler, draw a line from the center of the filter
screw to auxiliary bore hole (3).
− Use an Allen key to tighten the filter housing up to the
stop in the direction of the arrow (by about 80-120°).

B813en 2019-02-01 Pneumatics 6‐67

 1 Filter casing
Fig. 85125
8. Install filter housing (1).

6.9 Filter elements in the compact dust

extractor

(see "Overview", pg. 6‐61)

Checking and replacing filter elements

Maintenance interval: 500 operating hours

Notes
■ Check the filter elements in the clean gas chamber of the
compact dust extractor for dust accumulation. Observe
the procedures and the safety information in the opera-
tor's manual provided by the manufacturer when replac-
ing the filter elements.
■ Filter elements must be replaced if:
The suction capacity falls
the filter resistance increases
the filter elements exhibit caking.
Ø Check the filter elements for damage:
− Wear, holes or cracks?
− Replace in case of heavy contamination.

6‐68 Pneumatics 2019-02-01 B813en

 6.10 Maintenance unit on compact dust
extractor

(see "Overview", pg. 6‐61)

Check the pressure reducer and the

compressed air supply

Maintenance interval: 2000 operating hours

1 Pressure setting knob 4 Filter bowl

2 Pressure gauge 5 Condensation water cap
3 Release screw

Fig. 49062

Ø Check whether the setting is at 5 ++0.5 bar.

B813en 2019-02-01 Pneumatics 6‐69

 Checking and, if necessary, replacing the
filter elements

Maintenance interval: 2000 operating hours

1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Push the release downwards.
3. Rotate the filter bowl to the right and pull it off downwards
(bayonet lock).
4. Take out the filter elements, check them for dirt and clean if
necessary.
5. Replace the filter element if it is strongly contaminated. Per-
form maintenance work in accordance with the delivery docu-
mentation.
6. To re-install the filter bowl, perform the above steps in
reverse order.
7. Turn the MAIN SWITCH to I.
8. Switch on the machine.

6.11 Filter (only with the compressed-air

cutting option)

(see "Overview", pg. 6‐61)

Replace the filter element [52]

Maintenance interval: 500 operating hours

1. Shut down the machine properly, switch off the MAIN

SWITCH, lock it and remove the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.
3. Screw out the filter housing.
4. Replace the filter element.
5. Assemble the filter housing.

6‐70 Pneumatics 2019-02-01 B813en

 6.12 Microfilter (only with the compressed-
air cutting option)

(see "Overview", pg. 6‐61)

Replace the filter element [52]

Maintenance interval: 2000 operating hours

1. Shut down the machine properly, switch off the MAIN

SWITCH, lock it and remove the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.
3. Screw out the filter housing.
4. Replace the filter element.
5. Assemble the filter housing.

6.13 Activated carbon filter 1 (only for the

compressed-air cutting option)

(see "Overview", pg. 6‐61)

Check activated carbon filter 1, replace if

necessary[47]

Maintenance interval: 500 operating hours

1. Shut down the machine properly, switch off the MAIN

SWITCH, lock it and remove the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.
3. Screw out the filter housing.

Note
Generally, the filter element from the activated carbon filter 2
can be inserted in the activated carbon filter 1.
4. Check the filter element. If it is slightly brown or smells of oil,
replace it.
5. Assemble the filter housing.

B813en 2019-02-01 Pneumatics 6‐71

 6.14 Activated carbon filter 2 (only for the
compressed-air cutting option)

(see "Overview", pg. 6‐61)

Check activated carbon filter 2, replace if

necessary[48]

Maintenance interval: 500 operating hours

1. Shut down the machine properly, switch off the MAIN

SWITCH, lock it and remove the key.
2. Shut off the compressed air supply to the machine at the
3/2-directional valve.
3. Screw out the filter housing.
4. Check the filter element. If it is slightly brown or smells of oil,
replace it.
5. Assemble the filter housing.

6‐72 Pneumatics 2019-02-01 B813en

 6.15 Spraying equipment

(see "Overview", pg. 6‐61)

1 Quick filler 4 Filler plug 6 Container pressure correction

2 Level indicator 5 Manual operation unit screw
3 Pressure gauge container pres- 7 Compressed air shut-off valve
sure
Fig. 33245

Refilling spraying agent [92]

Maintenance interval: As needed

The spraying agent container must be refilled with spraying

agent if the "Min. level" is reached on the level indicator.

In the following cases, the line must be filled/bled of air:

■ The container has been emptied completely.
■ If the spraying equipment is not spraying evenly.

Note
As specified on the sign on the spraying agent container, only
the TRUMPF-approved spraying agent, TRUMPF CutFluid,

B813en 2019-02-01 Pneumatics 6‐73

 should be used (1 l packing drum mat. no. 356258, 5 l - packing
drum mat no. 356259).
When using TRUMPF CutFluid, keep in mind that its service life
as printed on the barcode on the packing drum is limited to
approx. 6–9 months.
On TruLaser 3030, 3040, 3060, the container can be removed
and cleaned by the customer.

1. With the MAIN SWITCH ON, shut off the compressed air at
the compressed air shut-off valve. The container pressure
indicated by the pressure gauge drops to "0".
2. The compressed air supply does not have to be shut off if
the MAIN SWITCH is OFF.

1 Drawer pulled out

Pulled-out drawer for lubricant container Fig. 62359
3. Pull out the drawer.
4. Open the filler plug.
5. Use a funnel to fill the container up to the max. mark with
spraying agent.
6. Close filler plug.
7. If the original pressure is not reached:
Ø Press the compressed air shut-off valve.
The container pressure gauge will return to the original
pressure.
or
Ø To fill the container pressure quickly:
Ø Open the quick filler with an Allen key by about one turn
counter-clockwise (see Fig. 33245).
8. Use a screwdriver to rotate the manual operation unit to ON.

6‐74 Pneumatics 2019-02-01 B813en

 9. Push the drawer back in.

B813en 2019-02-01 Pneumatics 6‐75

 7.  Machine cooling circuit

7.1 Overview

There are two variants, depending on whether the machine has

a separate machine cooler or the machine components (LLK
plug, drives and electrical cabinet) are cooled by the laser proc-
ess cooler:
■ Cooling by external laser process cooler: In the standard
version, the cooling circuit of the machine is connected to
the laser process cooler. In this case, the water stop valves
in the laser process cooler must be opened during machine
operation. In the event of an error, the status of the shut-off
valve must be checked.
The stop valves in the laser process cooler must be closed
during maintenance work on the cooling circuit of the
machine.
■ Cooling by machine cooler: The machine has a machine
cooler which cools the optical components of the machine as
well as the electrical cabinet.
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".
The following description of the cooling water replacement
applies to the chiller, type L0/5 TK (water-air cooler). The
machine cooler cools the machine components.

Notes
■ No antifreeze agent is required.
■ 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. 6-7

6‐76 Machine cooling circuit 2019-02-01 B813en

 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).

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
Conductivity limit for Cu cooling circuit. max. 200 μS/cm
Tab. 6-8

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.

B813en 2019-02-01 Machine cooling circuit 6‐77

 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. 6-9

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).

6‐78 Machine cooling circuit 2019-02-01 B813en

 7.2 Machine cooler , water-air chiller

(see "Overview", pg. 6‐76)

1 Machine cooler
Fig. 90451

Checking and refilling the level

Maintenance interval: When indicated by the control sys-

tem

Means, Tools, Materials

■ Demineralized water.

Note
Generally, little water is lost from the closed cooling circuit, as
long as the water tank has been closed properly. The cause
must be found if the cooling circuit loses water within a short
period..

B813en 2019-02-01 Machine cooling circuit 6‐79

 1 Level indicator
Level in the machine cooler Fig. 74624

1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Check the filling level. When the minimum level is reached,
top up with water.

Checking filter mat; replacing, if necessary

Maintenance interval: When indicated by the control sys-

tem

The degree of contamination of the filter mat depends on the

respective manufacturing conditions.
If the LCD display "Er.15" flashes on the display of the chiller,
the filter mat must be cleaned.

Note
The filter mat protects the condenser from dirt.

6‐80 Machine cooling circuit 2019-02-01 B813en

 1 Fixing screw 3 Filter mat
2 Grid sheet
The machine cooler filter mat Fig. 74623

1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Remove filter mat.
3. Replace the filter mat.

B813en 2019-02-01 Machine cooling circuit 6‐81

 Change cooling water

Maintenance interval: Annually

Cleaning biocide is added to the cooling circuit 2 hours before

the cooling water replacement. 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.

Conditions
■ Laser device is ready for operation and assigned to the
machine.
■ The machine's drives are switched on: The
MACHINE ON/OFF button lights up.

Means, Tools, Materials

■ 320 l demineralized water.
■ Easy Kit Al-2.
■ 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.

6‐82 Machine cooling circuit 2019-02-01 B813en

 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

B813en 2019-02-01 Machine cooling circuit 6‐83

 Starting the cleaning cycle 1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Open the water tank 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 off cooling water 5. After 2 hours end the cleaning cycle: Press the MACHINE
ON/OFF button.
6. Provide a collecting container for used cooling water.

1 Water outlet
Machine cooling unit water drain Fig. 74626
7. Remove the black blanking plug (3).
8. Completely drain the cooling water
9. Seal the hose with blanking plugs.

Flushing the cooling circuit 10. Fill the tank up to about 60% with fresh, demineralized water.
11. Close the water tank.
12. Switch the drives on again: Press the MACHINE ON/OFF
button.
13. Wait for approx. 10 minutes.
14. Switch off the drives: Press the MACHINE ON/OFF button.
15. Drain the water completely.
16. Carry out the second and third flushing processes, each with
fresh water.

6‐84 Machine cooling circuit 2019-02-01 B813en

 Measure conductivity 17. After the third rinse cycle, measure the conductivity of the
water.
18. To measure the conductivity of the cooling water:
− Take off the tank cap from tank.
− Measure the conductivity of the cooling water.
The conductivity of the cooling water in the tank must be
≤20 μS.
19. If the conductivity is > 20 μS:
− As described: re-drain the cooling water and repeat the
purging process until the required conductivity is ach-
ieved.

Adding anticorrosive agent 20. If the conductivity is ≤20 μS:

− Fill up tanks completely.
− Tank of the Al cooling circuit (machine): Add the anticor-
rosive agent "Water Care-Copper" (yellow bottle lid) from
Easy Kit AL-2 to the cooling water.
21. After adding the anticorrosive agent wait for about 10
minutes.
22. Measure the conductivity of the water again. If the conductiv-
ity is more than 20 µS/cm: repeat the complete cooling water
replacement.
The cooling water replacement is completed when the con-
ductivity of the water does not exceed 20 µS/cm.
23. After completing the cooling water replacement, close the
water tank with the tank cap.
24. After completing the cooling water replacement, clean the
condenser with an industrial vacuum cleaner (see the opera-
tor's manual for the process cooler from KLH).
Attention: No dirt may fall into the tank in the process!
25. Clean the interior space of the process cooler with a cloth.
26. After completing all maintenance work, close the process
cooler again.
27. Document the cooling water replacement on the process
cooler.

B813en 2019-02-01 Machine cooling circuit 6‐85

 8.  External laser cooling circuit
(TruDisk 3001 / 4001, standard
version)

8.1 Overview

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. 6-10

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.

Cooling water requirement

of external laser device
cooling circuit

Cooling circuit Design Laser device Easy Kit Volumetric Water require-
capacity of ment for cool-
cooling circuit ing water
in l / gallons replacement
in l / gallons
Type RL12/0 TK Tropical version TruDisk 3001 Cu4 approx. 140 (37) approx.
560 (148)
Type RL14/0 TK Tropical version TruDisk 4001 Cu4
Type RL16/0 SK Standard version TruDisk 3001, Cu4
TruDisk 4001
External laser device cooling circuit Tab. 6-11

6‐86 External laser cooling circuit (TruDisk 3001 / 4001, 2019-02-01 B813en
standard version)
 8.2 Process cooler: Laser (water-air)

(see "Overview", pg. 6‐86)

1 Level indicator 2 Filter mat

Process cooler, type RLxx/0 TK/TR (water-air) Fig. 74218

Replacing the filter mat

Maintenance interval: Annually

Means, Tools, Materials

■ Filter mat, cut to size.

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 addition-
ally switched on and off.

1. Switch off the MAIN SWITCH Machine.

2. Remove the filter mat and replace with a new one.

B813en 2019-02-01 External laser cooling circuit (TruDisk 3001 / 4001, 6‐87
standard version)
 Checking and refilling the level

Maintenance interval: When indicated by the control sys-

tem

Means, Tools, Materials

■ Demineralized water.

Note
Generally, little water is lost from the closed cooling circuit, as
long as the water tank has been closed properly. The cause
must be found if the cooling circuit loses water within a short
period..

Ø Check the filling level. When the minimum filling level is

reached: Top up with water.

Check the ventilation fan and clean, if

necessary.

Maintenance interval: Annually

Ø Check the ventilation fan in the process cooler; clean, if nec-

essary.

Change cooling water

Maintenance interval: Annually

Cleaning biocide is added to the cooling circuit 2 hours before

the cooling water replacement. 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.

6‐88 External laser cooling circuit (TruDisk 3001 / 4001, 2019-02-01 B813en
standard version)
 Condition
■ Laser device is ready for operation and assigned to the
machine.

Means, Tools, Materials

■ Demineralized water.
■ Conductivity measuring device.
■ Protective gloves.
■ Safety glasses.
■ Water collecting container.
■ Clean cleaning cloth.
■ Easy Kit.

Notes
■ For each rinse cycle, the tank is filled up to 60% with fresh
water.
■ If the laser device and/or process cooler have their own
MAIN SWITCHES these MAIN SWITCHES must be addition-
ally switched on and off.
■ Replace all of the water filters which are part of the cleaned
cooling circuit after each replacement of the cooling water.

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.

B813en 2019-02-01 External laser cooling circuit (TruDisk 3001 / 4001, 6‐89
standard version)
 1 Compressor 4 Condenser
2 Water tank 5 Vaporizer
3 Pump 6 Water connections (to the laser)
Cooling circuit for external laser device cooler Fig. 90982

6‐90 External laser cooling circuit (TruDisk 3001 / 4001, 2019-02-01 B813en
standard version)
 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.

6. Switch off the MAIN SWITCH Machine.
7. Open the longitudinal side on the process cooler again.

Note
The water container, pump and pipelines must be drained.
8. Drain the water.
9. When the water tank is empty, mount the sealing caps again
and thoroughly clean the inside of the water tank.

Flushing the cooling circuit 10. Fill the tank up to about 60% with fresh, demineralized water.
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.
14. Wait for approx. 10 minutes.
15. Switch off the drives: Press the MACHINE ON/OFF button.
16. Drain the water completely.
17. Carry out the second and third flushing processes, each with
fresh water.

Measure conductivity 18. After the third rinse cycle, measure the conductivity of the
water.
19. To measure the conductivity of the cooling water:
− Take off the tank cap from tank.
− Measure the conductivity of the cooling water.
The conductivity of the cooling water in the tank must be
≤20 μS.
20. If the conductivity is > 20 μS:
− As described: re-drain the cooling water and repeat the
purging process until the required conductivity is ach-
ieved.

B813en 2019-02-01 External laser cooling circuit (TruDisk 3001 / 4001, 6‐91
standard version)
 Adding anticorrosive agent 21. 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.
22. After adding the anticorrosive agent wait for about 10
minutes.
23. Measure the conductivity of the water again. If the conductiv-
ity is more than 20 µS/cm: repeat the complete cooling water
replacement.
The cooling water replacement is completed when the con-
ductivity of the water does not exceed 20 µS/cm.
24. After completing the cooling water replacement, close the
water tank with the tank cap.
25. After completing the cooling water replacement, clean the
condenser with an industrial vacuum cleaner (see the opera-
tor's manual for the process cooler from KLH).
Attention: No dirt may fall into the tank in the process!
26. Clean the interior space of the process cooler with a cloth.
27. After completing all maintenance work, close the process
cooler again.
28. Document the cooling water replacement on the process
cooler.

6‐92 External laser cooling circuit (TruDisk 3001 / 4001, 2019-02-01 B813en
standard version)
 9.  Cooling circuit of the machine
(TruDisk 6001)

9.1 Overview

Note
The following maintenance work is only valid in connection with
a TruLaser 3030 (L49) or TruLaser 3040 (L50) with TruDisk
6001.

9.2 Process cooler for machine

(see "Overview", pg. 6‐93)

Exchange filter mat

Maintenance interval: 100 operating hours

1 Filter mat
Process cooler Fig. 74217

1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Pull out the filter mat (1) upwards.

B813en 2019-02-01 Cooling circuit of the machine (TruDisk 6001) 6‐93

 3. Push in a new filter mat.

Checking the filling level

Maintenance interval: When indicated by the control sys-

tem

Means, Tools, Materials

■ Easy Kit Al-1.
■ Demineralized water with a conductivity of ≤10 μS.
■ Protective gloves.
■ Safety glasses

1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Read off the cooling water level on the level indicator (2),
(see "Fig. 59558", pg. 6‐97).

Note
If more than half the volume of the water tank is filled with
demineralized water, one bottle of the anticorrosive agent
"Water Care Aluminum" (light blue bottle lid) will have to be
added to the cooling water.

Cooling water and cooling water additives are aggressive!

WARNING
Injuries to skin and eyes.
Ø Avoid direct skin contact with cooling water and cooling
water additives.
Ø Wear protective gloves and safety glasses when working
with cooling water and cooling water additives.

3. Fill up the cooling water or replace all the cooling water if the
minimum marking on the level indicator or if the maintenance
interval for all the cooling water has been reached.
4. Switch off the MAIN SWITCH, lock it and pull out the key.

6‐94 Cooling circuit of the machine (TruDisk 6001) 2019-02-01 B813en

 1 Quick release fastener
Process cooler, tank cover Fig. 74982
5. Open two quick-release fasteners (1) and remove the tank
cover.

1 Tank
Process cooler Fig. 74220
6. To top up the cooling water:

B813en 2019-02-01 Cooling circuit of the machine (TruDisk 6001) 6‐95

 − Take off the tank cap from tank (1).
− Fill demineralized water until the max. marking on the
level indicator is reached.
− If more than half the volume of the water tank is filled
with demineralized water: Add anticorrosive agent "Water
Care Aluminum" (light blue bottle lid) to the cooling water.
7. Mount the tank cap and tank cover.

Replace cooling water

Maintenance interval: Annually

Means, Tools, Materials

■ Easy Kit Al-1.
■ Conductivity measuring device.
■ Pump (included in the scope of delivery of the machine).
■ Approx. 160 l demineralized water with a conductivity of
≤10 μS.
■ Collecting container.
■ Protective gloves.

Cooling water and cooling water additives are aggressive!

WARNING
Injuries to skin and eyes.
Ø Avoid direct skin contact with cooling water and cooling
water additives.
Ø Wear protective gloves and safety glasses when working
with cooling water and cooling water additives.

6‐96 Cooling circuit of the machine (TruDisk 6001) 2019-02-01 B813en

1 Tank filling 3 Tank drain valve 4 Yellow seal cap
2 Level indicator
Process cooler Fig. 59558

Carry out the cleaning cycle 1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Add the cleaning biocide (red bottle lid) from Easy Kit Al-1 to
the used cooling water via the tank filling opening (1)(see
"Fig. 59558", pg. 6‐97).
− Perform a 2-hour cleaning cycle (the process cooler
pump must be running).
3. Switch off the MAIN SWITCH, lock it and pull out the key.

Pumping off the cooling 4. On the "Tank emptying" connection, remove the yellow seal
water cap (4).
− Mount the reducer 1/2-3/4'' to the valve piece.
− Engage a hose.
− Connect the suction side of the pump to the hose.
5. Engage another hose on the pressure side of the pump and
connect to the collecting container on hand.
6. Provide a collecting container for used cooling water.
7. Open tank drain valve (3).
8. Put a drilling machine on the pump and pump off the cooling
water into the collecting container.
− To empty completely: Tilt the process cooler.
9. Close the tank drain valve.

Filling cooling water 10. Connect the pressure side of the pump to the drain valve of
the process cooler.
11. Connect the suction side of the pump to the container for
demineralized water.

B813en 2019-02-01 Cooling circuit of the machine (TruDisk 6001) 6‐97

 12. Open the tank drain valve.
13. Fill demineralized water until the max. marking on the level
indicator (2) is reached.
14. Close the tank drain valve.
15. Switch on the MAIN SWITCH and allow the pump to run for
30 minutes .
16. Switch off the MAIN SWITCH, lock it and pull out the key.

Measure conductivity

1 Quick release fastener

Process cooler, tank cover Fig. 74982
17. Remove two screws (1) and take off the tank cover.

6‐98 Cooling circuit of the machine (TruDisk 6001) 2019-02-01 B813en

 1 Tank
Process cooler Fig. 74220
18. To measure the conductivity of the cooling water:
− Take off the tank cap from tank (1).
− Measure the conductivity of the cooling water.
The conductivity of the cooling water in the tank must be
≤20 μS.
19. If the conductivity is > 20 μS:
− As described: re-drain the cooling water and repeat the
purging process until the required conductivity is ach-
ieved.

Adding anticorrosive agent 20. If the conductivity is ≤20 μS:

− Add the anticorrosive agent "Water Care-Aluminum" (light
blue bottle lid) from Easy Kit Al-1 to the cooling water via
the tank filling opening (1).
− Close the tank filling.
21. Mount the tank cap and tank cover, dismantle the pump and
accessories.

B813en 2019-02-01 Cooling circuit of the machine (TruDisk 6001) 6‐99

 10.  External laser cooling circuit
(TruDisk 6001)

10.1 Overview

Note
The following maintenance work is only valid in connection with
a TruLaser 3030 (L49) or TruLaser 3040 (L50) with TruDisk
6001.

10.2 Laser process cooler

(see "Overview", pg. 6‐100)

Replacing the filter mat [91]

Maintenance interval: 100 operating hours

1 Level indicator 2 Filter mat

Process cooler, type RLxx/0 TK/TR (water-air) Fig. 74218

1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Remove filter mat (2).

6‐100 External laser cooling circuit (TruDisk 6001) 2019-02-01 B813en

 3. Fit a new filter mat.

Checking the filling level [81]

Maintenance interval: When indicated by the control sys-

tem

Means, Tools, Materials

■ Protective gloves.
■ Safety glasses

1. Switch off the MAIN SWITCH, lock it and pull out the key.

1 Level indicator 2 Filter mat

Process cooler, type RLxx/0 TK/TR (water-air) Fig. 74218
2. Read off the cooling water level from the level indicator.

B813en 2019-02-01 External laser cooling circuit (TruDisk 6001) 6‐101

 Replace cooling water

Maintenance interval: Annually

Means, Tools, Materials

■ Easy Kit Cu-4.
■ Conductivity measuring device.
■ Pump (included in the scope of delivery of the machine).
■ Demineralized water to a volume of four times the volume of
the tank with a conductivity of ≤ 10 μS.
■ Collecting container.
■ Protective gloves.
■ Safety glasses

Cooling water and cooling water additives are aggressive!

WARNING
Injuries to skin and eyes.
Ø Avoid direct skin contact with cooling water and cooling
water additives.
Ø Wear protective gloves and safety glasses when working
with cooling water and cooling water additives.

Check filling level 1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Read off the cooling water level from the level indicator.

Topping up cooling water Note

Replace all the cooling water if the minimum marking on the
level indicator or if the maintenance interval has been
reached.
3. Remove two screws and take off the tank cover.

6‐102 External laser cooling circuit (TruDisk 6001) 2019-02-01 B813en

 1 Tank
Laser process cooler Fig. 74219

4. To top up the cooling water:

− Take off the tank cap from tank (1).
− Fill demineralized water until the max. marking on the
level indicator is reached.
− If more than half the volume of the water tank is filled
with demineralized water: Add anticorrosive agent "Water
Care Aluminum" (light blue bottle lid) to the cooling water.

Measure conductivity 5. To measure the conductivity of the cooling water:

− Take off the tank cap from tank.
− Measure the conductivity of the cooling water.
The conductivity of the cooling water in the tank must be
≤20 μS.
6. If the conductivity is > 20 μS:
− As described: re-drain the cooling water and repeat the
purging process until the required conductivity is ach-
ieved.

Adding anticorrosive agent 7. If the conductivity is ≤20 μS:

− Add the anticorrosive agent "Water Care-Copper" (yellow
bottle lid) from Easy Kit Cu-4 to the cooling water via the
tank filling.
− Close the tank filling.
8. After completing the cooling water replacement, clean the
condenser with an industrial vacuum cleaner (see the opera-
tor's manual for the process cooler from KLH).
Attention: No dirt may fall into the tank in the process!

B813en 2019-02-01 External laser cooling circuit (TruDisk 6001) 6‐103

 9. Close process cooler again.

6‐104 External laser cooling circuit (TruDisk 6001) 2019-02-01 B813en

 11.  TruDisk

11.1 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.

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. 6-12

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.

Cooling water requirement Laser device Easy Kit Volumetric capacity

of internal laser device of cooling circuit
in l / gallons
cooling circuit
TruDisk 3001 Cu3 approx. 55 / 14.5
TruDisk 4001
TruDisk 6001
Internal cooling circuit of the laser device Tab. 6-13

B813en 2019-02-01 TruDisk 6‐105

 11.2 TruDisk cooling circuit

(see "Overview", pg. 6‐105)

Changing the cooling water and tank

Maintenance interval: Annually

Ø See Operator's manual TruDisk, Chapter "Maintenance".

Checking the cooling for tightness

Maintenance interval: As needed

Ø See Operator's manual TruDisk, Chapter "Maintenance".

Cleaning or replacing the contamination

filter

Maintenance interval: When indicated by the control sys-

tem

Note
After each cooling water replacement and if the message: "Tem-
perature in the laser device too high" is displayed.

Ø See Operator's manual TruDisk, Chapter "Maintenance".

6‐106 TruDisk 2019-02-01 B813en

 Replacing the water microfilter

Maintenance interval: When indicated by the control sys-

tem

Note
After each cooling water replacement and if the message: "Pump
has reached its capacity limit" is displayed.

Ø See Operator's manual TruDisk, Chapter "Maintenance".

B813en 2019-02-01 TruDisk 6‐107

 12.  Laser cooling circuit with Easy Filter

12.1 Overview

What Easy Filter is The Easy Filter is required in a specific size, depending on the
required? amount of water.
The amount of water also plays a role for the cooling water addi-
tives (Easy Kits).

The following table shows the relationship between water vol-

ume, Easy Kits and Easy Filter:

Water volume in Easy Kit Easy Filter

cooling circuit (in
liters)
5 – 14 Easy Kit Cu-1
15 – 49 Easy Kit Cu-2 Easy Filter – size M
50 – 119 Easy Kit Cu-3
120 – 359 Easy Kit Cu-4
Easy Filter – size XXL
360 – 999 Easy Kit Cu-5
30 – 79 Easy Kit Al-1 Easy Filter – size M
80 – 199 Easy Kit Al-2
Easy Filter – size XXL
200 – 599 Easy Kit Al-3
600 – 1199 Easy Kit Al-4 Easy Filter – Size XXL (2x)
50 – 119 Easy Kit Cu-3 KK4 –
Tab. 6-14

6‐108 Laser cooling circuit with Easy Filter 2019-02-01 B813en

 12.2 Cooling circuit with Easy Filter

(see "Overview", pg. 6‐108)

Reconditioning cooling water

Maintenance interval: Annually

Conditions
■ The filter valves for connecting the Easy Filter are installed in
the process cooler.
■ The system is switched on.
■ The following work from the maintenance instructions "Clean-
ing the cooling circuits" has been carried out:
− If tanks are dirty:
The tanks have been cleaned and filled with fresh cooling
water.
− For operation with glycol:
The cooling water containing glycol has been drained
completely, the cooling circuit has been flushed and the
water has been replaced with fresh cooling water.
− The 2-hour cleaning cycle with cleaning biocide is com-
pleted.

Means, Tools, Materials

■ Conductivity measuring device, mat. no. 0140745

The following table shows the required cooling water quantities

for the maintenance of 1 cooling circuit if Easy Flilter is used.
The water quantity is specified in the percentage of the tank vol-
ume. You can find the tank volume either on the tank or in the
operator's manual for the process cooler.

The cooling circuit is not freeze- Cooling circuit freeze-protected

protected (glycol)
The cooling circuit is freeze-pro-
tected:
■ Removing glycol residues 60 %
–
(flushing)
■ Fill the tank – 100 %
Tank dirty:
■ Additional tank filling 100 % –18
Cleaning cycle with cleaning biocide

18 Any dirty tank is cleaned after the additional flushing operation, and
then filled.

B813en 2019-02-01 Laser cooling circuit with Easy Filter 6‐109

 The cooling circuit is not freeze- Cooling circuit freeze-protected
protected (glycol)
Water reconditioning with Easy Filter
Restoring freeze protection – –19
Total water volume for annual
maintenance:
■ If the tank is clean – 160 %
■ If the tank is dirty 100 % 160 %
Cooling water quantities for annual maintenance with Easy Filter Tab. 6-15

Installing Easy Filter 1. Remove the lower process cooler covers and position the fil-
ter valves with the hoses towards the outside.
Make sure that the two shut-off valves on the hose feed lines
to the Easy Filter are closed (lever at right angles to the
hose).

1 Filter valve 2 Easy Filter

Fig. 88750
2. Connect the respective Easy Filter to the corresponding filter
valve (see "Fig. 88750", pg. 6‐110):
− Position the filter valve on the Easy Filter in such a way
that the marking on the filter head is in alignment with
the marking on the Easy Filter, as illustrated.
− Turn in the filter until the second marking on the filter
head is in alignment with the marking on the Easy Filter,
as illustrated.
3. Position the Easy Filter in such a way that it is always verti-
cal during regeneration.
− Do not install it in passage areas - risk of tripping!
− If necessary, secure the area accordingly.

19 No water is required. However, approx. 30 % of the water must be

drained and topped up with glycol to retain the freeze protection.

6‐110 Laser cooling circuit with Easy Filter 2019-02-01 B813en

 Starting cooling water Note
treatment
Should the system indicate a flow error during water recon-
ditioning, turn the shut-off valve on every Easy Filter to the
45° position to reduce the flow. The reconditioning time is
thus extended.

Fig. 89062
4. Open the shut-off valves on the hose feed lines.
In doing so, check all connections for tightness.
The cooling water is now pumped by the filter cartridges of
the Easy Filter and regenerated.
5. Check the conductivity of the cooling water every 30 – 60
minutes. To do this, lift the cover of the corresponding tank
and immerse the measuring probe of a conductivity measur-
ing device in the cooling water.
Cooling water reconditioning is complete when a conductivity
below 10 µS/cm is reached.

Removing Easy Filter 6. After cooling water reconditioning: close the shut-off valves
and remove the filter valves.
− To do this proceed in the reverse order of assembly.
− Dispose of used Easy Filters correctly.
7. Store filter valves with the hoses in the process cooler and
close the covers.

B813en 2019-02-01 Laser cooling circuit with Easy Filter 6‐111

 13.  Electrics

13.1 Overview

All components in the electrical 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.

13.2 Electrical cabinet

(see "Overview", pg. 6‐112)

Checking and, if necessary, cleaning the

electrical cabinet

Maintenance interval: Annually

Condition
■ The machine's main switch is switched off and secured
against being switched on again.

Electrical voltage!
DANGER
Risk of fatal injury due to electric shock!
Ø Work in the electrical cabinet may only be carried out by
electricians or persons instructed in carrying out electrical
work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is powered down and is no
longer live.

6‐112 Electrics 2019-02-01 B813en

 1. Open the electrical cabinet door and check for contamination.
2. If the electrical cabinet is dirty: carefully vacuum out the dust
from the inside of the electrical cabinet using an industrial
vacuum cleaner.
3. Check the cable entry system and the seal around the door
lock for wear.

Checking the door monitoring

Maintenance interval: Annually

Ø Request Technical Service.

Checking the power supply

Maintenance interval: Annually

Ø Request Technical Service.

Checking the function of the fan on the

electrical cabinet

Maintenance interval: Every 5 years

Conditions
■ The machine's main switch is switched off and secured
against being switched on again.
■ Attach lock to cover.

Electrical voltage!
DANGER
Risk of fatal injury due to electric shock!
Ø Work in the electrical cabinet may only be carried out by
electricians or persons instructed in carrying out electrical
work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is powered down and is no
longer live.

B813en 2019-02-01 Electrics 6‐113

 1. Open the electrical cabinet door.
2. Check the fan slow-down time (left side enclosure).
or
Ø When the fan is idle: press the door lock switch. The fan
should start up after a brief delay.
3. If the fan is defective Request Technical Service.

Cleaning the fan [64]

Maintenance interval: 1000 operating hours

Condition
■ The main switch on the electrical cabinet is switched off and
is secured against being switched on again.

Warning of electrical voltage!

DANGER
Ø Work in the electrical cabinet may only be carried out by
electricians or persons instructed in carrying out electrical
work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is switched off and is no
longer live.

1. At the electrical cabinet: switch off and lock the MAIN

SWITCH, pull out the key.
2. Open the electrical cabinet door.

Cover at the IPC Fig. 66204

6‐114 Electrics 2019-02-01 B813en

 3. Screw off the cover.

Position of the screw at the fan insert Fig. 66205

4. Loosen screw and pull out the complete fan insert.

Fan with pulled off filter mat Fig. 66206

5. Clean the fan and, if need be, the filter mat with compressed
air and clothes.
6. Push the fan insert in again and tighten the screw.
7. Reinstall the cover and tighten the screws.

Replacing the BIOS battery

Maintenance interval: Every 5 years

The buffer battery on the motherboard of the IPC (industrial PC)

must be replaced in the de-energized state after 5 years.

B813en 2019-02-01 Electrics 6‐115

 If replacement takes longer than 5 seconds, the time, date and
basic settings must be reconfigured in the BIOS (Basic Input/
Output System). Technical Service must configure the BIOS.

Condition
■ The machine's main switch is switched off and secured
against being switched on again.

Notes
■ The 5-year interval begins with the production date of the
IPC. The production date can be found on the nameplate on
the side of the IPC. If this maintenance interval is exceeded,
there is a risk of data loss.
■ For machines with a maintenance contract, the BIOS battery
will be replaced during routine maintenance by Technical
Service.

Electrical voltage!
DANGER
Risk of fatal injury due to electric shock!
Ø Work in the electrical cabinet may only be carried out by
electricians or persons instructed in carrying out electrical
work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is powered down and is no
longer live.

1. Check the production date of the IPC.

2. Request Technical Service.

Replacing the NCU fan unit

Maintenance interval: Every 5 years

The complete fan unit is replaced.

Condition
■ The machine's main switch is switched off and secured
against being switched on again.

Notes
■ The battery secures the data in BIOS (Basic Input/Output
System). If the replacement of the fan unit takes longer than

6‐116 Electrics 2019-02-01 B813en

 15 minutes, the data (time and date) saved in the BIOS will
be lost.
■ Three years from the delivery date of the Siemens control.

1 Fan unit 2 Battery

NC-CPU fan unit Fig. 74622

1. Open the electrical cabinet.

2. Pull the fan unit off downwards.
3. Fit a new fan unit.
4. Close the electrical cabinet.

Replacing the NCU fan battery

Maintenance interval: Every 3 years

Electrical voltage!
DANGER
Risk of fatal injury due to electric shock!
Ø Work in the electrical cabinet may only be carried out by
electricians or persons instructed in carrying out electrical
work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is powered down and is no
longer live.

B813en 2019-02-01 Electrics 6‐117

 Risk of injury if the battery contents come in contact with
WARNING skin or eyes.
Ø Do not charge the battery.
Ø Do not use force to open batteries.
Ø Do not throw batteries into fire.
Ø Dispose of the battery properly.

1 Locking mechanism 2 Double fan/battery module

Detail: electrical cabinet, NCU control system Fig. 59814

1. Open electrical cabinet (NC control).

2. Press the locking mechanism (1) of the double fan/battery
module somewhat to the rear and tilt the module a bit down-
wards.
3. Pull out the double fan/battery module from the recess of the
control unit.

6‐118 Electrics 2019-02-01 B813en

 1 Plastic rail 4 Battery
2 Fan 5 Locking mechanism
3 Battery plug
Fan unit Fig. 59815
4. First pull off the plug (3) and then take out the battery (4).
5. Connect the plug at the cable of the new battery with the
mating plug in the double fan/battery module and push in the
battery.
6. Clean the fan (2) with a dry brush.
7. Hold the double fan/battery module tilted at an angle towards
the front with the open side pointed up (battery visible).
8. Push in the plastic rail (1) into the recesses at the underside
of the control unit.
9. Tilt the double fan/battery module upwards until the front
interlock engages.

Note
The double fan/battery module can be replaced during opera-
tion. When doing this, note that the control unit may be oper-
ated for no more than one minute without fan.
If this time is exceeded, the control unit automatically
switches off.
10. Close the electrical cabinet.

Replacing the UPS rechargeable battery

pack

Maintenance interval: Every 5 years

UPS stands for Uninterruptible Power Supply.

B813en 2019-02-01 Electrics 6‐119

 Condition
■ The machine's main switch is switched off and secured
against being switched on again.

Means, Tools, Materials

■ Rechargeable battery pack
■ 1 or at most 2 mm flat screwdriver
■ Allen key 3 mm AF

Electrical voltage!
DANGER
Risk of fatal injury due to electric shock!
Ø Work in the electrical cabinet may only be carried out by
electricians or persons instructed in carrying out electrical
work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is powered down and is no
longer live.

Risk of injury due to the contents of the rechargeable

WARNING battery pack in the event of skin or eye contact!
Ø As described below: load the rechargeable battery pack only
when it is fitted.
Ø Do not use force to open the rechargeable battery pack.
Ø Do not throw rechargeable battery packs into fire.
Ø Dispose of rechargeable battery packs correctly.

6‐120 Electrics 2019-02-01 B813en

 1 Screws 3 Rechargeable battery pack
2 Wires
Electrical cabinet Fig. 74213

1. Switch off the MAIN SWITCH, lock it and pull out the key.
2. Open the electrical cabinet door.
3. Detach 3 wires (2) from the battery's terminal strip.
4. Remove the mounting screws (1).
5. Remove the old rechargeable battery pack (1).
6. Mount the new rechargeable battery pack.
7. Correctly reconnect the wires to the terminal strip.
8. Close the electrical cabinet door.

Note
The new rechargeable battery pack is not charged. Charging
time approx. 5 h at 2.5 Ah.
9. To charge the new rechargeable battery pack: leave the
MAIN SWITCH on for at least 5 hours.

B813en 2019-02-01 Electrics 6‐121

 Replace the buffer battery for the real time
clock

Maintenance interval: Every 3 years

Condition
■ The machine's main switch is switched off and secured
against being switched on again.

Means, Tools, Materials

■ Recommended batteries: Varta CR2025, Panasonic BR2020.

Notes
■ The battery must be replaced with an identical battery or one
recommended by the manufacturer.
■ The service life of a 170 mAh battery (VARTA CR2025) is 5
to 6 years, at an ON time of 8 hours a day and an ambient
temperature of 30 °C. This value depends on the actual
ambient temperature and on the ON duration.
To make sure that the battery is not discharged prematurely,
it is recommended that you replace it after 3 to 5 years!

Electrical voltage!
DANGER
Risk of fatal injury due to electric shock!
Ø Work in the electrical cabinet may only be carried out by
electricians or persons instructed in carrying out electrical
work.
Ø Unless otherwise indicated, maintenance work should only
be carried out once the machine is powered down and is no
longer live.

Risk of injury in the case of contact with skin and eyes!

WARNING
Ø Do not charge the battery.
Ø Do not use force to open batteries.
Ø Do not throw batteries into fire.
Ø Dispose of the battery properly.

Electrostatic charge!
NOTICE
Plug-in cards can get damaged.
Ø A ground strap must be worn for work on the plug-in cards.
The ground strap is in the electrical cabinet.

6‐122 Electrics 2019-02-01 B813en

1 Screws on the plug-in card 2 Buffer battery
Location of the buffer battery Fig. 55500

1. Open the electrical cabinet door.

2. Remove all wires from the plug-in card.
3. Undo 4 screws (1) on the plug-in card.
4. To pull out the plug-in unit:
− Push the white lever down.
− Push the black lever down.
5. Pull out the plug-in card approx. 6 cm.

Note
Do not touch the heat sink. The heat sink can be very hot.
6. Remove the old buffer battery.
7. Insert the new buffer battery:
− The positive pole must point outwards.
− Do not touch the contact surfaces.
8. Insert the plug-in card until it touches the bus at the back.
9. To connect the plug-in card to the bus at the back:
− Lock the lever into place and press it up.
− Insert the screws.
10. Plug in all cables, fit all covers.
11. Close the electrical cabinet.

B813en 2019-02-01 Electrics 6‐123

 Note
Replacing the buffer battery stops the real time clock.
12. At the user interface: reset the time and date.

13.3 Safety light barriers

(see "Overview", pg. 6‐112)

Cleaning the safety light barrier [51]

Maintenance interval: As needed

Means, Tools, Materials

■ Soft rag or cotton pad.
■ Alcohol (30 %).

Ø Clean the mirror surfaces.

6‐124 Electrics 2019-02-01 B813en

 14.  Optics

14.1 Overview

General guidelines

Disassembly of the cutting unit or laser light cable is not

NOTICE permitted!
Damage to the optical components.
Ø Cutting unit may only be disassembled by the Technical
Service.
Ø The laser light cable plug may only be undone by the Tech-
nical Service.

Utmost cleanliness and the greatest care must be ensured when

handling optical components. A clean environment, a clean work
station, and clean additional equipment are absolutely essential.
■ All work involving the removal, installation and cleaning of
optical components, as well as the adjustment of the laser
beam after cleaning, if necessary, may only be carried out by
trained personnel.
■ All work involving the removal, installation, and cleaning of
optical components should be performed in clean rooms and
not in the vicinity of the machine itself.
■ The protective glass must be placed on a soft and lint-free
surface for cleaning. Make sure your hands are clean and/or
wear lint-free gloves.
■ Only use the additional equipment that is listed.

Additional equipment, tools, ■ Optics cleaning set, compl. (mat. no. 1675885).
materials ■ Protective glass support (mat. no. 1652982).
■ LED lamp (mat. no. 1632115).
■ Bellows, rubber (mat. no.: 0779473).
■ Optical adhesive tape (mat. no. 1317829).
■ Methanol, bottle (mat. no. 0764334).
■ Swabs (Mat. no. 1222024).
■ Finger caps (mat. no. 0145843).
■ Hook wrench (mat. no. 1655965).

B813en 2019-02-01 Optics 6‐125

 14.2 Cutting unit

(see "Overview", pg. 6‐125)

Check the nozzle and blowing nozzle, and

clean if necessary [93]

Maintenance interval: 8 operating hours

The nozzle must be regularly cleaned of smoke residue and

slag.

Means, Tools, Materials

■ Clean, lint-free cloth.
■ Soft brush.

Hot nozzle during replacement immediately after machine

CAUTION operation
Risk of burns.
Ø Only touch hot components with protective gloves.

1. Press Technology, "Laser", Setup position.

The axes of the machine move into a position in which the
cutting unit is easily accessible.
2. Screw out the nozzle and blowing nozzle.
3. Check the nozzles for deformations, scratches near the
mouth of the nozzle and for tight fit.
4. Replace damaged nozzles.
5. Carefully clean the nozzle with a brush.
− Remove slag and smoke residue with a cloth.
− Remove slag with a soft brush.

6‐126 Optics 2019-02-01 B813en

 14.3 Cartridge in the cutting unit

(see "Overview", pg. 6‐125)

Cleaning the protective glass [08]

Maintenance interval: Annually

Means, Tools, Materials

■ Optics cleaning set, compl. (mat. no. 1675885).
■ Protective glass support (mat. no. 1652982).
■ LED lamp (mat. no. 1632115).
■ Bellows, rubber (mat. no.: 0779473).
■ Optical adhesive tape (mat. no. 1317829).
■ Methanol, bottle (mat. no. 0764334).
■ Swabs (Mat. no. 1222024).
■ Finger caps (mat. no. 0145843).
■ Hook wrench (mat. no. 1655965).

Notes
■ As far as possible, cleaning of protective glass should be
performed in clean rooms and not in the direct vicinity of the
machine.
■ Only clean protective glass with clean hands and finger cots
on a soft and lint-free surface.
■ The main switch on the electrical cabinet can remain
switched on.

Danger of poisoning due to methanol!

WARNING
Ø Do not breathe in or ingest methanol fumes.
Ø Make sure there is plenty of fresh air.
Ø Wash your hands after the cleaning process.

Fire hazard due to methanol!

NOTICE
Ø Keep methanol away from ignition sources.
Ø Do not smoke.

B813en 2019-02-01 Optics 6‐127

 Disassembly of the cutting unit or laser light cable is not
NOTICE permitted!
Damage to the optical components.
Ø Cutting unit may only be disassembled by the Technical
Service.
Ø The laser light cable plug may only be undone by the Tech-
nical Service.

1 Protective glass
Fig. 79184

Clean the protective glass 1. Undo the knurled nut using the hook wrench and unscrew it
completely.
2. Cover the opening on the cutting unit with optical adhesive
tape so that no dust can enter the cutting unit.

Note
The protective glass lies loosely in the mounting device in
the laser cutting unit.

6‐128 Optics 2019-02-01 B813en

 1 Swab 3 Protective glass
2 LED lamp
Protective glass support Fig. 74190
3. Switch on the LED lamp (2), place on the protective glass
support.
− Only touch the protective glass (3) on the edge and
place it on the protective glass support.

Notes
■ Use the swab only once.
■ Scorched spots or baked-on deposits cannot be removed
with the swabs. In this case, the protective glass must be
replaced.
■ Do not look into the intensive, white light emitted by the
lamp.
4. Moisten swab (1) with methanol and remove dirt on the pro-
tective glass.
− Turn the protective glass over and repeat the cleaning
step with a fresh swab.
5. Clean the sealing surfaces, the inside of the cartridge and
the thread with the swab while it is still wet.
6. Insert the protective glass into the cartridge. Make sure that
the O-ring the protective glass rests on is present and not
damaged.
7. Screw in the union nut and tighten as much as possible
8. Insert the cartridge and tighten the knurled nut with the hook
wrench, until the arrow is exactly below the lock symbol.

B813en 2019-02-01 Optics 6‐129

 1 Lock symbol 2 Arrow
Arrow marking in the cutting unit Fig. 59872

Checking the nozzle and 9. Check the nozzle for deformations, scratches near the mouth
blowing nozzle of the nozzle and that it is fitted firmly.
10. Check the air air nozzle for deformations and blockages.
11. If the nozzle holder and/or the nozzle has been replaced,
then the nozzle must be centered to the beam (see "Center
the beam to the nozzle", pg. 5‐10).

6‐130 Optics 2019-02-01 B813en

 15.  RotoLas

15.1 Support housing, outside

Cleaning the support housing

Maintenance interval: As needed

Danger from dust that is stirred up.

CAUTION
Dust that is stirred up can injury to the respiratory tract
and mucous membranes. The following safety precautions
must be observed on all work for which the operator comes
into contact with the dust: wear
Ø breathing masks of safety class FFP3.
Ø Do not throw cigarette butts or other burning objects into the
work area of the machine.

Ø Check the support housing regularly for contamination. Brush

off large elements of dirt and dust or remove them using an
industrial vacuum cleaner.

15.2 Four-jaw collet chuck

Checking and cleaning the collet chuck

Maintenance interval: As needed

1. Check the jaw chuck for sluggishness.

The clamping jaws and the flat thread must be cleaned if the
jaw chuck is hard to move.
2. Remove the clamping jaws.
3. Clean the clamping jaws and the flat thread with a brush and
kerosene.
4. Do not use compressed air since otherwise metal dust and
chips can be pressed into the guides and the toothing.
5. Lightly oil the parts and reinstall the clamping jaws after
cleaning.

B813en 2019-02-01 RotoLas 6‐131

 15.3 RotoLas spatter guard

Check the buffer and exchange, if

necessary.

Maintenance interval: 2000 operating hours

A movable spatter guard is installed on the Z slide for RotoLas

operation. The buffers on the bottom plate of the spatter guard
must be checked regularly for wear.

1 Buffers (2x) 2 Bellows of the spatter guard

Fig. 69165

1. Release the rear bellows (2) of the spatter guard and pull it
upward.
2. Check the buffer (1) of the spatter guard for wear.
3. In the case of heavy wear, exchange the buffer.

6‐132 RotoLas 2019-02-01 B813en

 16.  CoolLine

16.1 CoolLine water container

Refilling the water container

Maintenance interval: When indicated by the control sys-

tem

1 Water container cover 2 Lever on manually actuated

valve
CoolLine water container Fig. 81029

1. Open the cover (1) of the water container.

2. Move the lever (Fig. 81029, item 2) on the manually actuated
valve from the lower to the middle position.
3. Allow a bleeding time of about 5 s.
4. Move the lever (Fig. 81029, item 2) on the manually actuated
valve from the middle to the upper position.
5. Add demineralized water up to the max. mark on the level
indicator.

B813en 2019-02-01 CoolLine 6‐133

 6. Move the lever (Fig. 81029, item 2) on the manually actuated
valve from the upper to the lower position.
7. Check that the setting pressure is 2.0 ±0.2 bar at the pres-
sure gauge.
8. Close the cover of the water container again.

Check the water filter and replace if

necessary

Maintenance interval: 2000 operating hours

1 CoolLine water filter

Fig. 74212

Ø Check the water filters and replace if visibly contaminated.

6‐134 CoolLine 2019-02-01 B813en

 Chapter 7

Safety light barrier

1 Safety light barrier SICK M 4000 7‐2

2 Installation of safety light barrier 7‐3

2.1 Mounting the posts 7‐3
2.2 Aligning the columns 7‐4

B813en 2019-02-01 Safety light barrier 7‐1

 1. Safety light barrier SICK M 4000

The SICK M 4000 safety light barrier consists of the following

individual parts:

■ Safety light barrier transmitter M40S-025010AR0 with trans-

parent display pane.
■ Safety light barrier receiver M40E-025010RR0 with integrated
laser alignment aid.
■ Mirror posts suitable for M40S-025010AR0 and
M40E-025010RR0.
■ Equipment columns.
■ Alignment template for mirror.
■ Alignment template for transmitter.
■ SICK documentation
The laser alignment aid integrated in the receiver is primarily
used to align the mirror posts and their individual mirrors prop-
erly.

The laser alignment aid corresponds to class 2.

WARNING
Laser radiation can cause permanent damage to the eyes.
Ø Never look directly into the laser beam.

7‐2 Safety light barrier SICK M 4000 2019-02-01 B813en

 2. Installation of safety light barrier

2.1 Mounting the posts

Means, Tools, Materials

■ Screwdriver.
■ Allen key SW 3.
■ Allen key SW 4.
■ Allen key size 6.
■ Open-end wrench, size 17.
■ Drilling machine with 10 mm drill.
■ Hammer.
■ Spirit level.

Note
The number of mirror posts and the appropriate installation site
depend on the respectively applicable installation plan or installa-
tion layout.

1. Mark the working range of the machine (protected field) as

per the installation plan or the installation layout, using a
chalk line.
2. Align the compensation plates for the posts by using the
engraved indents on the cross-hairs of the factory floor.
3. Mark and position the drilling for the locators.
4. Place the transmitter, receiver and mirror posts in the respec-
tive corners of the protected field, align them roughly and
screw them tight.
5. Dismantle cover plates and shutters at the sender and
receiver columns.
6. Set the sender, mirror and receiver perpendicular and at the
same height on the ground with the help of the posts or a
swivel mounting.

B813en 2019-02-01 Installation of safety light barrier 7‐3

 2.2 Aligning the columns

Condition
■ The posts are mounted and roughly aligned with one
another.

Note
The laser alignment aid is automatically activated when the
safety light barrier is switched on if the light beams are not yet
adjusted or the light path is interrupted.
If the laser alignment aid is not automatically activated, please
refer to the SICK documentation.

1. Check using a box level, whether the supports are perpen-

dicularly mounted.
2. Check whether the sender, mirror and receiver are at the
same height.
3. Loosen the clamping screws of the receiver bar at the safety
light barrier.
4. Glue the alignment template for the mirrors to the lower mir-
ror of the first mirror post (starting from receiver bar).

Fig. 42294

5. Activate the laser alignment aid by switching on the power

supply or by using one of the two configuration buttons at
the receiver.
6. Turn the receiver bar until the alignment beam goes exactly
through the center of the hole in the alignment template at
the lower mirror of the first mirror post.
7. Tighten the locking screws of the receiver bar.
8. Use the alignment template to align the mirrors of further mir-
ror posts.
9. Remove the alignment template for mirrors.
10. Splice the alignment jig for senders at the sender bar.

7‐4 Installation of safety light barrier 2019-02-01 B813en

 Fig. 42295

11. Align the mirror of the last mirror post to the transmitter.
The transparent display pane of the transmitter lights up if
the transmitter is aligned properly.
12. Check whether further adjustment is required, using the 7-
segment display of the receiver. For more about this, see the
SICK documentation, chapter 7, commissioning.
13. Precisely align the upper beam path in the same way.
14. Functional test
− Switch on the machine.
Activate safety light barrier.
− Check proper functioning.

B813en 2019-02-01 Installation of safety light barrier 7‐5

7‐6 Installation of safety light barrier 2019-02-01 B813en
 Chapter 8

Test certificate on the noise

level of the
TruLaser 3030 (L49),
TruLaser 3040 (L50)

1 Test certificate 8‐2

2 Measurement result 8‐4

3 Position of the measuring points 8‐5

B813en 2019-02-01 Test certificate on the noise level of the 8‐1

TruLaser 3030 (L49), TruLaser 3040 (L50)
 1. Test certificate

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.

Note
The testing was done on a technically comparable machine that
is representative of the planned manufacturing process (see EC
Machinery Directive 2006/42/EG, appendix I, section 1.7.4.2.).

Noise measurement in accordance with standard EN ISO 11553-3; also applicable: DIN EN ISO 3744
Measurement in accuracy class 2.
Machine
Type Solid-state laser-flatbed machine
Type TruLaser 5030 (L68) with TruDisk 8000
Dimensions of the system Basic machine: L x B x H: 9.2 m x 4.6 m x 2.2 m
Manufacturer TRUMPF Werkzeugmaschinen GmbH + Co. KG
Serial number / year of manufacture A2231E0005; year of manufacture 2014
Cooler / dust extractor Riedel PC501.2L4-D40L.T-6C / Handte MF-L 2500
Measurement conditions
Operating states Loudest operating mode: high-pressure cutting mode
Material machined: 1.4301, thickness 20 mm
Cutting nozzle EAQ95, N2 cutting gas pressure 16 bar.

Typical operating mode: oxygen cutting mode

Material machined: S355, s = 3 mm
Cutting nozzle 1.2 mm, O2 cutting gas pressure 4.0
bar.
Installation Sound emission components according to standard lay-
out (drawing 93739-5-10). In deviation: the laser is at a
different point, the machine process cooler has not
been installed. Both units can be neglected for the
noise measurement.
Installation site VFW-Halle Ditzingen, location 61
Sound sources active during measurement Laser process cooler, dust extractor, resonator, cutting
unit, drives, electrical cabinet. (see "Fig. 75977",
pg. 8‐5)
Acoustic environment
Description of the measuring environment The system is clear on four sides, there is a clearance
to adjacent machines or wall elements all around
>2.0 m.
Acoustic suitability of the measuring environment The ambience correction is 1.7 dB.
(<2 dB à The measurement can be done in accuracy
class 2).

8‐2 Test certificate 2019-02-01 B813en

 Atmospheric pressure Temperature: 20.3 °C, rel. humidity: 36 %, air pres-
sure:
1030 hPa
Measuring device
Sound level meter Brüel & Kjær, type 2250; serial number: 2645064
Date of calibration: 2014-05-20
Microphone Brüel & Kjær, type 4189; serial number: 2631420
Date of calibration: 2014-05-20
Calibrator Brüel & Kjær, type 4231; serial number: 2642622
Date of calibration: 2014-05-20
Acoustic data
Base Rectangle (L x W):
6.90 m x 7.10 m
Measuring distance: d=1 m
Number and position of measuring points at a height of 16 measuring points (see "Fig. 75977", pg. 8‐5)
1.55 m.
Extraneous noise adjustment K LA 0 dB
Ambience correction K 2A 1.7 dB
Sound pressure level L' pi (see "Tab. 8-2", pg. 8‐4), (see "Tab. 8-3", pg. 8‐4)
Maximum sound pressure level from L' pi 77.1 dB(A)
Workplace-related sound pressure level at control 75.5 / 74.0 dB(A)
panel/pallet changer
Extended measuring unit U 3.2 dB
Extension factor k 2
Coverage probability 95 %
Person, location, date Jörg Zaiß, Ditzingen, 2015-01-02
Test certificate Tab. 8-1

B813en 2019-02-01 Test certificate 8‐3

 2. Measurement result

Mild steel, 3 mm O2 Measuring point (MP) L'pi

1 68.2
2 70.2
3 72.1
4 71.8
5 70.6
6 68.6
7 70.1
8 67.8
9 66.8
10 66.2
11 64.3
12 65.2
13 65.7
14 66.9
15 68.2
16 68.3
Sound pressure level L'pi (dB) at the measuring points Tab. 8-2
(MP)

Stainless steel, 20 mm N2 Measuring point (MP) BrightLine fiber L'pi

1 68.2
2 71.8
3 74.9
4 77.1
5 74.3
6 73.5
7 74.8
8 74.7
9 72.6
10 73.2
11 72.2
12 71.6
13 73.7
14 72.8
15 76.7
16 72.0
Sound pressure level L'pi (dB) at the measuring points Tab. 8-3
(MP)

8‐4 Measurement result 2019-02-01 B813en

 3. Position of the measuring points

The range of sound emission components is marked gray. The

machine process cooler is not included in this installation.

Position of the measuring points Fig. 75977

B813en 2019-02-01 Position of the measuring points 8‐5

8‐6 Position of the measuring points 2019-02-01 B813en
 Chapter 9

TRUMPF RotoLas tube

cutting unit
Description RotoLas 9‐3

1 Safety information 9‐4

2 Technical data 9‐5

3 The most important assemblies 9‐6

3.1 Rotary unit 9‐6
3.2 Suction system 9‐6
Increasing the suction power 9‐7
3.3 Support housing, outside 9‐9
3.4 Roller cabinet 9‐10
3.5 Supports 9‐11
3.6 NC stop 9‐13
3.7 Automatic collet chuck (option) 9‐14
3.8 Clamping methods 9‐15
Clamping workpieces 9‐15

B813en 2019-02-01 TRUMPF RotoLas tube cutting unit 9‐1

 Turning and drilling jaws (clamping method 9‐16
no. 30-35, 40, 41)
Basic jaws 9‐17
Bolt clamping set (clamping method no. 36) 9‐18
Prism clamping set (clamping method no. 9‐19
37, 38)
Clamping with a minimized dead area 9‐20
(clamping method no. 39)
Clamping method table 9‐21

4 Notes on achievable accuracy during tube 9‐23

processing
4.1 Unprocessed material: tubes and profiles 9‐23
Cross section error 9‐23
Length error 9‐24
Tube distortion 9‐25

5 Operating the RotoLas tube cutting unit 9‐26

5.1 Support housing, outside Installing and remov- 9‐26
ing
5.2 Preparing the support housing for tube proc- 9‐28
essing
5.3 Preparing the machine for tube processing 9‐31
5.4 Switching the machine to plane machining 9‐32
5.5 Selecting/Deselecting the longitudinal conveyor 9‐32
belt
5.6 Move support 9‐33
5.7 Measuring the tube center at a certain point 9‐33
5.8 Resetting the coordinate displacement 9‐33
5.9 Utility program CP_RLPRG 9‐34
Cutting spacers 9‐34
Spatter guard for tubes 9‐35
Mounting disks for rectangular tubes 9‐36
5.10 Utility program CP_TRIM_OFF 9‐37
5.11 Working with the automatic collet chuck 9‐37
(optional)
Clamping with the automatic collet chuck 9‐37
Relieving with the automatic collet chuck 9‐37
Information on working with the automatic 9‐38
collet chuck
5.12 Changing the dead range of the clamping jaws 9‐39
5.13 Determining the zero point offset 9‐40
5.14 Running test mode 9‐42

9‐2 TRUMPF RotoLas tube cutting unit 2019-02-01 B813en

 Description RotoLas

Fig. 66916

B813en 2019-02-01 TRUMPF RotoLas tube cutting unit 9‐3

 1. Safety information

Sharp edges on the ends of the tubes can lead to severe

DANGER injuries!
Tubes may start to move and crush your hands.
Ø Wear protective gloves and safety shoes.

Risk of crushing due to closing clamping jaws!

WARNING
When the "close" button for clamping the clamping jaws is
pushed while persons are in the danger zone, hands or
fingers can get stuck between the jaw chucks and the
workpiece.
Ø Only press the "close" button when no persons or body
parts are in the danger zone.

Risk of injury due to the tipping of the external support

CAUTION housing!
Ø Only load the support housing after mounting it on the
safety cabin.
Ø Do not use the support housing as a loading aid.
Ø Wear personal safety equipment.

Risk of collision due to the use of incompatible programs!

NOTICE
RotoLas processing programs from TruLaser 3030 (L20) are
not suitable for use on a TruLaser 3030 (L49), TruLaser
3040 (L50) or TruLaser 3060 (L66) with RotoLas. Using
incompatible programs can cause collisions on the
machine.
Ø Only use RotoLas machining programs created for TruLaser
3030 (L49), TruLaser 3040 (L50) or TruLaser 3060 (L66) on
this machine.

9‐4 Safety information 2019-02-01 B813en

 2. Technical data

RotoLas
Effective tube Min. 370 mm
diameter or outside
max. effective aperture 20 mm
diameter
of the chuck
165 mm
Tube weight max. 200 kg
Vertical load of a sup- max. 150 kg
port
Wall thickness max. 10 mm (mild steel)
max. 6 mm (stainless steel)
max. 5 mm (aluminum)
Precision Concentricity in the 0.15 mm
collet chuck
0.03 degrees
Max. positioning accu-
0.01 degrees
racy
Max. backlash
Type of drive Rotary axis Maintenance-free tor-
que motor
Velocity Max. 80 rpm
Support housing, outside
Length 3-meter variant 2550 mm
6-meter variant 5650 mm
Weight 3-meter variant, incl. 1 150 kg
support with step roller
6-meter variant, incl. 2 250 kg
supports with step roll-
ers
Technical data RotoLas Tab. 9-1

B813en 2019-02-01 Technical data 9‐5

 3. The most important assemblies

1 Operating elements of the auto- 4 Support 7 Support housing, outside

matic collet chuck (option) 5 NC stop on the motion unit 8 RotoLas door
2 Rotary axis with collet chuck 6 Roller cabinet
3 Workpiece
RotoLas assemblies Fig. 67717

3.1 Rotary unit

The rotary unit is flanged on the left lateral carrier and is sup-
ported on the front cross-beam.
It mainly consists of:

■ Torque drive
■ Rotary axis with four-jaw collet chuck

3.2 Suction system

Automatic switch-over A suction unit on the rear side of the drive unit is used for the
suction process. The unit is connected to the suction channel in
the basic machine via a flexible metal tube.
The suction unit on the rotational axis is automatically activated
by means of a flap when switching from flat to tube processing,
i.e. manual operations are not required for the switch-over.

9‐6 The most important assemblies 2019-02-01 B813en

 Increasing the suction power

For Rotolas operation with the outside support housing, a higher

suction power might be required in order to ensure a sufficient
suction effect in the support housing.

Stage 1 By taking the following measures, the suction power can be

increased by one stage.

1 End cap 2 Connection socket 3 Cover

Fig. 69168

1. Remove the cover (3) from the RotoLas door.

2. Remove the end cap (1) from the connection socket (2) so
that the outside support housing can be connected to the
connection socket (2).

B813en 2019-02-01 The most important assemblies 9‐7

 Suspended cover in machine exhaust flap 3 Fig. 63208
3. Suspend the cover with tube connecting pieces in the third
machine exhaust flap.

Stage 2 To increase the suction power by another stage, proceed as fol-

lows.

1 End cap
Fig. 69169
4. Mount the end cap (1) on the connecting piece of the sus-
pended plate.

9‐8 The most important assemblies 2019-02-01 B813en

 3.3 Support housing, outside

Fig. 69154

In order to support the tubes or tube profiles outside of the

safety cabin and to guide them into the machining position inside
the safety cabin, a support housing is used for the RotoLas
option.
During installing the system with RotoLas, the installation
position of the support housing is defined and a threaded sleeve
is embedded in the floor to install the support housing. If not
used for a long time period, the support housing can be
removed to save space. The support housing can be reinstalled
at any time.

The support housing is available in the following two lengths:

■ For processing tubes with a length of up to 3000 mm (with 1
support with step roller).
■ For processing tubes with a length of up to 6000 mm (with 2
supports with step rollers).

B813en 2019-02-01 The most important assemblies 9‐9

 Support with step roller

1 Step roller handle 4 Scale

2 Stop plate 5 Index bolt
3 Step roller 6 Friction bearing
Support with step roller Fig. 69153

Depending on its length, a support housing contains 1 or 2 mov-

able supports with step rollers. With the step roller, the tubes
and tube profiles can be supported centrically and guided into
the machining position inside the safety cabin.
The step roller can be adjusted to the diameter of the tube or to
the diameter of the circumscribed circle of the profile step-by-
step using the scale (4).

3.4 Roller cabinet

A roller cabinet for depositing and storing the accessories is

included in the delivery of the RotoLas option.

9‐10 The most important assemblies 2019-02-01 B813en

Roller cabinet for Rotolas accessories with different storage options. Fig. 69164

Roller cabinet for Rotolas accessories with different storage options. Fig. 70382

3.5 Supports

The tube cutting unit can be equipped with one or more supports
for additional workpiece support.
The support consists of two parts – the holder and the
workpiece holder – which can be connected fast and easily
using hand screws.

Holders ■ The holder for the first support remains in the machine and
is merely pushed in the X direction out of the pallet collision
range and into its parking position after tube processing is
finished.

■ All further holders must be taken out of the machine after

tube processing is finished.

B813en 2019-02-01 The most important assemblies 9‐11

 ■ The parking position of the first holder is monitored by a non-
contacting proximity switch so that collision between pallet
and holder is prevented.

■ The holder is latched into the pallet feed chain and can only
be moved using the chain.

Workpiece holder (in two sizes) for round or angular tubes.

■ The workpiece holder that is appropriate for the particular

working range is used.

■ For round tubes, setting to the specific tube diameter is done

using adjustable supports with spacers.

■ For square/rectangular tubes, a two-part disk is placed in the

workpiece holder. The disks can be produced by the cus-
tomer himself using the "CP_RLPRG.lst" program.

■ Spacers for round tubes and disks for rectangular tubes can
be cut using the "CP_RLPRG.lst" program.

1 Round tube 4 Adjustable support

2 Support holder 5 NC stop
3 Workpiece holder
Fig. 63211

Support displacement The supports can be displaced using the pallet feed chain. To do
this the supports are connected to the chain using a latch (max.
vertical load of a support approx. 60 kg for round tubes and 30
kg for rectangular tubes). This allows the dead areas that are

9‐12 The most important assemblies 2019-02-01 B813en

 caused by the position of the workpiece holder to be machined
as well.

3.6 NC stop

The NC stop is attached to the cross member of the basic

machine (see Fig. 63211, pos. 6). It can be swung down into
work position by means of a pneumatic cylinder.

Function Tubes pushed through the collet chuck in X direction can be

stopped at a defined position by the NC stop. Achievable inser-
tion accuracy with the NC stop of ±2 mm.

Note
In case a greater insertion accuracy is needed, a trimming cut
has to be made in X+ direction to create a straight reference
edge.

1 Round tube 4 Adjustable support

2 Support holder 5 NC stop
3 Workpiece holder
Fig. 63211

B813en 2019-02-01 The most important assemblies 9‐13

 3.7 Automatic collet chuck (option)

The RotoLas pipe and tube cutting facility can be optionally

equipped with an automatic collet chuck.

Function The automatic collet chuck can be opened or closed in the

machine at the press of a button by means of a hydraulically
driven cam.
Outside the machine, it is operated via the user interface of the
machine or via a foot switch (option).
The clamping pressure can be adapted to the rigidity of the
workpiece. It is set by a setting knob.

1 Clamping pressure gauge 4 "Move clamping jaws inwards"

2 Setting knob for setting the button
clamping pressure 5 "Move clamping jaws outwards"
3 "Set clamping pressure" button button

Operating elements on the automatic collet chuck Fig. 58012

9‐14 The most important assemblies 2019-02-01 B813en

 1 Move clamping jaws inwards 2 Move clamping jaws outwards
Foot switch for operating the collet chuck Fig. 58031

3.8 Clamping methods

Clamping workpieces

The workpieces for tube processing vary to a great extent in

terms of their shape, dimensions and weight. That is why a con-
cept has been developed for the TRUMPF RotoLas pipe and
tube cutting facility, which covers the wide range of clamping
options for standard profiles and special shapes to a great
extent.
A few terms are explained in the following which are of signifi-
cance in connection with clamping workpieces:

Blank machining During blank processing the tube is stopped by the jaw chuck, a
stepped jaw or a stop on the jaw.

Continuous machining During continuous machining the tube is pushed through the jaw
chuck. The maximum tube diameter is limited to 165 mm by the
free aperture.

B813en 2019-02-01 The most important assemblies 9‐15

 "Not supported clamping" With "not supported clamping" the tube is only clamped with the
jaw chuck (without additional workpiece support).

Long clamping The tube is clamped by "long" jaws; is usually used for "not sup-
ported clamping" to achieve a stable support with high extension
rigidity and a good axial alignment of the tube.

Short clamping The tube is clamped "flexibly" by "short" jaws; an additional

workpiece support is required for this clamping method (e.g. a
support). The tube is guided in the clamping jaws only for a
short distance, thus limiting the clamping force.

Inner clamping The tube is clamped form the inside by the clamping jaws, which
means the clamping jaws are applied to the tube walls from the
inside. Continuous machining is not possible with this clamping
method.

Outer clamping The tube is clamped form the outside by the clamping jaws,
which means the clamping jaws are applied to the tube walls
from the outside. Both blank processing and continuous machin-
ing can be performed with this clamping method.

Clamping with minimized With this clamping method the tube is clamped with special
dead area clamping jaws to allow machining with almost no dead area. As
a result the tube can be machined over its entire length without
producing any waste. The prerequisite for this is that the stand-
ard active dead area for this clamping method is adapted man-
ually to the respective machining task.

Turning and drilling jaws (clamping method

no. 30-35, 40, 41)

Standard configuration: ■ A total of eight hardened stepped jaws belong to the stand-
turning and drilling jaws ard equipment of the tube cutting facility:
− 4 turning jaws
− 4 drilling jaws

■ The tubes are clamped using 4 stepped jaws (see Fig.

22040).

■ Round and square tubes can be clamped with the turning

and drilling jaws.

■ The clamping length for short clamping is about 22 mm.

9‐16 The most important assemblies 2019-02-01 B813en

 1 Turning jaws 2 Drilling jaws
Fig. 22040

Basic jaws

The prerequisite for using any types of jaws, apart from the drill-
ing and turning jaws, is that the collet chuck is equipped with
basic jaws (mat. no. 254985) (see Fig.22041).

1 Basic jaws 2 Protective cover

Fig. 22041

Add-on jaws Different add-on jaws (option) are screwed onto the basic jaws,
depending on the application.
The individual jaw types and clamping methods are described in
detail in the following.

B813en 2019-02-01 The most important assemblies 9‐17

 Bolt clamping set (clamping method no. 36)

■ The tubes are clamped with 2 add-on jaws with applied bolts
(see Fig. 22039).
■ With rectangular tubes, the bolts extend into the opposite
corners of the inside of the tube.
■ The bolts are available in three sizes. The radius of the bolt
should always be larger than the corner radius of the work-
piece.
■ The workpiece must be pushed fully over the bolts during the
clamping procedure.
■ The large bolts are screwed directly onto the basic jaws.
■ Three locking bore holes have been applied to the add-on
jaws, allowing the bolts to be quickly adapted to the required
clamping range.
− Working range 1: 50 - 210 mm (inner diagonal)
− Working range 2: 175 – 340 mm
− Working range 3: 300 - max. permissible outside diame-
ter

Fig. 22039

9‐18 The most important assemblies 2019-02-01 B813en

 Prism clamping set (clamping method no.
37, 38)

■ Square and rectangular tubes are clamped diagonally from

the outside by means of 2 add-on jaws with prism inserts
(see Fig. 13331).
■ The prism clamping set is used for rectangular tubes with a
side ratio smaller than 2 : 1.
■ The prism inserts are available in two sizes:
■ Size 1: tubes with corner radius ≤R12.
■ Size 2: tubes with corner radius ≤R25.
■ The tubes must be clamped over the entire length of the
prisms (100 mm) since the tube will otherwise wobble in the
tool holder.
■ Prism clamping set, continuous (37): For blank processing, a
stop is only applied to one jaw so that only one change has
to made during the conversion.
■ Prism clamping set, blank (38): With tubes with an outside
diameter larger than 160 mm, there is an increased risk of
the flat thread of the jaw chuck becoming dirty. With smaller
outside diameters, the flat thread is covered by the add-on
jaws.

Note
When using the prism clamping set, positions X < 54 must not
be approached in X direction! Otherwise there is a risk of
collision with the motion unit.

B813en 2019-02-01 The most important assemblies 9‐19

 1 Add-on jaws 3 Prism insert size 1
2 Prism insert size 2
Prism clamping set, size 1 and 2 Fig. 22038

Clamping with a minimized dead area

(clamping method no. 39)

■ Square and rectangular tubes are clamped from the inside

by means of two add-on jaws (with extension piece) with
screwed-in bolts (see Fig. 22037).
■ This clamping method enables machining with a minimized
dead area.
■ The bolts are available in three sizes and are used according
to the respective inner diagonals of the workpiece:
− small bolts: 50 - 210 mm (inner diagonals)
− medium-sized bolts: 175 - 340 mm (inner diagonals)
− large bolts: 300 - max. permissible outer diameter
■ Four add-on jaws can be used for round tubes, if necessary.
■ The minimum inside diameter or inner diagonal is 40 mm.
■ The add-on jaws can be turned 180° to clamp workpieces of
large diameters.

9‐20 The most important assemblies 2019-02-01 B813en

 1 Add-on jaws 4 Large bolt
2 Small bolt 5 Stop in X direction
3 Medium-sized bolt
Fig. 22037

Clamping method table

Turning/drilling jaws Bolt clamping set Prism clamping set Clamping jaws with
min. dead area
Clamping Not supported or With support Not supported or With support
with support with support
Blank processing x x x x
Continuous machin- x x
ing
Round tube Square x x
tube
Rectangular tube x x x
Square tube
Suitable for rectan- x x x
gular tube with side
ratio < 2:1
Clamping method See table below 36 37, 38 39
number
Tab. 9-2

B813en 2019-02-01 The most important assemblies 9‐21

 The following table provides an overview of the various clamping
jaws which can be used with RotoLas. The table is supple-
mented by an overview of the clamping methods which are pos-
sible with the turning and drilling jaws. The number of the
respective clamping method is entered in the corresponding field
in the "Tube loading table".
Clamping methods with turning and drilling jaws

Turning jaws Turning jaws Turning jaws Drilling jaws Drilling jaws Drilling jaws
Clamping Step A inside Step B inside Step C out- Step A out- Step B out- Step C out-
method side side side side
Clamping 30 31 32 33 34 35
method num-
ber
Tab. 9-3

Clamping methods with turning and drilling jaws Fig. 58050

9‐22 The most important assemblies 2019-02-01 B813en

 4. Notes on achievable accuracy during
tube processing

The achievable accuracy and quality when processing tubes

depends on a number of factors.
The most important factors and ways of reacting to any inaccur-
acies or minimizing them as far as possible are described in the
following.

4.1 Unprocessed material: tubes and

profiles

Raw material – finished part: It is impossible for the finished part to be more accurate than the
Quality counts! raw material. This simple fact must be the basis for all consider-
ations. The achievable accuracy and quality of the finished part
depend to a high degree on the quality or accuracy of the raw
material, meaning both the tubes and profiles.

Tip
TRUMPF recommends using cold drawn precision tubes with
specified even corner radiuses in particular for the corresponding
requirements on the finished parts.
The most frequent errors or inaccuracies which can occur with
the raw material as a result of manufacturing are listed in the fol-
lowing:

Cross section error

Fig. 44001

B813en 2019-02-01 Notes on achievable accuracy during tube 9‐23

processing
 Fig. 44002

Fig. 44003

Fig. 44004

Length error

Fig. 44054

9‐24 Notes on achievable accuracy during tube 2019-02-01 B813en

processing
 Fig. 44005

Tube distortion

The tubes are under inner tension as a result of the procedures

for the production of tubes (rolling, bending, seam welding).
This fact must be taken into account when designing and execut-
ing programs:

■ The parts further away from the collet chuck are cut first dur-
ing machining.
■ Reduced cutting parameters may have to be used.
■ Insert a spatter guard in the tube if possible.
■ Execute long contours section by section.
■ The tube sticking out of the collet chuck should be as short
as possible.
■ Tubes with a welding seam must always be inserted in the
same direction, which means always with the welding seam
facing downwards.
Further information on machining can be found in the
TruTops Tube manual, in the programming manual for the
machine and in the chapter on operation in this operator's man-
ual.

B813en 2019-02-01 Notes on achievable accuracy during tube 9‐25

processing
 5. Operating the RotoLas tube cutting
unit

5.1 Support housing, outside Installing

and removing

Condition
■ EMERGENCY STOP is active.

Means, Tools, Materials

■ Star handle, M16, with threaded rod.
■ Set screw.

Risk of injury due to the tipping of the external support

CAUTION housing!
Ø Only load the support housing after mounting it on the
safety cabin.
Ø Do not use the support housing as a loading aid.
Ø Wear personal safety equipment.

Installing the support

housing

1 Additional storage drawer 2 Cover

Fig. 69150

1. Remove cover (2) from the machine and store it securely in

the additional storage drawer of the support housing (1).

Note
The star handle with threaded rod necessary for mounting is
fixed in the recess at the front foot of the support housing.
The set screw, which is used to protect the threaded sleeve,
can also be deposited in this recess.

9‐26 Operating the RotoLas tube cutting unit 2019-02-01 B813en

 1 Star handle with threaded rod 2 Threaded sleeve in the floor
Fig. 69151
2. Remove the set screw from the threaded sleeve and screw
the star handle (1) into the threaded sleeve (2) in the ground
with about three turns.

1 Support housing 3 Star handle with threaded rod 5 Drill bushes (2x)
2 Mounting plate opening 4 Bolts (2x)
Fig. 69152

B813en 2019-02-01 Operating the RotoLas tube cutting unit 9‐27

 3. Move the support housing (1) toward the machine. While
doing so, make sure that both pins (4) move into the drill
bushes (5) on the machine and the threaded rod of the star
handle (3) moves into the opening (2) of the mounting plate
on the support housing.

1 Ball rollers (2x) 2 Star handle

Fig. 69155
4. Screw the star handle (2) further into the threaded sleeve to
fix the support housing to the floor. The ball rollers (1) are
spring-loaded and can retract. Make sure that the mounting
sleeves for the ball rollers rest on the floor.

Dismounting the support 5. Dismount the support housing in the opposite order.
housing 6. After dismounting, seal the threaded sleeve in the floor with
the enclosed set screw to avoid contamination.
7. Move the support housing to a suitable position and store
there until it is to be used again.

5.2 Preparing the support housing for

tube processing

Condition
■ EMERGENCY STOP is active.

Note
With the support housing, tubes or profiles with a length of up to
3000 mm or 6000 mm and a diameter/diameter of the circum-
scribed circle up to 165 mm can be processed.

9‐28 Operating the RotoLas tube cutting unit 2019-02-01 B813en

1 Index bolt 3 Stop plate 2 Support with step roller
2 Step roller scale
Fig. 69157

1. Open the cover of the support housing and move the support
with step roller (4) to the foremost position.
2. Remove the stop plate (Fig 69157, item 3) and adjust the
step roller to the diameter of the tube or the diameter of the
circumscribed circle of the tube profile using the scale (Fig
69157, item 2).
If the exact diameter is not available, select the next larger
diameter.

Risk of injury due to heavy and sharp-edged tubes!

DANGER
Ø When loading and unloading the tubes and tube profiles,
wear protective gloves and safety shoes.

B813en 2019-02-01 Operating the RotoLas tube cutting unit 9‐29

 1 Plastic slats 3 Tube
2 Support with step roller
Fig. 69158
3. Place the tube (3) in the support housing. In the front area,
the tube should rest on the step roller (2), in the rear area
on the plastic slats (1).

1 Stop plate 2 Tube

Fig. 69159
4. Push the tube (2) by hand through the collet chuck (3) until
the stop plate of the support with step roller can be used
again.
5. Close the cover of the support housing.
The tube or profile can now be pushed forward into the
desired position (NC stop) using the handle of the support
with step roller.

9‐30 Operating the RotoLas tube cutting unit 2019-02-01 B813en

 5.3 Preparing the machine for tube
processing

After selecting a tube processing program, a tooling dialog is

started. This offers support while carrying out the following work
steps which are necessary to switch the machine from plane to
tube processing:

1 Drive unit of the automatic col- 3 Support holder

let chuck (optional) 4 Cover of the support guide rail
2 Protective cover
TRUMPF RotoLas tube cutting unit Fig. 58863

Suspended cover in machine exhaust flap 3 Fig. 63208

1. Move both pallets into the pallet changer.

B813en 2019-02-01 Operating the RotoLas tube cutting unit 9‐31

 2. Remove baffle plate according to length and diameter of
workpiece to be machined.
3. For TruLaser 3030 (L49): suspend the cover with tube con-
necting pieces in the third machine exhaust flap.
To increase the suction power by another stage, mount the
end cap to the connecting piece of the suspended plate.
or
Ø For TruLaser 3040 (L50) and TruLaser 3060 (L66): Using
the operation "SETUP – Manual functions – Machine
exhaust flap, left, active", restrict the exhaust system on
the left side, thereby ensuring optimal suction power for
tube processing.
4. If supports are used, the covers of the support guide rail (4)
must be removed.
5. Remove the protective cover (2) from the jaw chuck. The
drive is automatically activated and the suction unit switched
to tube processing by removing the plates. The protective
cover can be attached to a hook on the safety cabin during
tube processing.
6. One or more supports can be used as required.

5.4 Switching the machine to plane

machining

After selecting a plane machining program, a tooling dialog is

started. This offers support while carrying out the following work
steps which are necessary to switch the machine from tube to
plane machining:

1. Remove the workpiece holder of the first support and push

the support holder in –X direction up to the back stop.
2. Remove the additional supports from the machine.
3. Reinstall the covers of the support guide rail (4).
4. Place the protective cover (2) on the jaw chuck.
5. Remove any waste parts which could get caught in the con-
veyor belt (> 60 x 300 mm) from the machine.
6. Insert baffle plates.

5.5 Selecting/Deselecting the longitudinal

conveyor belt

The longitudinal conveyor belt of the basic machine is usually

switched off during tube processing. This prevents large tube
pieces from getting caught in the conveyor belt. For this reason,

9‐32 Operating the RotoLas tube cutting unit 2019-02-01 B813en

 TruToPs Tube outputs the M68 function by default in order to
deselect the longitudinal conveyor belt.

Selecting the longitudinal For programs where it is no problem if tube sections get caught,
conveyor belt in the NC you can select the conveyor belt in the NC program by deleting
program the M68 function.

5.6 Move support

The supports can be moved from X400 to the end of the

working range using the pallet feed chain. To do this the sup-
ports are connected to the chain using a latch (max. vertical load
of a support approx. 60 kg for round tubes and 30 kg for rectan-
gular tubes). If several supports are attached, they are moved in
parallel.
This allows the dead areas that are caused by the position of
the workpiece holder to be machined as well.

5.7 Measuring the tube center at a

certain point

The tube center measurement can be specifically used when

one wishes to apply precise contours to long tubes.

■ The center of the tube in Y direction is measured using the

distance regulation at one position in X direction.
■ The tube center measurement displaces the coordinates in
the Y direction.
■ Used to machine individual contours with increased precision.
■ The measurement can be selected interactively in the pro-
gramming software before any contour.
■ The tube center can only be measured with non-supported,
clamped tubes.

5.8 Resetting the coordinate

displacement

The coordinate displacement resulting from a tube center meas-

urement at a certain point only applies to the level where the
measurement was taken. For this reason, a coordinate rotation
reset has to be programmed whenever:

B813en 2019-02-01 Operating the RotoLas tube cutting unit 9‐33

 ■ With round tubes, the rotation is performed significantly out
of the position in which the measurement was taken.
■ With rectangular tubes, the level to be machined is changed.
If you do not program a reset, an additional error will be added
to the tube angle error due to the coordinate rotation.
The reset can be selected interactively in the TruTops Tube pro-
gramming system before any contour.

Effect The Y displacement is reset to the rotary shaft center measured

last.

5.9 Utility program CP_RLPRG

To make work with the tube cutting unit easier and as support
for the tube processing technology, a dialog-driven utility program
CP_RLPROG is supplied with the tube cutting unit. Three differ-
ent functions can be performed alternatively with this program:

■ Producing spacers to be used for setting the rollers on the

support for round tubes.
■ Cutting a spatter guard for round and rectangular tubes.
■ Producing a mounting disk (basic disk and insert) for square
tubes.
These functions are displayed on the screen in a dialog after
selecting the program and can be called up as required.

Cutting spacers

When machining round tubes with a support, the rollers on the

support must be adapted to the respective tube diameters. This
can be done either by means of the clamping on the roller rods
or by means of spacers. With this function, the operator can pro-
duce their own spacers.

Note
We recommend always using spacers for large workpiece
weights.

If no spacer is to be cut, the operator can display the value by

which the rollers on the support have to be adjusted with the
slide calipers via the dialog. To do so, proceed as follows:

9‐34 Operating the RotoLas tube cutting unit 2019-02-01 B813en

 ■ Enter the technology table, work position, etc.
■ Press the Display length softkey.

Spatter guard for tubes

Note
For long, thin tubes, we recommend assembling the splatter
guard from several parts instead of a single piece.

1 Spatter guard 2 Round tube

Round tube with spatter guard Fig. 11341

Tube processing can have the following effects:

■ Increased spattering of inner tube walls.

■ Cutting through the tube on the side of the tube facing the
machining point.
■ Extreme overheating of the material.
The reasons for this are mainly:

■ Small tube diameter or outer circle.

■ High laser powers.
■ Thin walls.
To prevent this, a spatter guard can be cut using the function
"Spatter guard for round tube" or "Spatter guard for rectangular
tube", which is inserted in the tube before processing (see "Fig.
11341", pg. 9‐35).

Cutting a spatter guard for tubes

1. Start the CP_RLPRG program.

B813en 2019-02-01 Operating the RotoLas tube cutting unit 9‐35

 2. In the selection list, select the function Spatter guard for
round tube.
or
Ø In the selection list, select the function Spatter guard for
rectangular tube.
The further procedure is supported by means of a dialog.

Mounting disks for rectangular tubes

Note
The desired oversize can be entered in the "Oversize tube cor-
rection" field in order to prevent the tube from jamming in the
mounting disks when moving the support.
The tube is always inserted diagonally in the mounting disk.
Large tubes may have to be inserted horizontally since the free
passage of the mounting disks is limited by the attachment
plates.

A mounting disks consist of the following components:

■ Upper and lower basic disk (dependent on each end of the

tube).
■ Fastening plates.
■ Small parts (screws, washers, nuts, bolts etc.).
The basic disks can be produced by the customer using the
CP_RLPRG.lst utility program.

Making mounting disks

1. Start the CP_RLPRG program.

2. In the selection list, select the function Basic disc for insert-
ing rectangular tubes in the support.
The further procedure is supported by means of a dialog.

9‐36 Operating the RotoLas tube cutting unit 2019-02-01 B813en

 5.10 Utility program CP_TRIM_OFF

The dialog-driven CP_TRIM_OFF utility program can be used to

carry out the following functions:
■ Separate of the tube.
■ Cutting off tube sections.

5.11 Working with the automatic collet

chuck (optional)

Clamping with the automatic collet chuck

Clamping from inside When clamping, the button should not be actuated longer than
required to reach the clamping pressure. Otherwise, the
hydraulic system oil could overheat and trigger the temperature
fuse protection of the hydraulic unit. The clamping pressure is
monitored by means of a pressure switch.
The lamp in the illuminated button lights up 1.5 seconds after
the minimum clamping pressure of 30 bar is reached, indicating
that the minimum clamping pressure has been attained.
You must constantly make sure that the jaw chuck is not dirty
and is sufficiently lubricated. Otherwise, the required torque will
be increased and the clamping force reduced. The jaw chuck
must be disassembled, cleaned and lubricated if an idling torque
of 25 Nm is exceeded.

1. Set clamping pressure

2. Start the part program.
3. Clamp the workpiece by actuating the respective button or
foot-operated switch (option) or via "Manual function". The
clamping pressure can be read off the pressure gauge.

Relieving with the automatic collet chuck

The clamping direction is defined in the clamping method table.

Relieve the workpiece by actuating the respective button or foot-
operated switch (optional) or via "Manual function".
The workpiece is relieved in two stages:

B813en 2019-02-01 Operating the RotoLas tube cutting unit 9‐37

 First stage ■ The cam is retracted and the clamping jaws are opened
slightly.
■ The lamp in the illuminated button goes on.
■ In this position, the operator can push the tube further during
continuous machining.

Second stage ■ If the key is pushed after a waiting time of 1.5 s, the jaw
chuck will open wider.
■ The lamp in the illuminated button flashes.
■ There is no end stop for the clamping jaws. The clamping
jaws can be moved completely out of the jaw chuck when
opened outwards.

Information on working with the automatic

collet chuck

Clamping rectangular tubes The following clamping operation is not possible using the auto-
matic collet chuck.

■ Clamping with support when inserting the workpiece into the

mounting disk in a horizontal position.

Manual movement

Risk of crushing through the movement of the clamping

WARNING jaw!
When the close button for clamping the clamping jaws is
pressed while a socket wrench is in the jaw chuck, hands
or fingers can get stuck between the jaw chucks and the
socket wrench.
Ø Only press the close button when no persons or body parts
are in the danger zone.

If the round axis cannot be moved any further, e.g. because a

workpiece is stuck, it may under circumstances not be possible
to relieve the workpiece.
In this case, the jaw chuck must be opened manually with a
socket wrench.

9‐38 Operating the RotoLas tube cutting unit 2019-02-01 B813en

 5.12 Changing the dead range of the
clamping jaws

Note
With the corrected dead area, collisions can occur between the
clamping jaw and the collision contour of the cutting head under
certain circumstances, for example, if the collet chuck is wide
open. The operator must therefore be particularly careful when
operating in jog mode and should make absolutely sure that the
collet chuck is closed to the extent that no collisions are possible
whenever a program is to be started.
The risk of collisions is increased by changing the default value
initially entered for the dead area. The operator must therefore
close the collet chuck so that no collisions are possible each
time a program is to be started.

The dead area of the clamping jaws should be reduced for cer-
tain machining tasks, in order to be able to machine all program-
med contours for example.

1. Select the "SETUP – Manual functions" activity field.

2. Select "RotoLas" manual functions.
3. Press "Dead areas" manual function.
4. Dead areas are inactive.
5. Select the "SETUP – Traverse axes" activity field.
The "Jog mode" operating mode and "Continuous" travel
characteristic have been selected.
6. Turn the feed rate potentiometer to about 10%.
7. Select Y axis.
The axis selected is displayed on a yellow background.
8. Move the cutting head in Y direction to about the nozzle
center.
9. Select X axis.
The axis selected is displayed on a yellow background.
10. Move the cutting head carefully in the direction of the clamp-
ing jaws to determine the minimum X position, while repeat-
edly testing whether the A axis can be turned by 360°. The
minimum distance between the "Cutting head collision con-
tour" and "Clamping jaws collision contour" is 5 mm.
11. Read and note the value for the X position on the user inter-
face.
12. Move the X-axis to position X >300.
13. Select the "SETUP - Manual functions" activity field.

B813en 2019-02-01 Operating the RotoLas tube cutting unit 9‐39

 14. Select "RotoLas" manual functions.
15. Press "Dead areas" manual function.
16. Select the "TECHNOLOGY – Tube technology – Clamping
method" activity field.
17. Select the clamping method used.
18. Press the Copy softkey.
19. Enter a new number (between 1000 – 9999).
20. Enter the table name.
21. Press the Copy softkey.
A copy of the table is made.
22. Select "Dead area X closed" parameter.
23. Enter the noted value on the keyboard.
The corrected value for the dead area is adopted.

5.13 Determining the zero point offset

Note
For every clamping device, the front edge for the measurement
is the stop for the tube in X direction.

A special clamping device should be used for blank processing.

The zero point offset for this clamping method must be deter-
mined first however.

1. Measure the reference value R on the turning jaw step B

(see Fig. 22080).

9‐40 Operating the RotoLas tube cutting unit 2019-02-01 B813en

 Fig. 22080
2. Note down the measured value.

Fig. 22081
3. Measure the X dimension on the special clamping method
(see Fig. 22081). Note down the measured value. In this
example, a clamping jaw was used for clamping with a mini-
mized dead area.
4. Select "TECHNOLOGY – Clamping method".
5. Select the clamping device no. 31 (turning jaw step B inside).
6. Read and note the value for the zero point offset.
7. [Zero Point Offset clamping method No. 31] + [X-R] = zero
point offset special clamping method

B813en 2019-02-01 Operating the RotoLas tube cutting unit 9‐41

 8. Press the Copy softkey – save clamping method number
(1000 – 9999)
9. Enter the calculated zero point offset in the relevant field.
10. Determine the dead area of the special clamping method.
(See the "Changing the clamping method dead area" operat-
ing procedure) and also enter in the table.

5.14 Running test mode

Function To test a program for tube processing, it is possible to first do a

run-through in test mode. In this way it is possible to check, for
example, whether all contours have been programmed correctly.
The laser is operated in "marking mode" and the piercing points
in the program are punch marked to allow the traversed contours
to be followed easily without destroying the workpiece.

1. Select program
2. Check the technology tables; the parameters for marking and
dot marking must be correct.
3. Select the "SETUP - Manual functions" activity field.
4. Press the Selection softkey.
5. Select "Laser machining" manual functions.
6. Select "Test marking" manual function.
7. Select PRODUCTION activity.
8. Press the START PROGRAM button.
The NC program is processed in test mode.
To run the program normally, test mode must be deselected by
pressing the Test marking softkey again.

9‐42 Operating the RotoLas tube cutting unit 2019-02-01 B813en

Index
Check activated carbon filter 2, replace if
necessary ................................... 6‐11, 6‐72
Filter element, replacing ..6‐11, 6‐12, 6‐70,
A 6‐71
Compressed air
Accessories ............................................. 1‐35 Properties ............................................ 2‐25
Active store movements ..........................4‐48 Supply lines .........................................2‐25
Alarm message Compressed air supply ........................... 2‐25
Display ............................................... 4‐147 Connection and consumption values . 2‐25
Ambient conditions .................................. 2‐10 Condition Guide
Axes Operation ........................................... 4‐148
Moving manually ................................. 4‐98 Conversion software ..............................4‐153
Cooling circuit TruDisk .......................... 6‐105
Cooling water
Storage ................................................ 2‐38
B Cooling water additives ..... 6‐78, 6‐86, 6‐105
Beam-block key switch ........................... 1‐26 Easy Kit ..........................6‐78, 6‐86, 6‐105
Brakes for the Z axis drive, releasing ....4‐99 Cooling water requirement .......... 6‐86, 6‐105
Buffer battery Cooling circuit, external laser device . 6‐86
Fan unit, NCU ..........................6‐13, 6‐116 Cooling circuit, internal laser device 6‐105
Button ...................................................... 4‐12 CoolLine
Acknowledging feed stop (feed start) .4‐14 Operate ..............................................4‐130
Change of application ......................... 4‐12 Cover sheets
Feed hold (Pause) .............................. 4‐14 Cover sheets, cleaning ..............6‐10, 6‐51
Laser On/Off ........................................4‐13 Creating programs
Laser test ............................................ 4‐13 Parts, managing ................................ 4‐116
Machine On/Off ................................... 4‐12 Cutting flaw detection
Magnifying glass ................................. 4‐12 PlasmaLine .......................................... 3‐25
Navigation keys ...................................4‐13 Cutting gas filter
Reset (Stop) ........................................ 4‐13 Replacing filter elements ...........6‐12, 6‐65
Start (Program start) ........................... 4‐14 Cutting gas supply
Tab ....................................................... 4‐13 Supply lines .........................................2‐19
Touchscreen ........................................ 4‐12 Cutting gases .......................................... 2‐17
Purity ....................................................2‐17
Requirements on the connection point ....
2‐22
C
Cable rack ............................................... 2‐12
Calibrate .................................................. 4‐32 D
CE marking ................................................1‐4
Cleaning brush ...................................... 4‐100 Danger zone
Collision detection ....................... 3‐27, 4‐152 Safeguarding device ........................... 1‐23
Compact dust extractor Date ......................................................... 4‐33
Cleaning dust chamber ............. 6‐10, 6‐36 Dew point .................................................2‐11
Exhaust air system ............................. 2‐12 Dew point diagram .................................. 2‐11
Compact dust extractor: extinguisher system Dusts ........................................................1‐21
(option) .....................................................6‐13
Compressed-air cutting (option)
Check activated carbon filter 1, replace if
necessary ................................... 6‐11, 6‐71

B813en 2019-02-01 Index 10‐1

 Isolating transformer ................................2‐31
IT system .................................................2‐32

E
Edit NC program
Create NC sub program ................... 4‐106
J
Editing NC programs .............................4‐105 Job status ................................................ 4‐50
Modifying technology tables ............. 4‐108
Modifying texts .................................. 4‐108
Opening NC programs in the editor .4‐106
Renumbering program blocks ........... 4‐110 K
Searching and replacing ................... 4‐109
Electrics ................................................... 2‐27 Key switch
EMERGENCY STOP push-button .......... 1‐25 Operating mode .................................. 4‐14
Unlock ..................................................4‐25 Key switch, OPERATION LOCK
EU Declaration of Conformity ...................1‐4 TruDisk ................................................ 1‐26
Exhaust air .............................................. 1‐21
Expansion joints ........................................ 2‐8
External support
support housing ...................................3‐37
L
Language .................................................4‐33
Laser light cable
Description ...........................................3‐10
F Laser network ............................................1‐8
FEED HOLD ............................................1‐25 Laser warning lamp
Feedrate potentiometer ........................... 4‐13 Laser device ........................................1‐27
Flexible entry ........................................... 4‐71 Liability disclaimer ................................... 1‐36
Floor quality ...............................................2‐8 Longitudinal conveyor belt (hinge conveyor)
Floor requirements .................................... 2‐6 Hinge conveyor (longitudinal conveyor
belt) ......................................................3‐13

G M
Gas supply .............................................. 2‐16
Machine
Switch off .............................................4‐25
Switch off the if malfunctions occur . 4‐149
H Switch on .............................................4‐25
Machine cooler .............................. 6‐12, 6‐14
Hazardous materials ............................... 1‐40 Main switch ..............................................1‐25
High-pressure cutting .............................. 2‐18 Maintenance numbers
High speed .............................................. 3‐20 Symbol ...................................................6‐9
Highspeed Eco ........................................ 3‐33 Manual functions ..................................... 4‐95
cut interruption .................................... 5‐21 Master file
Import .................................................4‐105
Load in the internal management system
............................................................ 4‐105
I Measuring system ................................... 4‐33
Message history
ID tube profiles ........................................4‐83 Displaying .......................................... 4‐147
Composition .........................................4‐83 MobileControl app ................................... 3‐43
Installed options Monitored properties
TOS ..................................................... 4‐36 Showing ............................................. 4‐148
Intended use ..............................................1‐7 Multi-sheet processing ................. 3‐20, 4‐117

10‐2 Index 2019-02-01 B813en

Multiple-machine operation ................... 4‐101 Job status ............................................4‐50
Job with intermediate layer .................4‐70
Job, creating with SortMaster .............4‐56
Job, deleting ........................................4‐63
N Job, disabling ...................................... 4‐63
Job, modifying ..................................... 4‐57
NC program Modifying the sequence of the jobs ... 4‐58
Copy ...................................................4‐112 Parts, manually sort ............................ 4‐67
Creating block-by-block .......................4‐99 Pause (stop) ........................................4‐60
Delete .................................................4‐111 Preparatory loading .............................4‐70
Display ............................................... 4‐106 Prepare ................................................ 4‐59
Load in the internal management system Production packages, creating ........... 4‐58
............................................................ 4‐105 Resume ............................................... 4‐62
Managing ........................................... 4‐104 Sheet, manually loading ..................... 4‐67
Output (export) as master file ...........4‐110 Start ..................................................... 4‐60
NC text Status ...................................................4‐50
Searching and replacing ................... 4‐109 Status, displaying ................................ 4‐67
Network link .............................................2‐34 Tool setup check ................................. 4‐59
Nitrogen for cutting unit ventilation .........2‐24 Profile ID ..................................................4‐83
Nozzle changers Composition .........................................4‐83
Operation ........................................... 4‐135 Program
Cancel ..................................................4‐43
Creating ............................................. 4‐113
Execute ................................................4‐41
O Flexible entry .......................................4‐71
Offsetting zero point pausing ................................................ 4‐43
Deleting ................................................4‐97 Prepare ................................................ 4‐40
On-screen keyboard ................................4‐33 Reading in via USB interface ............. 4‐41
Activate ................................................ 4‐33 Switching view .....................................4‐42
Online calculation .................................... 3‐44 Purity
Online Update Manager ..........................4‐34 Cutting gases ...................................... 2‐17
Open TRUMPF Operating System (TOS) .... Push-button
4‐34 EMERGENCY STOP .......................... 4‐12

P R
Page up/Page down ............................... 4‐12 Remote support .......................................2‐34
Password ................................................. 4‐22 Internet ...............................................4‐149
User group .......................................... 4‐22 Renumbering program blocks ............... 4‐110
Pilot laser .................................................1‐11 Requirements, space ................................ 2‐6
Planning aid ...............................................2‐4 Residual risks .......................................... 1‐37
Post-production ........................................4‐44
Power supply ................................. 2‐27, 2‐30
IT system .............................................2‐32
Outer conductor grounded ..................2‐31 S
Pressure control ...................................... 2‐23 Safety-Mode key switch .......................... 1‐26
Process cooler .........................................2‐14 Safety cabin .............................................1‐24
Outdoor installation ............................. 2‐14 Safety light barrier ................... 1‐24, 7‐1, 7‐2
Platform installation ............................. 2‐14 Safety light barrier interrupted ................ 4‐13
Production plan ....................................... 4‐49 Show status
Create job ............................................4‐51 Machine ............................................... 4‐44
Inventory, creating ............................... 4‐65 Signal lamps ..........................................4‐148
Inventory, modifying ............................ 4‐66 Single pallet mode .................................. 4‐69

B813en 2019-02-01 Index 10‐3

Software ...................................................1‐35
Software version
Display ............................................... 4‐148
Spare parts ..............................................1‐35 U
Standard pressure cutting .......................2‐17
Star handle .............................................. 9‐26 UPS .................................... 2‐30, 6‐13, 6‐119
Stress due to vibration ............................2‐10 USB port ..................................................4‐15
Structural stress analysis .......................... 2‐9 User administration ................................. 4‐22
Sub program ..........................................4‐107 User group ..................................... 4‐22, 4‐23
Program name .................................. 4‐107 Log on ................................................. 4‐23
Support housing ...................................... 9‐26 User interface .......................................... 4‐37
Support housing, outside .......................... 9‐9 Close ....................................................4‐37
Support, with step roller ..........................9‐10
Switching on
Laser machine .....................................4‐25
W
Warning message
Display ............................................... 4‐147
T Warning signs ..........................................1‐28
Tank system ............................................ 2‐24 Water protection ...................................... 1‐35
Technology correction WebCalculate .......................................... 3‐44
Edge technology ................................. 4‐86 Weight load ............................................... 2‐9
Laser technology .................................4‐81 Wireless Operation Point ........................ 3‐47
Load tube ............................................ 4‐85
Loading ................................................ 4‐78
Measuring sheet position ....................4‐80
Microjoint ............................................. 4‐82
Z
Part technology ................................... 4‐85 Zero point
Program properties ............................. 4‐79 Move .................................................... 4‐97
Select technology ................................4‐77
Sheet technology ................................ 4‐79
Sheet, loading ..................................... 4‐88
Tube technology ..................................4‐83
Technology parameters
Modifying in the editor ...................... 4‐108
Technology tables
Modifying in the NC program ........... 4‐108
Test certificate ........................................... 8‐2
Time ......................................................... 4‐33
Touchscreen
Calibrate .............................................. 4‐32
TruConnect
Connectivity ......................................... 3‐46
Production control ............................... 3‐45
Production overview ............................3‐43
Remote support ...................................3‐48
TruControl ................................................ 4‐38
Switching ............................................. 4‐38
TruDisk Laser
................................................................ 3‐8
TruTops Fab app .....................................3‐44
TruTops FMC .........................................4‐101
TruTops Monitor
Production overview ............................3‐44

10‐4 Index 2019-02-01 B813en