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3-46

Control system/programming

B337EN03.DOC

3-D programming

ToPs 800 is the programming system for 3-D laser machining
developed by TRUMPF. ToPs 800 is process-oriented and thus
clearly structured. It helps prepare 3-D data and create NC
programs.

The programming of 3-D contours is carried out using the Teach
panel (programming handheld device) of the Siemens SINUMERIK
840D control system.

Teach panel

The teach panel is an independent device with a complete set of
operating elements. It is connected control panel and used for
teach-in programming only. All the actions required for teaching
can be carried out from the teach panel.

TRUMPF has extended the unit’s basic functionalities, such as e.g.
entering technologies, programming standard geometries, as well
as carrying out auxiliary functions.

Teach panel

ToPs 800

Manual programming

Fig. 22877

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Summary of Contents for LASERCELL 1005

Page 1: ...Operator s manual TRUMPF LASERCELL 1005...

Page 2: ......

Page 3: ...Operator s manual TRUMPF LASERCELL 1005 Edition 07 2004...

Page 4: ...ion are reserved to TRUMPF Werkzeugmaschinen GmbH Co KG even in case of patent and industrial rights applications No part of this documentation may be reproduced processed duplicated or distributed by...

Page 5: ...parts list for the TLC 1005 Spare parts list for the TLF Laser Wiring diadram for the TLC 1005 Wiring diadram for the TLF Laser Data collection TLC 1000 TLC 1005 TLC 6005 TLC CUT 5 Technical informati...

Page 6: ...0 6 Before You proceed B337EN00 DOC...

Page 7: ...sing the appropriate spare parts and operating materials 1 12 Water protection 1 13 Fire protection 1 14 3 3 Measures taken by the manufacturer 1 16 Securing the danger zone of the machine 1 16 Suctio...

Page 8: ...itions TLC 1000 and TLC 1005 1 Installation site 2 5 1 1 Space requirements 2 5 1 2 Floor requirements 2 5 1 3 Weight loading 2 6 1 4 Ambient conditions 2 9 1 5 Exhaust air conduction for compact dust...

Page 9: ...port 2 32 1 1 On delivery checking the system 2 35 1 2 Unloading machine and transporting to the installation site 2 35 Transport of TLC 1005 basic machine 2 36 Base for machine body 2 39 Machine tabl...

Page 10: ...sing optics 3 32 Central lubrication 3 35 Instrument panel 3 36 4 2 The laser 3 38 Targeting laser 3 39 4 3 Electrical installation 3 40 Safety interface optional 3 40 Digital user interface optional...

Page 11: ...Z axis brake switch 4 21 2 Operating panel with color display 4 22 2 1 Control elements on the machine 4 23 2 2 Control elements of the control system 4 30 3 ASCII keyboard 4 34 Part 2 User interface...

Page 12: ...ts for TLF laser statuses 2 4 74 4 5 PRODUCTION Tables 4 75 Laser technology 4 75 Laser power cycles 4 86 Welding table 4 88 Tube section technology table 4 93 4 6 PRODUCTION Summary production plan 4...

Page 13: ...ty 4 149 7 1 Zero point offset 4 149 8 MAINTENANCE INITIAL START UP activity 4 151 8 1 MAINTENANCE INITIAL START UP Data backup 4 151 8 2 MAINTENANCE INITIAL START UP Display 4 152 8 3 MAINTENANCE INI...

Page 14: ...rive brakes 4 179 3 6 Releasing the Z axis drive brake 4 180 4 Executing a program 4 181 4 1 Calling up and starting a program 4 181 4 2 Stopping a program during machining 4 182 4 3 Aborting a progra...

Page 15: ...4 210 12 Electrically driven safety doors 4 210 12 1 Opening the lift door 4 211 12 2 Closing the lift door 4 211 12 3 Referencing the safety door 4 212 12 4 Referencing the safety door 4 213 12 5 Cl...

Page 16: ...e program manager 4 233 17 Managing NC programs 4 234 17 1 Displaying NC text 4 234 17 2 Editing NC text 4 235 Searching for a block in the NC text 4 235 Searching for a function in the NC text 4 235...

Page 17: ...setting the focus position 5 25 Adjusting the setting on the cutting head 5 29 Determining focus position f 0 5 30 Correcting focus position 5 32 6 Adjustment work on the welding head 5 33 6 1 Install...

Page 18: ...uring probe 5 83 14 Welding wire feed optional 5 86 14 1 Inserting welding wire 5 86 15 Setting the rotary axis optional 5 90 15 1 Shifting the rotational axis horizontally in X direction 5 90 15 2 Ad...

Page 19: ...on basic machine 6 19 4 2 Maintenance of compact dust extractor 6 23 5 Maintenance of pneumatic components and filters 6 30 5 1 Instrument panel 6 30 5 2 Maintenance on basic machine 6 36 5 3 Mainten...

Page 20: ...5 1 Auxiliary tools and materials 7 8 5 2 Maintenance work 7 11 6 RF generator 7 18 6 1 Notes on safety 7 18 6 2 Auxiliary tools and materials 7 19 6 3 Construction of RF generator 7 19 6 4 Short cir...

Page 21: ...onal equipment for aligning 8 2 2 System example 8 3 3 Aligning the light beam 8 4 4 Setting mirror 8 6 5 Cross hairs to cut out 8 7 Chapter 9 Noise levels Test certificate TLC 1005 1 Mess Test certif...

Page 22: ...0 22 Table of Contents B337EN00 DOC...

Page 23: ...1...

Page 24: ...sures to be taken by the user operator 1 6 Observe information and warning plates 1 6 Instructing personnel 1 6 Care needed while operating the machine 1 7 Eliminating malfunctions during operation 1...

Page 25: ...23 5 3 Dangers due to laser radiation 1 24 5 4 Protection against radiation 1 25 Measures to be taken by the user owner 1 25 Measures taken by the manufacturer 1 27 5 5 Hazardous substances 1 30 Dust...

Page 26: ...and CE label Type plate and CE marking are located on the front of the machine body As the manufacturers of this machine we wish to use this comprehensive safety chapter to acquaint you the owner wit...

Page 27: ...esponsible for the transportation installation start up operation maintenance and cleaning of the machine and for the repair of malfunctions on the machine 3 Operating safety The machine is built usin...

Page 28: ...n must comply with the national regulations valid in the country where the machine is operated The user is responsible for compliance with these laws The following is not permitted Laser cutting of pl...

Page 29: ...instructed personnel only Work on electrical pneumatic hydraulic and laser specific equipment may only be carried out by specially trained specialists The following measures must also be carried out b...

Page 30: ...so be tested for proper functioning If the arrangement of light transmitter and light receiver has been changed After all maintenance and service work on a light barrier The operator must always make...

Page 31: ...persons authorized by the user may only operate the machine if it is in perfect condition The user must set up the machine in accordance with the installation plan and the installation conditions The...

Page 32: ...he respective pressure gauge at the instrument panel In the 3 D workspace of the machine there is a general risk of collision between the motion unit Z clamping sleeve and processing optics and custom...

Page 33: ...If the malfunction cannot be eliminated using the operating panel press E STOP 4 Correct the malfunction with a brief intervention into the machine 5 If there are malfunctions which need to be elimin...

Page 34: ...d or lost A sample with the required data in accordance with EN 378 is contained in the operator s manual of the cooling unit An installation log is to be maintained A sample is contained in the opera...

Page 35: ...and accessories The instructions for using the appropriate operating materials in particular lubricants and cleaning agents must be observed If a safety specifications sheet European Guideline 91 155...

Page 36: ...he federal states specify how this precautionary principle should be followed Information on water protection Water pollutant substances Lubricants Water hazard class WGK 2 Volume of the water polluta...

Page 37: ...ontainer for each material group and label it When the processing program has been completed wait until the end of the lag time for the suction unit and change the container Regularly maintain the com...

Page 38: ...e in the filter plates triggers an acoustic and a visual alarm The CO2 fire extinguishing unit is automatically triggered The following measures should then be taken 1 Switch off the MAIN SWITCH of th...

Page 39: ...ased The following then occurs automatically The laser beam is switched off The beam trap is closed The axis motion is stopped The cutting gas and protective gas supply is interrupted To switch the ma...

Page 40: ...2 E STOP on the teach panel 3 E STOP on the control panel E STOP impact buttons Depending on the model there are an additional E STOP impact buttons on the unit At the operating panel of the electrica...

Page 41: ...3600 min C axis 5 rpm 1800 min A axis 5 rpm 1800 min Laser switches automatically to LASERTEST To be able to move the axes in automatic mode the pulse trigger switch must be permanently pressed As so...

Page 42: ...ngs Follow the directions and prohibitions of the warnings They are for your own protection Warnings contain A symbol A signalling word Information about the source and type of danger Precautions you...

Page 43: ...c fields Signalling words The warnings are indicated by one of the following key words Danger Warning Caution Meanings of the signalling words are as follows indicates great danger If this is not avoi...

Page 44: ...Danger of injury Risk of injury Risk of injury Due to being caught or wound in Motion of the movable workstation Pallet transport optional Movement of the round table optional Danger of injury Risk of...

Page 45: ...igned to Laser Class 4 Danger of injury Do not look over the lift partition panel Do not climb up onto objects or support tables in the working area Danger from substances Through contact with or by i...

Page 46: ...orkpiece in working position No personnel are in the machine s danger zone Note The danger class of the laser system in normal mode is class 1 Service mode concerns laser operation for setting and ser...

Page 47: ...ol and laser class 4 warning sign Wavelength 10 6 m Laser class 4 Technical data for CO2 laser Warning Invisible high energy laser radiation Severe skin burns and eye injuries may occur Severe impairm...

Page 48: ...tor are stated in the European norm EN60825 1 Radiation safety of laser systems and other similar international norms Additionally each country s regulations apply For the jurisdiction of laws in the...

Page 49: ...over at least Instruction of personnel in the operating procedures of the laser Correct application of laser protection Necessity of personal protection Procedures involved in documenting accidents Bi...

Page 50: ...red radiation caused by the reflection of the laser beam from the workpiece is effectively absorbed by the safety cabin The red laser warning lamp on the safety cabin indicates that the laser is ignit...

Page 51: ...Laser warning symbol and information sign indicating invisible laser radiation of laser class 4 INVISIBLE LASER RADIATION CLASS 4 LASER MAX C W OUTPUT CARBON DIOXIDE LASER 10 6 m Sign 5 Identificatio...

Page 52: ...B337EN01 DOC Laser processing 1 29 The circled numbers in the following display indicate the numbered signs listed in the previous section Schematic illustration of machine signs Fig 17160...

Page 53: ...rs are set optimally Apart from the cutting parameters the type of material also has an important influence on the volume of emission For this reason the emission quantity during the machining of mild...

Page 54: ...mg m Acetaldehyde 0 007 0 005 90 Acetone 0 111 0 204 2400 Butanol 0 334 0 022 300 Butyl acetate 0 081 0 007 950 Decane 0 060 0 004 No limit value Ethyl acetate 0 237 0 002 1400 Ethyl benzene 0 034 0 0...

Page 55: ...onene nonadiene N decane 1 decene decadiene N undecane 1 undecene undecadiene Further n alcane 1 alcanes diene pairs Toluene Ethyl benzene L limonene N butyl benzene sulfonamide Measurements of exhaus...

Page 56: ...position of the lens by absorption of laser radiation e g due to contamination or pits on the lens Note If a laser power of 2500 watts is used for operations make absolutely sure that the lens in the...

Page 57: ...ouching decomposition products can damage your health Press E STOP Leave the area surrounding the machine Wait at least 30 minutes for the reaction to die off Clean the cutting head mirror and beam gu...

Page 58: ...mit the invoice number or delivery order number under which the lens was purchased at TRUMPF If these details are not specified acceptance of the return goods will be refused 5 7 Hazards caused by fla...

Page 59: ...ttached at the following points Discharge path at the resonator X51 terminal box in front of the telescope cover Auxiliary ignition in front of the telescope cover Switch cabinet of the RF generator M...

Page 60: ...tor is operated as intended Compliance with the guidelines EMC guideline for limits on radiation according to EN 55011 is ensured by taking constructive measures Warning Risk to health from radiation...

Page 61: ...1 38 Laser processing B337EN01 DOC...

Page 62: ...2...

Page 63: ...onsole on the machine body Lasers of large series on base TLF 2000 TLF 2700 TLF 3200 TLF 4000 TLF 5000 TLF 6000 TLF 8000t TLF 12000t The TLC 1000 and TLC 1005 are systems that are designed for laser c...

Page 64: ...reducer 2 13 Laser gas supply from cylinders 2 14 Central laser gas supply fixed piping 2 14 2 2 Cutting gases 2 15 Purity 2 15 Gas consumption 2 15 Supply lines to cutting gas supply 2 18 Cutting gas...

Page 65: ...checking the system 2 35 6 2 Unloading machine and transporting to the installation site 2 35 Transport of TLC 1005 basic machine 2 36 Base for machine body 2 39 Machine table 2 40 Base plate 2 40 Sy...

Page 66: ...ter are fulfilled If this is not the case the TRUMPF service personnel will not be able to put the machine into service The machine is put into service by TRUMPF service technicians This includes Alig...

Page 67: ...d the basic machine may not exceed 10 mm The changes resulting from tilting the machine should not pro duce laser beam migration of more than 0 5 mm on the lens The entire installation surface for the...

Page 68: ...rt bracket for the working area X 1250 mm X 2000 mm X 3000 mm X 4000 mm approx 5000 approx 6000 approx 9000 approx 11000 The weight is distributed on 6 wedge mounts area 120 mm x 175 mm or 8 wedge mou...

Page 69: ...n of weight Machine body including support bracket and laser unit1 For laser Small series Large series approx 4200 approx 5100 Weight is distributed on 4 wedge mounts surface 120 mm x 175 mm The max l...

Page 70: ...net for pallet changer optional approx 200 The edges support the main load Laserpac approx 300 The edges support the main load Transformer optional approx 250 The edges support the main load Compact d...

Page 71: ...degreasing units If the ambient temperature is between 35 C 43 C the system must be equipped with the tropical version of the laser The control system is cooled by inner air circulation in the closed...

Page 72: ...clear gas duct of the compact dust extractor The pipeline must be configured as follows Maximum of two 90 bends radius diameter x 1 5 Max length 10 m Tube diameter 250 mm Flange design according to D...

Page 73: ...installation of cooling unit A weather protection cover is necessary if the cooling unit is to be installed outdoors In order to allow access for maintenance and repair work comply with the minimum d...

Page 74: ...he relevant norms e g DIN 477 No 6 DIN EN 559 DIN 8541 part 3 VBG 15 VBG 62 46 47 Warning Gas conduits and electrical cables laid out in the same cable duct A short circuit could cause damage to a gas...

Page 75: ...1 32 x 1 14 according to DIN 477 no 10 Pressure reducer specifications3 Type Admission pressure bar Back pressure range bar Min flowrate Nm3 h Shut off valve purge valve two stage with metal membrane...

Page 76: ...manually or automatically The following demands are made on fixed piping Copper or stainless steel pipes refrigerator quality must be used for the fixed piping Have the piping done by qualified profes...

Page 77: ...Duration of the laser cutting To help you get a rough estimate of the potential cutting gas consumption consumption values with standard and high pressure cutting are shown below For a differentiated...

Page 78: ...minimum line pressure available at the connection point to the machine is 8 bar with gas consumption of 10 Nm3 h a nozzle 1 7 mm and 6 bar cutting gas pressure p b a r 0 2 4 6 8 1 0 0 1 2 3 4 5 6 d 1...

Page 79: ...ailable at the connection point to the machine is 27 bar with a gas consumption of 55 Nm3 h a nozzle with 2 3 mm and cutting gas pressure of 20 bar During high pressure cutting with O2 the minimum lin...

Page 80: ...individual machines In this way the supply lines for example can be blocked off and bled during servicing using the purge valve on the connection point of the machine Note The gas temperature must no...

Page 81: ...e banks and also for changing cylinders The switch over is carried out manually or automatically 5 Cylinder or cylinder bundles are usually installed some distance away from the laser machine For this...

Page 82: ...in all cases Requirements for high pressure cutting with nitrogen Do not use a tapping point pressure regulator between the gas tank and the machine after the pressure regulating station A stopcock mu...

Page 83: ...c10 bar 21 21 34 Max cutting gas pressure bar 6 12 20 Volume rate of flow11 Nm h 10 20 55 Nozzle diameter mm 1 7 1 7 2 3 Cutting gas supply machine connection 9 The safety pressure regulation system i...

Page 84: ...vol Nitrogen N2 2 8 99 8 vol Carbon dioxide CO2 2 5 99 5 vol Welding gas purity Supply lines Note The customer must provide the supply lines for the protective gases up to the connection point on the...

Page 85: ...he laser control cabinet The symbol on the left marks the connection point in the installation plan Electrical supply Connecting line Cable Cross section Ground wire Carried out acc to DIN EN 60204 1...

Page 86: ...the machine is larger than the set residual current the machine must be separated from the network using an isolating transformer See EN 50178 pt 5 2 11 1 VDE 0160 For IT and TT network structures as...

Page 87: ...nit at 400 V A at 460 V A 80 63 80 80 100 80 100 100 125 125 160 125 160 160 315 250 Connected loads of the cooling unit kVA 18 21 21 26 44 44 65 73 Fuse protection cooling unit at 400 V A 50 50 50 50...

Page 88: ...allow connection of the machine control system to a network e g connection to a programming system If more than one machine is included in the network a personal hub network distributor is needed This...

Page 89: ...ing equipment etc approx 30 approx 55 customized Short time max consumption over a period of 2 min once an hour at the most Nm3 h approx 65 Minimum nominal width of the supply pipelines DN13 Ring pipe...

Page 90: ...e conducted through the B C gearbox by way of the rotational transformer Caution If the compressed air supply is switched off without a sealing gas supply connected then water could penetrate the rota...

Page 91: ...circuits a copper and an aluminum cooling circuit For cooling water demineralized de ionized or distilled water is mandatory Cooling water must be provided by the customer at system start up Cooling w...

Page 92: ...r to avoid impairment of the water quality The water must be transported in clean plastic containers without deposits no odors Avoid all unnecessary contact with the water e g with hands Contact with...

Page 93: ...ith a risk of frost cooling water is mixed with the antifreeze agent purest ethylene glycol The mixing ratio depends on the temperature conditions at the actual installation site Temperature C to 15 U...

Page 94: ...5 t Gantry crane carrying capacity 12 t or armored rollers 1 steerable 2 fixed Hydraulic hoisting jack TLC 1000 3 jacks with a carrying capacity of at least 5 t attachment height 50 mm TLC 1005 4 jack...

Page 95: ...mm X 3000 mm 1500 2000 2500 3000 1500 1500 1500 1500 700 700 700 700 500 660 800 920 Base plate with exhaust trap without exhaust trap 1100 1100 1100 1100 500 700 500 700 210 135 Large series laser TL...

Page 96: ...420 1420 1420 800 1400 2200 3000 800 800 800 800 800 800 800 800 2100 2100 2100 2100 2100 2100 2000 2000 970 1020 1040 1060 820 750 1520 2050 Cooling unit for laser TLF 2000 to TLF 4000 TLF 5000 TLF 6...

Page 97: ...Suspended load Entering the danger area could lead to serious injury or death Observe relevant safety regulations regarding the handling of heavy loads Do not go under a suspended load Use tested and...

Page 98: ...Move Y slide into position Y 0 Move Z slide into position Z 0 Position round stop and back stop optional approx 1000 mm from the right hand stopping point Mount transport securing devices on the lase...

Page 99: ...ngth of transport unit C Stopping point of rotational moving device T Cross beam with hanging chains 1 2 Swivel bearer M36 stopping point of cross beam 4 Positioning surface for rotational moving devi...

Page 100: ...n 4 fig 32509 must fit closely to stop position C During transport no persons are allowed in the danger zone For transport on armored rollers 1 Position hydraulic hoisting jacks at the front and rear...

Page 101: ...to fit the length of the base and always attached symmetrically 1 1 1 1 1 Securing points corner bracket M36 Base securing points Base for machine body for working area X 1250 mm X 2000 mm X 3000 mm X...

Page 102: ...ne or crane truck Base plate The base table is attached to 4 eyebolts M12 2 tapping holes are at the front and 2 to the rear of the support surface Caution Improper transport of the base plate can cau...

Page 103: ...with steel bands Move pallet to the installation site using a forklift or lift truck 6 3 Installing the system Prerequisites The foundation is prepared holes and cut outs have been made in the factory...

Page 104: ...he system is delivered X Y X Zero point line for installation in X direction Y Zero point line for installation in Y direction Bore hole for anchoring 6 holes Preparing the factory floor 1 On the fact...

Page 105: ...ith EN 60825 1 VBG 93 14 weeks but no later than calendar week Conditions at the installation site 20 Determine the machine s final position Take into consideration space requirements using installati...

Page 106: ...lation site connection purity compressed air requirements 4 weeks but no later than calendar week Working materials Acquire stocks of operating materials laser gases cutting gases and operating materi...

Page 107: ...3...

Page 108: ...ate system zero point working range 3 7 3 1 Coordinate system 3 7 1 2 Zero point working range 3 8 4 The modules of the laser cutting center 3 11 4 1 The modules of the basic machine 3 14 Machine body...

Page 109: ...Electrical installation 3 40 Safety interface optional 3 40 Digital user interface optional 3 42 1 4 Suction unit and compact dust extractor 3 42 Suction 3 42 Compact dust extractor 3 43 2 Control sys...

Page 110: ...required system components are configured depending on the machining process the range of workpieces clock cycles and specified quality criteria The machine is equipped with a CO2 laser of the TRUMPF...

Page 111: ...ion A axis at R 200 mm 0 001 mm or 0 001 0 1 mm or 0 015 0 03 mm or 0 005 0 0083 TRUMPF CNC control Hard disk memory Disk drive Platform Color monitor Modem Based on Siemens SINUMERIK 840D with PCU 50...

Page 112: ...Surface plate diameter centering diameter tapping hole Max workpiece diameter Weight n x 360 480 rpm 138 rad sec 2 3 kgm 2 with n 480 rpm 7 kgm 2 with n 220 rpm 500 kg 500 kg 0 01 0 004 400 mm 132 H7...

Page 113: ...asers Laser power Adjustable as desired According to Laser used 700 W to 4500 W Electrical connection Total consumption depending on the laser TLF 2000 TLF 2700 TLF 3200 TLF 4000 TLF 5000 TLF 6000 TLF...

Page 114: ...is Rotary axis optional parallel to the machine body 360 B axis Rotary movement of the processing optics around the Y axis 120 C axis Rotary movement of the processing optics around the Z axis 360 The...

Page 115: ...ing range 2 D machining The zero point of the Z axis refers to the pivotal point in the B C gear see Fig 36720 Pos C X direction Y direction Z direction 1250 mm 1500 mm 500 or 750 mm 2000 mm 1500 mm 5...

Page 116: ...velling range Processing optics A in mm B in mm 3 75 cutting head 140 200 5 cutting head 140 200 7 5 cutting head 140 265 Welding head f 150 mm 140 150 Welding head f 200 mm 140 200 Welding head f 270...

Page 117: ...he workspace of the machine There is a particular risk of collision When using a Z center sleeve with a travel path of Z 500 mm under a working height of 900 mm in relation to Z 0 When using a Z cente...

Page 118: ...laser on laser console small series laser 3 1 2 4 5 6 7 8 9 1 TLF laser on support bracket 2 Compact dust extractor 3 Switch cabinet of the machine 4 Laser cooling unit 5 RF generator 6 Switch cabine...

Page 119: ...e base large series laser 3 2 4 5 6 7 8 9 1 1 TLF laser on base 2 Compact dust extractor 3 Switch cabinet of the machine 4 Laser cooling unit 5 RF generator 6 Switch cabinet for laser 7 Safety cabin 8...

Page 120: ...ng of laser unit and optical components Operator s manual Cooling unit 5 RF generator Generates the high frequency energy Operator s manual and electrical circuit diagram for RF generator 6 Laser swit...

Page 121: ...2 Back stop optional 3 Machine body 4 Rotary axis optional 5 Beam guideway 6 Motion unit X Y Z 7 Z clamping sleeve with processing optics 8 Support table Basic machine modules 1 Only for machines wit...

Page 122: ...processing 3 Machine body Holds the motion unit beam generator beam guideway as well as all components relevant for functions 5 Beam guideway Laser beam guidance between laser unit and processing opti...

Page 123: ...are relevant to the machine s accuracy These include Holding the motion unit X Y Z extension arm Guiding the X carriage Laser unit for small series lasers and beam guideway Mounting the safety cabin...

Page 124: ...ith Y carriage X axis drive Z axis drive and guide The B and C axis drives the processing optics and if available the welding wire feed optional are integrated in the Z axis 1 2 3 4 1 Cantilever 2 Y c...

Page 125: ...ared with analog feed drives guarantee high dimensional accuracy Digital drives are not subject to interference caused by electrical fields The compact design and low rotor inertia enable the highly d...

Page 126: ...on the position of the processing optics 1 2 3 4 6 5 1 3 D workpiece 2 Device for 3 D workpieces 3 Support slats 4 Drawer 5 Basis bridge 6 Table frame Support table Standard 550 mm or 700 mm The max l...

Page 127: ...ity the cutting and welding results will be Note Devices are not part of the machine s scope of delivery Support slats are subject to wear As required the user can cut the support slats on the machine...

Page 128: ...that purpose 1 4 1 2 3 1 Flap 2 Suction piping connection 3 Fastening plate 4 Circumferential support slat Base plate with exhaust trough Working height above the floor 550 mm or 700 mm Dimension 110...

Page 129: ...ntial machined support slat with spacer holes For cutting the base table has in addition an exhaust trough There is a flap on each side of the exhaust trough for removing the waste parts Suction pipin...

Page 130: ...he rotary axis is attached to a rail assembly along the machine body and can be moved or swivelled vertically or horizontally according to the respective version Rotary table with CNC rotary axis move...

Page 131: ...by the customer 150 100 50 150 100 50 50 100 150 50 100 150 0 0 M12x20 36x Rotary plate hole pattern The rotary axis has a rotary transmission leadthrough for con necting with water and gas supplies f...

Page 132: ...ecting the back stop to or customized jigs and fixtures The base plate can be moved parallel to the X axis Freely rotating clamping sleeve with pneumatic stroke 100 mm incl travelling centering spike...

Page 133: ...n favor of a structural solution The direct drive rotary axis is particularly suitable for small dimensioned workpieces which are processed at a high rpm and high acceleration This leads to the follow...

Page 134: ...lly shifted or swivelled vertically or horizontally depending on the respective version in a manner analogous to conventional rotary axes 1 1 Surface plate Mounting on the machine body The rotary axis...

Page 135: ...axis deflection mirror Si 3 Deflection mirror Si 4 Adaptive telescopic mirror Cu 5 Phase shifter Si 6 X Y axis deflection mirror Cu 7 Y Z axis deflection mirror Cu 8 Deflection mirror Cu in the angula...

Page 136: ...7 9 10 8 7 1 Beam bending mirror Cu laser machine 6 X Y axis deflection mirror Cu 7 Y Z axis deflection mirror Cu 8 AutoLas Plus mirror or deflection mirror Cu in the angular gear 9 Cutting head defl...

Page 137: ...ing water pressure The phase shifter changes the polarization of the laser light The linear polarization is converted into circular polarization All beam bending mirrors in the beam guideway as well a...

Page 138: ...at extent The focus position is automatically adjusted to the respective material thickness and type While a program is running the focus position can be varied automatically making it possible to opt...

Page 139: ...d with 7 5 lens The beam bending mirror in the cutting head guides the beam onto the focusing lens The lens bundles the arriving laser beam and in doing so turns it into a cutting tool The diameter of...

Page 140: ...or from the side onto the workpiece The welding nozzle is movable in order to protect the machine in case of a collision In the case of a collision the welding nozzle swings about 15 mm out thus activ...

Page 141: ...an extremely thin molten mass is produced which can easily result in an unstable seam Seam splitting is reduced considerably and the process consistency and quality of the welding seam is increased b...

Page 142: ...ments Service refer to Calling up the lubrication cycle in the section Operating the machine in the Operation chapter The TC_LUBRQ cycle is used to call up and immediately start a lubrication cycle au...

Page 143: ...el On machines with a small series TLF laser the instrument panel is located under the laser console The main operating devices can be accessed by removing the cover On machines with a large series TL...

Page 144: ...sable filter 30 Welding beam guideway ventilation disposable filter 31 Pressure relief valve 32 Forwards HD supply unit cutting gas N2 8 32 Rear HD supply unit cutting gas O2 8 33 Lubricating pressure...

Page 145: ...regulations in the chapter on safety must be observed TLF laser on the support bracket The following types of laser are used on the TLC 1005 Small series laser Large series laser TLF 2000 TLF 8000t TL...

Page 146: ...tor This reduces the maintenance requirements and also the gas consumption The laser control system offers the following options Logbook function Laser power control Power cycles Frequency modulation...

Page 147: ...technical customer service Safety interface optional The safety interface is a functional extension of the integrated interface control system also referred to as PLC With the safety interface Additio...

Page 148: ...LD will be triggered at the machine and the following message will be generated Feed hold due to Handling system 1 safety doors or light grid 1 B5 B6 If the contact is interrupted a FEED HOLD will be...

Page 149: ...gramming guide TLC 1000 TLC 1005 TLC 6005 4 4 Suction unit and compact dust extractor Suction There is a suction system under the support slats of the support table which consists of several suction c...

Page 150: ...cycles for purging the filter inserts are controlled according to the jet pulse principle dependent on differential pressure An acoustic alarm goes off and the warning lamp lights up if a fire is dete...

Page 151: ...ows rapid use of all further PC micro processors and operating systems The hardware consists of three main components whose functional units communicate with each other via accessible inter faces NC k...

Page 152: ...lp for operation and programming provides information and explanations on the current topic Malfunctions in the operational sequence are detected by sensors and can be selected for viewing on screen v...

Page 153: ...mming handheld device of the Siemens SINUMERIK 840D control system Teach panel The teach panel is an independent device with a complete set of operating elements It is connected control panel and used...

Page 154: ...ach probe located in the processing optics There are different teach probes for the cutting head and for the welding head A For cutting head B For laser welding head Teach probe Note Teach in see Teac...

Page 155: ...am Detector is an image processing system developed by TRUMPF for measuring joint positions in connection with welding applications Seam sensor camera with welding head The TSD seam sensor system is a...

Page 156: ...ystem of the machine The measured values yielded from the image processing are transmitted to the control system The control system transforms these into axis coordinates A fundamental distinction is...

Page 157: ...with the sheet surface The distance between nozzle and workpiece is always kept constant with flat or with 3 D processing Collisions between the cutting head and the workpiece are thus avoided The co...

Page 158: ...accordingly You can choose to measure or process by rotating the B axis 1 1 Measuring probe Cutting head with measuring probe Dimensional and process tolerance of the measuring stylus and of the proc...

Page 159: ...mm or 1 2 mm The coil at the Z axis and the drive at the welding head can be removed Note The rotation of the welding head around the C axis is restricted to 200 if the welding wire feeder is in use 1...

Page 160: ...4...

Page 161: ...tion for operating and programming the machine All information on operating the machine which can be found in the programming manual and in this chapter can be called up by pressing keys at the contro...

Page 162: ...itch 4 21 2 Operating panel with color display 4 22 2 1 Control elements on the machine 4 23 2 2 Control elements of the control system 4 30 3 ASCII keyboard 4 34 Part 2 User interface 4 36 1 User int...

Page 163: ...Switch elements for TLF laser statuses 2 4 74 4 5 PRODUCTION Tables 4 75 Laser technology 4 75 Laser power cycles 4 86 Welding table 4 88 Tube section technology table 4 93 4 6 PRODUCTION Summary prod...

Page 164: ...6 1 NC Editor 4 139 6 2 NC program management 4 141 6 3 File management 4 143 6 4 Outputting NC programs from the management system 4 145 6 5 Selecting NC programs 4 147 7 Tooling activity 4 149 7 1 Z...

Page 165: ...cies 4 176 2 1 Triggering E STOP 4 176 2 2 Cancelling E STOP 4 176 3 Eliminating malfunctions 4 177 3 1 Triggering FEED HOLD 4 177 3 2 Acknowledging FEED HOLD 4 177 3 3 Acknowledging FEED HOLD after a...

Page 166: ...10 Support table indexing 4 205 10 1 Indexing support tables 4 205 10 2 Undoing electrical indexing 4 206 10 3 Undoing pneumatic indexing 4 206 11 Optional Driving pallet changers 4 207 11 1 Coupling...

Page 167: ...YWHERE1 4 227 15 4 Querying the software version 4 227 16 Managing master files 4 228 16 1 Uploading an NC program from the disk drive 4 228 16 2 Uploading an NC program from the hard disk 4 229 16 3...

Page 168: ...Creating a message text 4 241 20 2 Assigning a message text 4 242 20 3 Splitting up an interruption period 4 243 20 4 Evaluating machine data 4 244 21 Evaluating the ODC interface 4 245 21 1 Opening a...

Page 169: ...ating devices 1 Control elements other than on the operating panel 1 1 Control elements of the basic machine 2 1 3 1 MAIN SWITCH 2 E STOP on the teach panel 3 E STOP on the control panel Control eleme...

Page 170: ...vements of the machine pallet changer and any other available devices The cutting gas and or the cutting gas supply is interrupted Closes the beam trap and switches off the laser beam Immediately cuts...

Page 171: ...nt Explanation Parallel interface for connecting peripheral devices e g to data backup Service socket Voltage is also present even after MAIN SWITCH OFF 31 2 Floppy disk drive for data transfer Teach...

Page 172: ...ically driven safety doors can be opened and closed manually using switch or control elements on the safety cabin or automatically by means of the machining program Safety door control panel TLC 1005...

Page 173: ...cessary OPEN Electrically driven safety door has been applied E STOP is not active Door is not moving The safety door is opened by pressing the button SELECTOR SWITCH is at 1 Only the left hand workin...

Page 174: ...the machine control panel control panel user interface and is used exclusively for teach in programming All the actions required for teaching can be carried out from the teach panel TRUMPF has extend...

Page 175: ...he switch cabinet of the laser Fig 27492 Key switches on the laser switch cabinet Danger of electrical shocks The safety circuit of the machine has been bypassed All live components carry dangerous ch...

Page 176: ...RF generator etc will not activate the E STOP active The safety circuit of the system is active Opening a door switch cabinet RF generator etc activates the E STOP Master Control off The power supply...

Page 177: ...esignation of the NC axes pallets Fig 31106 Each start post is provided with an E STOP switch and a foot switch for acknowledging the respective light barriers Manually via switch elements or via exte...

Page 178: ...final position The pallets travel in work position towards a fixed stop They are not indexed in work position Danger of persons being struck or crushed in the area of the travelling tables Before pre...

Page 179: ...device is open Undefined status if button flashes at 2 Hz Button flashes at 4 Hz for transition between clamping and releasing The CLAMP button is disabled after pressing the ACKNOWLEDGE LOADING butt...

Page 180: ...the pallet manually into loading position The pallet keeps moving as long as the button is pressed down The pallet is stopped automatically once the final position has been reached Button flashes whi...

Page 181: ...ry switch in the switch cabinet of the machine Fig 31042 Caution As soon as and for as long as the rotary switch is at ON the Z axis will move down without braking until it reaches the stop Z 0 It is...

Page 182: ...ion B337ENE4_1 2 Operating panel with color display N10 N20 1 0 7 4 2 8 5 3 9 6 Esc LASER TEST LASER LASER 1 3 2 1 Operating devices of the machine 2 Color display 3 Operating devices of control syste...

Page 183: ...ON OFF 8 START 14 KEY SWITCH 2 FEEDRATE POTENTIOMETER 9 KEY SWITCH TEACH PANEL 3 ESTABLISH HOME POSITION BEAM BLOCK 15 LASER ON OFF 4 JOG MINUs 10 FEED HOLD 16 BEAM ON OFF POTENTIOMETER 11 KEY SWITCH...

Page 184: ...d by E STOP impact button and errors which actuate E STOP With MACHINE OFF The button flashes The power supply for the drives is switched off JOG KEYS E STOP is not active FEED HOLD is not active SETU...

Page 185: ...tton lights up as soon as the home position has been reached The illuminated button starts to flash if it is pressed again The button must be pressed every time the home position is to be established...

Page 186: ...m block is not active The laser beam is ignited or switched off by pressing this button Button is lit up as long as the beam is ignited LASER TEST LASER TEST FEED HOLD is not active The LASER test mod...

Page 187: ...de Feedrate with simultaneous axis motion 0 85 m min Screen display of the respective travel speed in percent and in m min E STOP None Pressing the impact button Stops all path movements of the machin...

Page 188: ...ITCH BEAM BLOCK None The safety circuit of the laser is inter rupted by turning the key switch Neither the pulse switch nor interface signals or the user interface can be used to ignite the laser beam...

Page 189: ...switched on or off by turning the key switch With teach panel active The machine can now only be operated by means of the teach panel LASER TEST is set automatically and the beam trap cannot be opene...

Page 190: ...ASER 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 14 1 DIAGNOSTICS 8 ESCAPE 15 FOCUS MENU 2 MAINTENANCE INITIAL START UP 9 ENTER 16 EXIT WINDOWS 3 TOOLING 10 DIGIT BLOCK 17 HELP 4 PROGRAMMING 11 PA...

Page 191: ...ds The buttons of the activated activity fields are illuminated PRODUCTION SETUP N10 N20 PROGRAMMING TOOLING MAINTENANCE DIAGNOSTICS EXIT WINDOWS None Pressing the EXIT WINDOWS button will shut down t...

Page 192: ...election within the menu bar FOCUS MENU None The cursor moves to the menu bar at the top edge of the screen if the FOCUS MENU key is pressed A menu can be selected and confirmed with ENTER PAGE UP PAG...

Page 193: ...d again with the same key CURSOR keys Cursor is on the screen The cursor buttons are used to move the cursor left right up or down on the screen The focus can be advanced element by element within a d...

Page 194: ...ment of the most important special keys is listed below F1 F1 is used to call up the online instruction guide F2 F9 These function keys are used for the softkey functions displayed at the bottom of th...

Page 195: ...his key and simultaneously enter a letter the letter appears in upper case INSERT Text passages previously marked and copied or cut out can be inserted at any position using the INSERT key DELETE The...

Page 196: ...the available topic blocks from which individual topics can be selected The menu bar is selected by pressing the FOCUS MENU key The desired topic can be selected there using the cursor keys The select...

Page 197: ...OG Machine in JOG submode SETUP activity Laser beam on beam trap closed AUTO Machine in AUTOMATIC submode PRODUCTION activity Laser beam on beam trap open MDA Machine in MDA submode Manual Data Automa...

Page 198: ...one or more separate frames Depending on the activity field selected are opened and current system statuses e g axis positions feed rate etc are displayed Individual fields can be selected using the...

Page 199: ...UTOMATIC submode The machine can only operate in the PRODUCTION activity field in AUTOMATIC submode This machine submode is indicated by the AUTO symbol in the status bar of the user interface If an N...

Page 200: ...selected with the six buttons to the right of the screen or via the menu bar of the user interface The activities can be divided into three groups Group 1 PRODUCTION SETUP Definition Parts programs c...

Page 201: ...um of three keys can be illuminated at the same time Group 2 N10 N20 PROGRAMMING MAINTENANCE INITIAL START UP TOOLING Analogous to the activities of group 1 the subordinate activities PROGRAMMING and...

Page 202: ...ions actual positions of these axes are displayed in the machine coordinate system MCS The remaining distance which the respective axis has to travel in order to reach the programmed setpoint is speci...

Page 203: ...ve axis has to travel in order to reach the programmed setpoint is specified in the third column of the table Geometry axes Distance to go nominal value actual value The unit of measure with which the...

Page 204: ...with the START button Program status running is also displayed if a feed block or read in block has been issued if feed rate correction is set to 0 if the axis monitoring system is triggered or if the...

Page 205: ...tched off with the Laser ON OFF button the automatic shutdown cycle will start and the resonator status Run down will be displayed At rest once the shutdown cycle has been completed the resonator will...

Page 206: ...igger switch The beam is switched off automatically by the control system after this time has expired Laser power displays the programmed laser output as a percentage of the rated laser output Gating...

Page 207: ...ed on the left hand side of the monitor parallel to the single job It is possible to select all of the switch element groups which belong to the PRODUCTION activity the switch elements can be operated...

Page 208: ...eet job has been released for processing Blocked the sheet job will not be taken into account during processing Ended the execution of the sheet job has ended Actual Required Main program the program...

Page 209: ...tines are in the first line The current position of the machine in the NC program section block number during the execution is displayed in the second line Program data The required number of program...

Page 210: ...ion in the 3 D working area Selection display Press the Display selection softkey in order to display information and switch elements on the left hand side of the monitor parallel to the processing pr...

Page 211: ...Instead of the automatic loading or unloading procedure manual loading or unloading is generated without the machine having to stop and issue an error message The deactivated components can still be o...

Page 212: ...a in front of the block number are ignored during the program sequence Test feed rate the fixed setting feed rate value is 5000 mm min If Test feed rate is activated If the programmed feed rate is gre...

Page 213: ...however only possible in the activity SETUP Correct rapid feed The correction switch for the feed rate also affects the rapid feed rate Programmed stop the program execution is stopped at the block i...

Page 214: ...an alarm window is opened containing the requirements for successfully switching over the switch element White green Switch over was successful The switch status described in words on the left is acti...

Page 215: ...AS characteristic curve The DIAS characteristic curve can only be recorded if the distance control system is switched on Distance control system press the switch to switch the distance control system...

Page 216: ...he respective task Collision recognition press the switch element when the reaction time of the distance control system is to be modified The reaction time of the distance control system after a recog...

Page 217: ...ng the applied delay of about 10 s The machine functions are idle during this time OFF There will be no pause when changing the type of gas or switching the gas pressure between piercing and cutting m...

Page 218: ...on dialog box e g for mode shots or with SERVICE MODE KEY SWITCH ON Zero point memory press the switch element to fill edit or delete the zero point memories G54 G55 G56 or G57 for individual axes or...

Page 219: ...brakes of the X and Y axes Closed Released Lubrication cycle status status display the status of the major automatic lubrication cycle will be displayed Off Requested Switch on On Delay time Activated...

Page 220: ...4_3 Welding switch elements Fig 27965en Welding switch elements Welding head release press this switch element to cancel E STOP after a collision involving the welding head during machining The axes a...

Page 221: ...Safety door open press switch element in order to open the safety door This switch element has no effect if the safety door has been isolated Undefined In motion Open Closed Open left Open right Safe...

Page 222: ...off and back on again The required reference run then starts auto matically Isolate safety door press switch element to isolate safety door The safety door can only be isolated in a static condition N...

Page 223: ...tus of front safety door Status display the status of the front safety door is displayed Closed In motion Open Status of right safety door Status display the status of the right hand safety door is di...

Page 224: ...applied to the machine the status of the door is displayed Left pallet changer status display switch elements Fig 27777en Closed Undefined Switch elements of the left pallet changer Position table X 1...

Page 225: ...play the coordinates of the table position are displayed Position table Y 1 Status display the coordinates of the table position are displayed Position table Y 2 Status display the coordinates of the...

Page 226: ...ation B337EN4_3 Right pallet changer status display switch elements Fig 27779en Switch elements of the right pallet changer Position table X 2 Status display the coordinates of the table position are...

Page 227: ...ricat count press the switch element to reset the lubrication counter to zero No of lubrications the number of major lubrication cycles which have been carried out will be displayed Number of Z lubric...

Page 228: ...auto matic mode as long as no other function has been programmed for the suction unit in the NC program The applied default setting of the vacuum flaps can be changed in JOG mode The selected setting...

Page 229: ...ning program depending on the position of the processing optics Closed Open Suction hose status optional Status display status of the flap for the suction unit interface provided by the customer Close...

Page 230: ...hine Separated support tables can be moved into the working area either separately one after the other or together after being coupled Indexing is actuated as soon as the table tables is are in the ri...

Page 231: ...if you want to index the table tables Disabled during active teach mode or the execution of a program The last switch element status active or inactive is retained Left index active actuate this switc...

Page 232: ...his switch element to active if you want to index the table tables Disabled during active teach mode or the execution of a program Indexing status left Status display Index released 2 way index both i...

Page 233: ...ff Slow purge actuate this switch element if you want to check whether the slow purge is switched on or off Fast gas supply actuate this switch element if you want to check if gas supply fast is switc...

Page 234: ...ther the turbine power supply is switched on or off Turbine 1 Start actuate this switch element if you want to check whether turbine 1 start is switched on or off Turbine 2 start the switch element is...

Page 235: ...ring the execution of an NC program on the machine a table from which the data is accessed by the control system is selected by means of a defined table call instruction Parameters such as cutting typ...

Page 236: ...ng parts will be flushed with gas when the gas is changed between piercing and cutting in accordance with the value entered The cutting gas is used for purging The same gas pressure is used as for cut...

Page 237: ...quired for machines with AutoLas Plus General cutting Manual setting dimension 7 setting dimension in mm States the position of the focus relative to the nozzle tip This value has to be set manually a...

Page 238: ...4 78 Operation B337EN4_3 Fig 39422 Fig 39423en Cutting a large contour Cutting a medium contour...

Page 239: ...he dimension is set automatically via the AutoLas Plus facility Laser output output of the laser in watts with which the programmed machining will be carried out This parameter is not effective if TC_...

Page 240: ...ameter is not required for machines without AutoLas Plus Piercing General AutoLas Plus 9 setting dimension AutoLas Plus setting dimension in mm States the position of the focus relative to the nozzle...

Page 241: ...ber of the ramp cycle which is executed when piercing the material Nozzle distance distance between the lower edge of the nozzle and the material surface in mm Blow out time this function is not avail...

Page 242: ...izing Nozzle distance distance between the lower edge of the nozzle and the material surface in mm Laser output output of the laser in watts with which the programmed machining will be carried out Thi...

Page 243: ...r edge of the nozzle and the material surface in mm Laser output output of the laser in watts with which the programmed machining will be carried out This parameter is not effective if TC_ACL is progr...

Page 244: ...hining will be carried out This parameter is not effective if TC_ACL is programmed for channel 1 Gating freq frequency in Hz with which the laser works 100 99000 Hz This parameter is not effective if...

Page 245: ...data input by pressing ENTER Switch between the input fields with TOGGLE Management Press the Management softkey in order to administer laser technology tables copy delete tables or reset table value...

Page 246: ...ions in automatic mode or after being previously selected in manual mode All parameters required for creating time dependent laser power cycles are stored in these tables Parameters can be subsequentl...

Page 247: ...ate the Cycle number softkey to go directly to the cycle number parameter in order to for example repeat an entry Active cycle Actuate the Active cycle softkey to select the cycle currently active Cyc...

Page 248: ...are stored in these tables The table programmed in the TC_LASER_WELD_ON cycle is accessed when executing an NC program Welding table names consist of a maximum of 10 alphanumeric characters and must b...

Page 249: ...ace Nozzle nozzle used notes space Pre warming time time in seconds during which the laser beam is switched on with the beam trap closed Pre warming output power in watts at which the laser beam is sw...

Page 250: ...en optional flow rate in l min 0 gas is inactive 0 gas is active When quantity regulation valves are utilized optional the flow rate must be entered Other shield gas optional flow rate in l min 0 gas...

Page 251: ...flow rate in l min 0 gas is inactive 0 gas is active When quantity regulation valves are utilized optional the flow rate must be entered Other shield gas flow rate in l min 0 gas is inactive 0 gas is...

Page 252: ...he data groups without having to scroll from page to page Page Press the Page softkey to go directly to the selection field of the welding technology data package Parameter Actuate the Parameters soft...

Page 253: ...g TPT 1 Fig 30936en Tube section technology table Cross section identification system for the geometry of the tube The default value 0 becomes effective if no value is entered Page 2 Cutting around co...

Page 254: ...uated for each step Fig 30937en Cutting around corners Programmed nozzle distance Step 1 the actual nozzle distance is increased by the value entered when the distance control system is actuated for S...

Page 255: ...he data groups without having to scroll from page to page Page Press the Page softkey to go directly to the selection field of the welding technology data package Parameter Actuate the Parameters soft...

Page 256: ...t jobs can only be generated from NC programs which are available in the NCU in split form Exactly one NC program is allocated to each sheet job The following are determined in the sheet job or 14 Val...

Page 257: ...be taken into account during processing Ended the execution of the sheet job has ended Actual Required Name the display shows the name of the sheet job Any character or number sequence can be entered...

Page 258: ...h to erase a sheet job from the production plan sums Set status Press the Set status softkey if you wish to change the status of the selected sheet job Press the softkey repeatedly until the desired s...

Page 259: ...locked the sheet job will not be taken into account during processing Active the sheet job is currently being processed Ended the execution of the sheet job has ended Actual Required Name the display...

Page 260: ...hine Note If a pallet changer is applied at the system then the Summary production plan is in effect Sheet jobs can only be generated from NC programs which are available in the NCU in split form Exac...

Page 261: ...aused after processing of the sheet job Blocked the sheet job is not enabled for processing and will not be processed The status needs to be set by the operator Ended the execution of the sheet job ha...

Page 262: ...ressed again for confirmation Modifying sheet job Press Modify sheet job softkey to modify the data of a sheet job in the production plan Delete sheet job Press the Delete sheet job softkey to delete...

Page 263: ...ns at the press of a button without having to know the respective NC functions Only those switch elements can be actuated which are appropriate for the current operation situation and can be carried o...

Page 264: ...the DIAS characteristic curve The DIAS characteristic curve can only be recorded if the distance control system is switched on Distance control system press the switch to switch the distance control s...

Page 265: ...the respective task Collision recognition press the switch element when the reaction time of the distance control system is to be modified The reaction time of the distance control system after a reco...

Page 266: ...as or switching the gas pressure between piercing and cutting machining will resume at once On A TIMER will be started when changing the type of gas or switching the gas pressure between piercing and...

Page 267: ...ntification connector of the welding head is installed The same applies if no processing optics are installed and no optics have been selected in the Head selection dialog box e g for mode shots or wi...

Page 268: ...Part 3 Operating the machine section Filling zero point memories G54 to G57 Auto shutdown press the switch element in order to switch the auto shutdown on or off ON after the processing program or a j...

Page 269: ...switch elements Type of gas press the switch element to select a gas type and gas pressure A dialog is started by pressing this switch element Gas pressure display of the current gas pressure Prometec...

Page 270: ...Head selection see chapter Setting work section Changing the processing optics The default setting of this switch element is OFF Measurement functions this switch element must be pressed when using t...

Page 271: ...configuration stage Gas Ar Weld head actuate this switch element to select the welding gas argon at the welding head Gas He Weld head actuate this switch element to select the welding gas helium at t...

Page 272: ...r lubrication cycles which have been carried out will be displayed Number of Z lubrications the number of minor lubrication cycles of the Z axis which have been carried out will be displayed Gantry sy...

Page 273: ...switch element if you wish to move the X1 table into loading position The following statuses are possible In loading position In work position In motion Not applied X1 table work position Actuate thi...

Page 274: ...n loading position In work position In motion Not applied Y1 table loading position Actuate this switch element if you wish to move the Y1 table into loading position The following statuses are possib...

Page 275: ...position In work position In motion Not applied Y2 table work position Actuate this switch element if you wish to move the Y2 table into work position The following statuses are possible In loading p...

Page 276: ...s switch element if you wish to move the X2 table into loading position The following statuses are possible In loading position In work position In motion Not applied X2 table work position Actuate th...

Page 277: ...move the X1 table with the JOG buttons Status table X1 The X1 table position is displayed The follow ing statuses are possible In loading position In work position In motion Not applied Release brake...

Page 278: ...ttons Jog mode table Y2 Actuate this switch element if you wish to move the Y2 table with the JOG buttons Status table Y The Y2 table position is displayed The following statuses are possible In loadi...

Page 279: ...elease brake table Y1 Actuate this switch element if you wish to move the Y1 table after a collision axis switch actuation The default setting of this switch element is OFF E STOP must be active in or...

Page 280: ...o move the X2 table with the JOG buttons Status table X2 The X2 table position is displayed The following statuses are possible In loading position In work position In motion Not applied Release brake...

Page 281: ...the suction unit The default setting of this switch element is OFF It is not possible to switch off the suction unit during the lag time of the filtering installation if the switch element is set to...

Page 282: ...f the machine Separated support tables can be moved into the working area either separately one after the other or together after being coupled Indexing is actuated as soon as the table tables is are...

Page 283: ...ant to index the table tables Disabled during active teach mode or the execution of a program The last switch element status active or inactive is retained Left index active actuate this switch elemen...

Page 284: ...this switch element to active if you want to index the table tables Disabled during active teach mode or the execution of a program Indexing status left Status display Index released 2 way index both...

Page 285: ...d either manually by means of switch elements or automatically from the NC program A maximum of three safety doors each consisting of three parts can be installed at the machine The switch elements of...

Page 286: ...ve as long as the safety door is not referenced the switch element will continue to flash red green Reference run active Referenced Drive OFF if a malfunction occurs during the reference run this can...

Page 287: ...ront safety doors switch element group illustrated below Fig 34599en Left safety doors Front safety doors Right safety doors Front safety doors Safety door open actuate this switch element when you wi...

Page 288: ...cuum pump on or off Purge fast actuate this switch element to switch the valves on or off for fast purging of the resonator Purge slowly actuate this switch element to switch the valves on or off for...

Page 289: ...if the mask is changed until this switch element is reset to OFF Turbine mains voltage actuate this switch element to switch on or off the mains voltage at the frequency converter of the radial turbi...

Page 290: ...axis The axis marked in yellow can be moved in jog mode by means of JOG buttons Selection Press Select to change to the list of SET UP switch elements Pressure control actuate this switch element to...

Page 291: ...de the NC axis highlighted in yellow selected by pressing the corresponding softkey can be moved manually using the JOG buttons The current actual positions are displayed in the axis table Reference p...

Page 292: ...system adds M30 automatically The MDA submode is disabled at the control panel if the TEACH PANEL KEY SWITCH is active Fig 27969en Warning The axes travel immediately to the first axis position progr...

Page 293: ...in this field Actions can be triggered or procedures blocked depending on the current program status Three different statuses can be displayed Program status running is displayed when a part program...

Page 294: ...ser beam and SERVICE MODE OFF menus the laser is in one of the three operating modes for production LLS normal LLS analog LLS cycles With SERVICE MODE ON the operation modes ALIGNMENT ON and ALIGNMENT...

Page 295: ...quired submode CW PULSING F PULSING T Duration display Laser power CW mode enter value between 75 and 100 PULSING F enter value between 1 and 100 Gating frequency PULSING F enter value between 100 Hz...

Page 296: ...ected in Alignment on operating mode Alignment OFF Duration Enter the duration for igniting the beam using the pulse trigger switch This value may not be greater than 25000 ms Laser output CW mode ent...

Page 297: ...hed off with the Laser ON OFF button the automatic shutdown cycle will start and the resonator status Run down will be displayed At rest once the shutdown cycle has been completed the resonator will h...

Page 298: ...ion display of duration for beam ON with active service mode open beam trap and actuated pulse trigger switch The beam is switched off automatically by the control system after this time has expired L...

Page 299: ...using the focus key The call up parameters can be entered directly into the selected cycle To help you edit NC texts you can use the softkeys and the integrated programming guide which provides consta...

Page 300: ...passages you wish to insert elsewhere Mark these text passages first by pressing the SHIFT and CURSOR keys simultaneously Paste Press the Paste softkey to insert NC text passages you have copied or cu...

Page 301: ...rogram MP contains subroutines SR these can be displayed by selecting the main program in question with the ENTER key Status origin date of creation modification and size are displayed for each progra...

Page 302: ...Program overview softkey to switch to the list of main programs Program notes Press the Program notes softkey to enter notes on a particular program Editor Press the NC Editor softkey to view or edit...

Page 303: ...ferred to the machine control system are stored in this directory as a master file In addition all network drives to which your control system is connected and the disk drive A are displayed In this m...

Page 304: ...om file Press the Subroutine from file softkey to transfer a file as subroutine to the program manager The corresponding main program must however already exist Application test programs created manua...

Page 305: ...tion You can also copy individual program sections as a file to the hard drive or to a diskette This menu appears if you press the Output program softkey within the PROGRAMMING File management activit...

Page 306: ...the hard drive Copy file Press the Copy file softkey to copy a program section main program or subroutine as a file to the hard drive Program overview Press the Program overview softkey to switch to...

Page 307: ...appears if you press the Select program softkey from the PRODUCTION Single job menu The list of programs is identical to that shown in the PROGRAMMING NC program management menu Only the allocation of...

Page 308: ...ob Press the Create sheet job softkey if you wish to accept the selected NC program as a sheet job in the production plan sums Production plan Press the Production plan sums softkey to switch to the p...

Page 309: ...system The following convention is recommended Note The distance from the machine s zero point to the center of the rotational axis A axis must be entered in the zero point memory G56 for the X Y and...

Page 310: ...ss the Modify softkey to activate the input field The value for the selected axis is changed in the input field Confirm the entry with the ENTER key Select function Press the Select function softkey t...

Page 311: ...defective hard drive or similar TRUMPF Customer Service must always be informed in such a case though since data is only allowed to be restored by service technicians even if the data concerned is cus...

Page 312: ...service technicians 8 2 MAINTENANCE INITIAL START UP Display The desired language and measurement system metric inch can be selected in the display menu Fig 27983EN Softkeys Adopt language Press the...

Page 313: ...A system status message is issued for the waiting component when the respective maintenance interval expires The real time interval appears in the interval column once a maintenance task has been ack...

Page 314: ...ia softkeys but also the cause effect error location and measures for eliminating the error Fig 27975EN Softkeys All Press the All softkey if the list with all errors and messages is to be displayed E...

Page 315: ...ic machine the laser and the automation components appear in the displayed mask The bits of the inputs and outputs and their respective status are displayed in the table The assignment to the names of...

Page 316: ...us locate and if necessary solve problems Remote diagnostics must be activated on site at the control system Fig 28435EN Softkeys Start Press the Start softkey to start remote diagnostics Menu Press t...

Page 317: ...ervice mode Note These values may only be modified by TRUMPF Customer Service or by specially trained technicians Fig 28436EN Softkeys Beam data Press the Beam data softkey if you wish to switch to th...

Page 318: ...The established leak rate is displayed in hPa Start pressure Enter the desired pressure at which the leak test starts e g 10 hPa End pressure The prevailing pressure in the laser after the entered ti...

Page 319: ...the comment line After the entered time has elapsed the pressure inside the laser is measured end pressure and used to calculate and display the leak rate leak rate end pressure start pressure duratio...

Page 320: ...nd black home position symbol appears next to the corresponding system component if it is in home position Fig 32399EN Softkeys Selection Display Press the Selection Display softkey to display current...

Page 321: ...untime However each interruption should also be assigned a reason in order to analyze machine operation precisely MDC message texts indicate exactly these reasons They are first stored by the operator...

Page 322: ...appears You can see all available messages texts in a list You can see the four reason types Rest period Active repair time Maintenance period and Non productive operating time as well as the message...

Page 323: ...is added to the list beneath the father text Delete MDC text To delete a message text select it from the list and then press the Delete MDC text softkey A window appears in which you are prompted to...

Page 324: ...ee a list in the mask of all the messages of the machine control system PLC message recorded within a period of time defined by the user The following information is displayed for each message Display...

Page 325: ...elf cannot be deleted Create modify If you wish to assign a new or a different message text to an interruption or if you wish to subdivide an interruption into periods of time select the corresponding...

Page 326: ...ars Fig 31274EN The mask is subdivided into three sections Creating and modifying interruptions You can see the message text of the selected interruption message as well as its exact time data in the...

Page 327: ...and the system returns directly to the Machine data collection mask Back Press the Back softkey to return to the Machine data collection mask 10 5 MDC Evaluating machine data You can have all of the r...

Page 328: ...Create evaluation softkey The program then generates the corresponding evaluation and adds it to the list beneath the input line Delete evaluation To delete an evaluation select it from the list and...

Page 329: ...ng information on the evaluated data appears below it Interr no the number of the interruption message Interruption text the corresponding message No the number of these messages within this period of...

Page 330: ...auswert txt already exists in this directory it is saved under the name ausw_old txt in the same directory while the new file is being created Back Actuate the Back softkey to return to the Evaluating...

Page 331: ...safety guidelines in the operator s manual must be strictly observed The machine may only be operated by trained personnel Calling up the online help To call up the online help Press HELP or To selec...

Page 332: ...NU Select Help Programming guide Or press button 3 3 Press ENTER Online help is opened the table of contents for the programming guide is displayed Or context sensitive activation in the NC Editor Sel...

Page 333: ...s of the Operating guide menu item in the Help main menu Press FOCUS MENU Select Help Operating guide Or press button 3 2 Press ENTER Online help is opened the table of contents for the user s guide i...

Page 334: ...rt up pressure The laser is filled with laser gas and the pressure raised to working pressure The radial turbine blower is switched on The button lights up when the laser is ready for operation The LI...

Page 335: ...oling unit and the vacuum pump are switched off The entire shutdown cycle is over after about 3 minutes The lamp in the button goes out when the laser is no longer ready for operation Press the MACHIN...

Page 336: ...er beam is switched off The beam trap is closed All motion stops The cutting gas supply is interrupted 2 2 Cancelling E STOP E STOP is triggered by pressing the E STOP impact button Eliminate the malf...

Page 337: ...e NC program is resumed at the point of interruption 3 3 Acknowledging FEED HOLD after a collision involving the nozzle FEED HOLD is triggered if the cutting nozzle collides with the sheet surface whi...

Page 338: ...that the optics have been discarded and UDP OFF is triggered as a consequence Unlock the E STOP impact button Select Operation Set up JOG mode Move the axes away from the point of collision using the...

Page 339: ...rive brakes Select SET UP Switch elements Service Select Releas brakes w o Z Press TOGGLE Press the ESTABLISH HOME POSITION button if it is flashing Press ESTABLISH HOME POSITION The axes travel to th...

Page 340: ...eased The brake is reapplied Unlock the E STOP impact button Press the ESTABLISH HOME POSITION button if it is flashing Press ESTABLISH HOME POSITION The axes travel to the reference point of the mach...

Page 341: ...program Select program Actuate the Select program softkey The settings at the cutting head are checked Press the START PROGRAM button The NC program is executed Prerequisite The machine is ready for o...

Page 342: ...es Press the START button FEED HOLD is acknowledged The machine resumes operation 4 3 Aborting a program The following operation steps should be performed if an NC program is to be stopped and not res...

Page 343: ...e in which program can be processed without the laser beam ignited LASER TEST button is lit up than on the marking test mode function Select Operation Set up Switch elements General Select Test markin...

Page 344: ...o point is set and immediately activated for all axes by programming these commands There are two ways of filling the zero point memory for individual axes several axes or all axes Note The coordinate...

Page 345: ...e machine coordinate system is active Continue Press Continue The TLC zero point memories G54 G55 G56 G57 mask is displayed while the control system loads the current actual positions of the axes and...

Page 346: ...nitial screen mask once the transmission is finished Exit Abort Press Exit Abort The process is over The dialog box is closed Note the dialog is aborted if this softkey is pressed before the Adopt sof...

Page 347: ...l axes Press All axes The TLC zero point memory all axes mask is opened Set all Press Set all The current axis positions in the Actual position field are entered in the Default position field Back Pre...

Page 348: ...itch elements General or select Production Switch elements General Select Zero point memory Press TOGGLE The display switches to ON The TLC zero point memory initialization mask appears The workpiece...

Page 349: ...int memory Individual axes Press Individual axes The TLC zero point memory individual axes mask is opened Select If needed press Select round Note the Select softkey can be used to switch to and fro b...

Page 350: ...sition field are transferred to the selected zero point memory Default position becomes Defined position and thus takes effect in the NCU The TLC zero point memories G54 G55 G56 G57 mask is displayed...

Page 351: ...zation mask appears Continue Press Continue The TLC zero point memories G54 G55 G56 G57 mask is displayed while the control system loads the current actual positions of the axes and the axis positions...

Page 352: ...lues in the zero point memory have not yet been deleted Fig 36070en Back Press Back Adopt Press Adopt The axis positions entered in the Defined position field are set to 0 for all axes The TLC zero po...

Page 353: ...on Switch elements General Select Zero point memory Press TOGGLE The display switches to ON The TLC zero point memory initialization mask appears Continue Press Continue The TLC zero point memories G5...

Page 354: ...e display is changed The values in the zero point memory have not yet been deleted Example Linear axes selection Fig 36069en Back Press Back Adopt Press Adopt The axis positions entered in the Defined...

Page 355: ...ing process for the code of the start posts begins at the pallet positioned furthest to the left The start post for this pallet is therefore assigned the code 1 This is the start post for the PCX1 pal...

Page 356: ...therefore always checked at the start of the summary production plan This sheet job begins as soon as the control system recognizes that the codes are identical and provided the sheet job is not yet...

Page 357: ...ctual Loca tion Pallets 10 Free 11 4711 5 3 01 PCY2 20 Free 12 4712 10 7 10 PWY1 30 Free 13 4713 5 4 01 PCY2 40 Free 14 4714 10 8 11 PCY1 PCY2 In this example the sheet jobs 11 12 and 13 are to proces...

Page 358: ...Create sheet job Enter the job data Create sheet job Press Create sheet job The message Sheet job has been created appears in the message line Repeat these steps until all NC programs to be added to t...

Page 359: ...is required Production Start Stop Press Production Start Stop The summary production plan is active Press ACKNOWLEDGE LOADING at the start post The pallet moves into work position The safety door is c...

Page 360: ...ect Operation PRODUCTION Single job Production plan Press Production plan Or Select Activity PRODUCTION Production plan Production Start Stop Press Production Start Stop The execution of the summary p...

Page 361: ...the control panel Note If a pallet changer is applied at the unit then the summary production plan is in effect instead of the production plan Sheet jobs can only be generated from NC programs which a...

Page 362: ...et job Press Create sheet job The message Sheet job has been created appears in the message line Select the NC program Repeat these steps until all NC programs to be added to the production plan have...

Page 363: ...to bottom Every NC program with the status free will be processed once Afterwards the status of the NC program switches to paused All of the workpieces must be loaded before the next run through can b...

Page 364: ...t Operation PRODUCTION Single job Production plan Press Production plan Or Select Activity PRODUCTION Production plan Production Start Stop Press Production Start Stop The execution of the production...

Page 365: ...Indexing support tables2 Select Operation Set up Switch elements Indexing Select Indexing active Press TOGGLE Set the switch element to ACTIVE Push the table tables into the working area of the machin...

Page 366: ...t of the working area of the machine 10 3 Undoing pneumatic indexing The index pin has to be released manually The release time can be set as required by means of a pneumatic timer The index pin reeng...

Page 367: ...to the user interface The switch elements of the components which have not been applied are in light gray in the Left pallet changer and Right pallet changer switch elements groups but are disabled T...

Page 368: ...d Press TOGGLE The pallets are coupled The mechanical coupling pin locks into place 11 2 Separating pallets Select SET UP Switch elements Pallet changer Set Separate pallets to Separated Press TOGGLE...

Page 369: ...allet is in motion 11 4 Moving pallets in automatic mode Press CLAMP The lamp in the button goes out Press ACKNOWLEDGE LOADING The lamp in the button goes out The CLAMP button is disabled If the light...

Page 370: ...e electrically driven safety doors are available in different versions The electrically driven safety doors can be opened or closed either manually using switch elements or automatically by means of t...

Page 371: ...fy obstacles within the danger zone Before opening the door the operator must make sure that nobody is within the danger zone and that a collision with the pallet changer is not possible Prerequisite...

Page 372: ...afety door switch element switches from Active to Referenced as soon as the reference run has been carried out successfully Note The electrically driven safety doors with the MxP101 drive system from...

Page 373: ...opened or Select SET UP Switch elements Safety doors Press Open safety door Press TOGGLE The safety door is opened 12 5 Closing the safety door At the safety cabin press CLOSE The safety door is clos...

Page 374: ...s Front safety doors Set Isolate safety door to On Press TOGGLE The door leafs are undocked from the drive system Push the door leafs away from the obstacle by hand Set Isolate safety door to Off Pres...

Page 375: ...ously A release run is carried out The switch element status switches to Released as soon as the reference run has been carried out successfully Further collision during the release run or internal co...

Page 376: ...ion cycle begins immediately starting at the current axis position Risk of collision between Z center sleeve processing optics and fixture or workpiece resulting in considerable damage to property The...

Page 377: ...e Press TOGGLE The display switches to ON The lubrication cycle is started The Lubrication cycle mask appears Fig 36071en Continue Press Continue The Current lubrication cycle configuration mask appea...

Page 378: ...he user interface during the lubrication cycle The dialog box can be exited at any time by pressing the Close softkey This has no affect on the lubrication cycle Only the display is closed 13 2 Starti...

Page 379: ...tarted button flashes The cooling unit and vacuum pump are switched on The pressure in the laser is reduced to start up pressure The laser is filled with laser gas and the pressure raised to working p...

Page 380: ...ay reads 1100 hPa before turning the system off at the main switch Laser gas supply Close the shutoff valves for the laser gas supply nitrogen carbon dioxide and last of all helium 14 3 Igniting the l...

Page 381: ...the button goes out 14 5 Opening the beam trap Press the OPEN CLOSE BEAM TRAP button The button is lit up if the beam trap is open 14 6 Closing the beam trap Press the OPEN CLOSE BEAM TRAP button The...

Page 382: ...4 8 Setting laser operation mode Select the SET UP Adjust laser beam activity field Operation mode Press the Operation mode softkey The selected laser operation mode is highlighted in blue A program c...

Page 383: ...ser power Select the SET UP Adjust laser beam activity field Use the focus key to select the Laser output display field 7 4 1 2 3 5 6 8 9 0 Use the keyboard to enter the desired laser output With an i...

Page 384: ...3 5 6 8 9 0 Use the keyboard to enter the start pressure Use the focus key to select the Measuring time display field 7 4 1 2 3 5 6 8 9 0 Use the keyboard to enter the start pressure The default measu...

Page 385: ...sures for eliminating errors are displayed Select the DIAGNOSTICS Fault diagnostics activity field An overview list of all current error messages is displayed Select the error message you wish to exam...

Page 386: ...ion field All inputs and outputs appear on the displayed mask Example You want to check whether the 2nd bit of input E33 has been set Keep on pressing the buttons until you reach the green bar in colu...

Page 387: ...e via modem and logs on with user name and password The machine checks the user name and password The modem connection between TRUMPF and the customer is now established Menu Actuate the Menu softkey...

Page 388: ...achine N10 N20 Select the PROGRAMMING File management activity field Select the drive column using the FOCUS key Select the drive A using the CURSOR keys Confirm with the TOGGLE key The contents of th...

Page 389: ...machine N10 N20 Select the PROGRAMMING File management activity field Select the drive column using the FOCUS key Select the C DH TOPSMANU DIR drive using the CURSOR keys Actuate ENTER The contents of...

Page 390: ...te N10 N20 Select the PROGRAMMING File management activity field Output program Press the Output program softkey Select the desired program with the CURSOR keys Insert a 3 5 diskette in the disk drive...

Page 391: ...eously displayed N10 N20 Select the PROGRAMMING File management activity field Output program Press the Output program softkey Select one or several programs SHIFT CURSOR Generate master file Press th...

Page 392: ...0 Select the PROGRAMMING File management activity field Output program Press the Output program softkey Select the desired program part main program or subroutine using the CURSOR keys Insert a 3 5 di...

Page 393: ...s the Delete MP SR softkey OK Press the OK softkey The NC program is deleted from the program manager of the control system together with all program parts and table entries If the NC program is also...

Page 394: ...ired program with the CURSOR keys Editor Press the Editor softkey If an NC program consists of several parts main programs and subroutines the correct program has to be selected once again from the di...

Page 395: ...xt Search Replace Press the Search Replace softkey Enter G90 in the input field OK Press the OK softkey G90 is marked in red in the NC text Search Re place Next If you have not yet found the desired t...

Page 396: ...up in yellow Enter G01 into the input box OK Press the OK softkey The function G00 is replaced by the function G01 Inserting an additional line Position the cursor bar at the start of the block in fro...

Page 397: ...t you wish to copy using the CURSOR keys The text appears in red Copy Press the Copy softkey Position the cursor bar at the start of the block in front of which you wish to insert the copied text pass...

Page 398: ...FT Hold down the SHIFT key and mark the text you wish to delete using the CURSOR keys The text appears in red Cut Press the Cut softkey The text passage is deleted but can be reinserted at any positio...

Page 399: ...ime the respective table is called up These changes are active in all NC programs in which the edited laser technology table is called up Position the cursor bar directly in front of the respect table...

Page 400: ...d maintenance tasks has to be performed the maintenance task has to be acknowledged after it has been carried out as follows Select the MAINTENANCE START UP Maintenance logbook activity Select the mai...

Page 401: ...tion refer to chapter Operation section Integrated MDR activity optional 20 1 Creating a message text New message texts can only be attached to message texts which already exist The message text to be...

Page 402: ...DR Data The Machine data collection mask is opened A list is displayed of all message texts during the entered period of time Select an interruption Stationary message to assign to a message text to C...

Page 403: ...Data Select an interruption Stationary message of which the time interval is to be split up Change text Press Change text The Create change MDR interruption mask is opened Select a message text Press...

Page 404: ...nter the title in the Comments input field Evaluate Press Evaluate The title and period of time are displayed in the list field Select Evaluation Display list Press Display list All downtimes within t...

Page 405: ...1 Opening a LOG file The operation data is saved monthly in a LOG file A data record is created for each workpiece Up to 25 000 data records can be stored per file The file name is made up of the year...

Page 406: ...ans of a spreadsheet program such as MS EXCEL 1 Open the LOG file in MS Excel Text wizard step 1 appears 2 Select the file type Separated 3 Select Continue Text wizard step 2 appears 4 Select the tab...

Page 407: ...reload the stored data back onto the PCU 50 on his own Machine data which have been changed in the meantime could be overwritten Prerequisite The control system starts up When the following image appe...

Page 408: ...4 248 Operation B337EN4_8 Fig 36634 Fig 36630 4 Select Backup to ZIP press 4 5 Press Enter...

Page 409: ...B337EN4_8 Operation 4 249 Fig 36626 Fig 36627 Backup starts 6 Enter file name press Enter 7 Press Y...

Page 410: ...approximately 30 to 40 minutes When the memory capacity of the first ZIP disk has been reached the lower display field will start flashing When the backup has been completed the following image will a...

Page 411: ...d not be run in normal operation when a Zip drive is connected to it 10 Press Enter 11 Switch off MAIN SWITCH in order to separate the ZIP drive from the control system and to delete temporary files 1...

Page 412: ...4 252 Operation B337EN4_8...

Page 413: ...5...

Page 414: ...ecking C axis and setting reference offset value 5 7 3 2 Checking the B axis and setting the reference offset value 5 9 4 Selecting processing optics 5 13 4 1 Selecting the cutting head 5 14 4 2 Selec...

Page 415: ...hines with AutoLas Plus 5 47 7 Determining the joint offset 5 65 7 1 Determine link offset of X and Y axis 5 67 Determining the joint offset for cutting head 5 67 Determining the joint offset for the...

Page 416: ...in Z direction 5 91 15 3 Swivelling the rotational axis by 90 5 92 16 Setting the back stop optional 5 93 16 1 Shifting the rotational axis horizontally in X direction 5 93 17 Further service program...

Page 417: ...nd eye injuries may occur Setting work which requires 100 laser power may only be carried out by specially trained service personnel Protective gloves and laser safety glasses must be worn during sett...

Page 418: ...Welding head CP_OFFSET_CUT LST CP_OFFSET_WELD LST At start up After installing new processing optics for which the joint offset has not been determined Determining the joint offset of the Z axis tool...

Page 419: ...Note All setting and maintenance work on optical components of the machine must be carried out in a clean environment and with clean hands 3 Checking and setting B and C axes To ensure the positioning...

Page 420: ...gauge C axis reference area 1 Select Operation Set up MDA 2 Enter B0 C0 3 Press Start The B and C axes travel to 0 4 Install the dial gauge and align it to the reference area Set the dial gauge to 0 5...

Page 421: ...9 Select C axis 10 Calculate the reference offset value If the actual value display for the C axis is in the positive range add the actual value to the application parameter If the actual value displa...

Page 422: ...lue Prerequisite The cutting or welding head has been fully installed The C axis has been checked and set Additional equipment tools material Dial gauge and measuring probe with stand SW4 SW5 hexagon...

Page 423: ...the measuring probe and align it to the reference area 5 Move the X axis slowly in jog mode enabling the pointer of the measuring probe to the reference area While doing so check the display on the m...

Page 424: ...on the B C angular gear 3 Undo the clamping screw for the friction clutch in the B C angular gear until the C axis can be turned with difficulty by hand 4 Select Operation Set up MDA 5 Enter B0 6 Pre...

Page 425: ...BS mark corresponds to the 0 reference marker again 10 Tighten the slipping clutch clamping screw hand tight Screw in the securing screw 11 Select Operation Set up MDA 12 Enter B0 C0 13 Press Start Th...

Page 426: ...iece The axis motion will not correspond to the programmed path When the Head change switch element is selected an identification dialog will only be started if the joint offset values entered in the...

Page 427: ...g if the wrong selection is made the control system identifies the identification connector of the welding head The dialog can be aborted by the user at any time using the Abort softkey 4 Press TOGGLE...

Page 428: ...utting head mask Note The Axis joint offset fields will be retained in the event of a software update The Information softkey is used to open the online help The Default values softkey is used to over...

Page 429: ...hed 4 2 Selecting the welding head Prerequisite The welding head is fully mounted The joint offset values have been determined and saved in the data management 1 Select Operation Set up Service 2 Set...

Page 430: ...sed to open the help on a particular subject The Default values softkey is used to overwrite the current joint offset for all axes of the selected optics with the theoretical joint offset 8 If needed...

Page 431: ...ed 10 Press Continue The joint offset is transferred to the machine data and is immediately effective in the control system NCU The Results display mask opens The current valid input range for the foc...

Page 432: ...8 9 10 1 Unassigned 2 Cutting gas connection 3 Cooling water return connection 4 Distance control system connection 5 Measuring probe connection 6 Cooling water supply connection 7 Beam guideway venti...

Page 433: ...off cutting head beam guideway using plugs danger of contamination 5 2 Mounting the cutting head 1 Move the Z center sleeve into a good changing position 2 Select Operation Set up MDA 3 Enter B0 C0 4...

Page 434: ...will be directed evenly around the focus spot 1 2 a b c 1 Nozzle orifice 2 Laser beam a Laser beam centered b c Laser beam off center Centering the laser beam to the nozzle Prerequisite The cutting h...

Page 435: ...Center it with the alignment pin 3 4 Tighten both fixing screws 4 hand tight 5 First screw in the adjusting screws 1 and position gently 6 Then screw in the dial gauges 2 and tighten hand tight 7 Res...

Page 436: ...space in jog mode 6 Select Operation Set up General switch elements 7 Set the He Ne targeting laser switch element to OFF 8 Select CP_TAPESHOT program 9 Press START PROGRAM A mask is opened 10 Select...

Page 437: ...d with the clamping screws 6 The sensor body and nozzle are connected rigidly The beam is adjusted by moving the sensor body 8 5 4 7 1 6 2 3 1 Adjusting screw 2 Dial gauge 3 Alignment pin 4 Fixing scr...

Page 438: ...rea are oval After finishing centering 3 Tighten the four clamping screws 6 on the cutting insert hand tight 4 Dismantle the setting device 5 Put the protective plug onto the cutting insert 5 and tigh...

Page 439: ...e nozzle tip Setting dimension 0 Focus is positioned below the nozzle tip Setting value and focus position Machines without AutoLas Plus On machines without AutoLas Plus the setting dimension must be...

Page 440: ...e parameter in the General laser technology table Character istic curve Processing optics 1 5 cutting head High pressure cutting 2 5 cutting head Standard pressure cutting 3 7 5 cutting head High pres...

Page 441: ...selection asking whether the correct setting value has been set on the cutting head If the AutoLas Plus setting from the laser technology table is outside the automatic setting range the differential...

Page 442: ...hile it is turned Each time it snaps the height is adjusted by 0 1 mm Example The setting dimension in the laser technology table is 1 1 mm The focus adjustment screw must be turned counter clockwise...

Page 443: ...ical value engraved for each gap defines the adjustment value by which the fixed setting value 3 mm or 5 mm has to be corrected on the focus adjustment screw The actual focus position f 0 corresponds...

Page 444: ...mm thickness gauge for 7 5 cutting head CP_FOCUS_CUT LST service program 1 Close the door 2 Position the cutting head above the sheet 3 Activate the CP_FOCUS_CUT program 4 Press START PROGRAM A dialo...

Page 445: ...ition 0 4 mm upwards Adjustment value 1 0 Turn the focus adjustment screw to shift the focus position 1 0 mm downwards 2 Reference the scale to the fixed setting value 3 0 or 5 0 Undo the clamping scr...

Page 446: ...nection 4 Welding wire feed driving motor electrical connection 5 Crossjet connection 6 Cooling water supply connection 7 TSD seam sensor system or welding wire feed connection 8 Welding nozzle Instal...

Page 447: ...r beam After cleaning or replacing the parabolic mirror The CP_TAPESHOT LST service program is used to trigger a laser pulse Additional equipment tools material Measuring magnifier 10 to 20 times enla...

Page 448: ...r washers of the appropriate thickness between the mirror carrier and housing Spacer washers of different thicknesses belong to the standard equipment of the machine 1 3 4 5 4 6 2 7 8 1 Adjusting scre...

Page 449: ...n X direction Undo the fixing screws on the mirror carrier Undo the hexagonal nut Adjust the adjusting screw Push the mirror carrier against the adjusting screw and retighten the fixing screws hand ti...

Page 450: ...the parabolic mirror in the welding head After adjusting the mode or the beam After mounting a factory fresh welding head for which the focus position has not yet been determined For machines without...

Page 451: ...focus position is corrected by the software A distinction is made between two strategies while doing so Focus search without power dependent focus shift the focus position is determined once at maximu...

Page 452: ...lding table are preset Recommended values that can be edited by the user as needed General welding table The feed rate laser output and warm up power parameters are dependent upon the laser used these...

Page 453: ...tool length will always need to be redetermined afterwards see Section 7 2 Determining joint offset Z axis tool length 2 3 4 mm 11 5 mm 1 A B A Welding head f 150 B Welding head f 200 or f 270 1 11 5...

Page 454: ...mm Prerequisite The welding head is fully mounted A nominal dimension of 4 mm is set at the welding head or a sleeve with a nominal dimension of 11 5 mm is utilized The beam is centered Clean nozzle i...

Page 455: ...for the current welding optics 14 Press Continue 15 Press following page 16 Press Start approximate search Program starts from the current axis position 11 welding seams of 40 mm length each are welde...

Page 456: ...m 4 mm 3 mm 2 mm 1 mm 0 mm 1 mm 2 mm 3 mm 4 mm 5 mm Shorten welding nozzle un changed Lengthen welding nozzle Deviation from nominal dimension valid for Z0 10 mm nozzle distance Note The position Z0 c...

Page 457: ...l focus position B Nominal focus position Example 19 Enter the deviation from the nominal dimension in the mask Input of deviation from nominal dimension determined mask 20 Press Apply value 21 Press...

Page 458: ...the Z axis by the deviation which has been determined here in the example by 2 mm in the minus direction upwards because the welding nozzle is extended 2 Adjusting the welding nozzle to the deviation...

Page 459: ..._WELD 2 Press Select program A dialog box is opened Focus search for welding heads mask 3 Select Results check 4 Press Continue 5 Press Prepare The program is aborted Note Pan the sheet or select a ne...

Page 460: ...parameters The focus position is determined precisely The focus shift 6 dependent on the beam length and the component tolerances of the beam guidance components are equalized throughout the entire w...

Page 461: ...4 mm thick sheet 600 mm x 150 mm St37 Gauge block 10 mm and 15 mm Utility program CP_FOCUS_WELD Note The sheet must lie completely flat on the support and is not permitted to warp during the welding s...

Page 462: ...e 16 Press Start approximate search Program starts from the current axis position 11 welding seams of 40 mm length each are welded The nozzle distance the focus position is increased with each welding...

Page 463: ...4 mm 3 mm 2 mm 1 mm 0 mm 1 mm 2 mm 3 mm 4 mm 5 mm Shorten welding nozzle un changed Lengthen welding nozzle Deviation from nominal dimension valid for Z0 10 mm nozzle distance Note The position Z0 cor...

Page 464: ...l focus position B Nominal focus position Example 19 Enter the deviation from the nominal dimension in the mask Input of deviation from nominal dimension determined mask 20 Press Apply value 21 Press...

Page 465: ...e the Z axis by the deviation which has been determined here in the example by 2 mm in the minus direction upwards because the welding nozzle is extended 2 Adjusting the welding nozzle to the deviatio...

Page 466: ...t program A dialog box is opened Focus search for welding heads mask 3 Select Results check 4 Press Continue 5 Press Prepare The program is aborted Note Pan the sheet or select a new starting position...

Page 467: ...S0 4 in the UP program COSTUMER_G820_TABLE Additional equipment tools material A flat oil free 4 mm thick sheet 600 mm x 150 mm St37 Slip gauge 15 mm Utility program CP_FOCUS_WELD Note The sheet must...

Page 468: ...to a focus position offset of 5 mm The evaluation data focus position offset parameters are engraved on the sheet after welding is completed Input of the determined focus position offset mask opens 15...

Page 469: ...e focus position offset and enter into the dialog Note The focus position offset is the amount by which the control system uses software to pan the AutoLas Plus characteristic curve Input of the deter...

Page 470: ...program A dialog box is opened Focus search for welding heads mask 4 Select Results check after fine search 5 Press Continue 6 Press Prepare The program is aborted Note Pan sheet or edit start positio...

Page 471: ...rammed at 100 H10 10000 for calibration point S0 4 in the UP program COSTUMER_G820_TABLE For focus search with minimum laser output The laser output has been programmed simultaneously e g H10 5500 for...

Page 472: ...earch for welding heads mask 9 Select Start the focus search for the current welding optics 10 Press Continue 11 Press following page 12 Press Start fine search 13 Press Prepare NC program is terminat...

Page 473: ...reference part illustrated below That means that the focus point is 2 mm too low and needs for that reason to be corrected by 2 mm X X Y Y S f 0 Foc Off 5 mm 4 3 1 0 2 1 4 3 2 S Start position Example...

Page 474: ...djust feed rate and pre warming power to minimum laser output 24 Open the UP program COSTUMER_G820_TABLE in the NC Editor and program minimum laser output 25 Press START 26 Press Continue Program star...

Page 475: ...ch was determined at maximum and minimum laser output Display dialog opens Entering the established power dependent focus shift mask 30 Press Continue The fine search is ended 31 Carry out monitoring...

Page 476: ...m laser output needs to be programmed in the UP program COSTUMER_G820_TABLE Note The maximum and or the minimum laser output needs to be reprogrammed for the respective fine search it is the laser out...

Page 477: ...Y A B 2 Foc Off 5 mm 4 3 1 0 2 1 4 3 2 A with maximum laser output B with minimum laser output S Start position Reference parts Focus position Results check The focus search is ended when the best wel...

Page 478: ...system This is done via a selection dialog refer to Selecting the processing optics on the user interface The dialog accesses the joint offset values in the data management and transfers them upon se...

Page 479: ...machine and processing optics These joint set values are noted in the acceptance protocol of the machine and stored in the joint offset memory at the control system The joint offset values of all pro...

Page 480: ...ically saved in joint offset dimension data management when it is adopted Determining the joint offset for cutting head The service program CP_OFFSET_CUT LST is used to cut a sample The dimensions A1...

Page 481: ...le distance of approx 5 mm observing start position 3 Select CP_OFFSET_CUT program 4 Press START PROGRAM A dialog box appears 5 Select the focal length Warning The axes travel directly to the entered...

Page 482: ...pair of lines form a continuous line without any offset after the fine evaluation has been completed Each pair of lines is assigned an adjustment value The determined joint offset values are saved to...

Page 483: ...welding head above the sheet with a 15 mm nozzle distance Use a gauge block to check or For machines with AutoLas Plus In the General welding table under the Welding focus position parameters enter 0...

Page 484: ...g link offset of Z axis tool length Z 1 E F F Reference value F E Sheet upper edge up to the reference area for dimension E Z Offset value for Z axis 1 Reference area for bottom edge of Al housing Z a...

Page 485: ...h element to ACTIVE Execute the selection dialog see section Selecting the processing optics 2 Select Operation Set up MDA 3 Enter B0 C0 4 Press Start The B and C axes travel to position 0 5 Position...

Page 486: ...ue The head parameters mask opens The joint offset values currently saved for the selected processing optics are displayed 8 Enter the joint offset for the Z axis 9 Press Adopt values The joint offset...

Page 487: ...ection B Cutting 2 Beam guideway ventilation connection 4 Cutting gas connection Z center sleeve gas and air connections 1 Plug the Crossjet 1 connector onto the beam guideway ventilation connector 2...

Page 488: ...ble After replacing the DIAS PC system Prerequisite The cutting head is fully installed The cutting head was installed at least 30 seconds ago The nozzle must be neither damaged nor dirty 1 Position t...

Page 489: ...light piece of paper for example lens cleaning paper under the nozzle and let go of it The blowing pressure is set correctly if the piece of paper is held by the low pressure The blowing pressure is...

Page 490: ...min Helium Argon Mild steel Approx 8 12 Approx 10 14 Stainless steel Approx 8 12 Approx 10 14 Recommended flow rate values 1 Select Operation Set up Welding switch elements 2 Set the Gas act switch el...

Page 491: ...ng gases carbon dioxide CO2 and form gas which has to be switched over if the welding gas is to be changed Prerequisite 5 welding gases are installed A A B 1 B 3 2 1 Shut off valve in front 2 Shut off...

Page 492: ...ch is slipped onto the prepared processing optics and fixed at an offset of 120 to the nozzle It is possible to either measure or alternatively machine by turning the B axis The measuring probe is eit...

Page 493: ...11 Connect the measuring probe to the Z center sleeve 12 Selecting and calibrating measuring probe Selecting measuring probe The measuring probe must be selected prior to each utilization made ready...

Page 494: ...t up Switch element group Service 2 Press Measurement functions Selection dialog opens Select Measurement function 3 Select measuring probe mode 4 Press Continue Selecting measuring probe 5 Select mea...

Page 495: ...ded C axis Note The data management can be set back to the default joint offset values using the softkey Standard Start values softkey Joint offset values which were determined by calibration are then...

Page 496: ...formation the control system transforms the coordinates on the workpiece measured with the measuring probe into TCP coordinates It is also necessary that the offset values between the measuring probe...

Page 497: ...m over the center of the sphere 6 Select Operation Production Single job 7 Select and start the CP_TOUCH_PROBE program Display dialog opens The parameters which define the measuring probe are displaye...

Page 498: ...is carried out four times in different B and C axis positions B 120 and C 0 B 120 and C 180 B 30 and C 0 B 30 and C 180 A dialog box appears after the end of the measurement The display shows the dev...

Page 499: ...round the C axis is restricted to 200 if the welding wire feeder is in use 1 Open the roller box Put the wire roll on the holder 2 Insert the welding wire into the leader hose 3 Open the driving rolle...

Page 500: ...ight 3 Retighten the clamping screw 4 Screw in the hose at the connection 1 2 3 4 1 Drive motor 2 Hose connection 3 Clamp lever 4 Guide roller Welding wire drive 1 Open the clamping lever 2 Screw in t...

Page 501: ...3 1 Fixing screw 2x 2 Holder 3 Welding wire nozzle Welding head with welding wire feed 1 Undo both fixing screws 2 Align the holder until the welding wire is exactly in the focus on the sheet surface...

Page 502: ...the roller box the guide roller at the welding wire drive and the welding wire nozzle all depend on the diameter of the welding wire If welding wire of a different diameter is to be inserted 1 Replac...

Page 503: ...s Auxiliary equipment 10 mm Allen wrench Note We recommended marking the defined initial position before shifting the rotational axis by using a fixed stop for example 1 4x 1 Clamping screw M12 socket...

Page 504: ...easure has been applied to the rotary table for position ing 1 4x 2 1 Clamping screw M12 socket head screw 2 Hand wheel connection for height adjustment Adjusting the rotary axis vertically 1 Remember...

Page 505: ...parallel to the X axis Auxiliary equipment 10 mm Allen wrench 2 5x 1 1 Hand wheel for swinging 2 Clamping screw M12 socket head screw Swinging the rotary axis 1 Undo the clamping screws 2 Turn the han...

Page 506: ...ly in X direction The back stop can be shifted manually on guide rails on the machine body and positioned in the workspace as desired Auxiliary equipment 10 mm Allen wrench 1 1 Clamping screw M12 sock...

Page 507: ...thickness CP_93918_445_120_ SACRIFIC LST Cutting sacrificial plate 1 Fig 39481 mild steel St 1203 1 mm sheet thickness CP_S99762_438_120_ SACRIFIC LST Cutting sacrificial plate 2 Fig 39487 mild steel...

Page 508: ...T PROGRAM A dialog box appears 3 Select the S Table which belongs with the utility program and the processing optics in the S Table field 4 Select the LTT which goes with the application in the T tabl...

Page 509: ...d 2 Select Operation Set up MDA 3 Enter B0 C0 4 Press Start The B and C axes travel to 0 5 Select Operation Production Single job 6 Select the program CP_TRIM_OFF 7 Press START PROGRAM A dialog box ap...

Page 510: ...both support slats Support slats with a long slit are used in the area around the transverse support of the support table Prerequisite The machine is equipped for laser cutting The cutting optics hav...

Page 511: ...Select Operation Production Single job 6 Select program AUF_ST or AUF_QU Note The laser technology table is designed for the TLF 4000 laser and St 1203 mild steel If you want to cut support slats out...

Page 512: ...crificial plates are loaded in the drawers of the support table for cutting in order to protect the drawers against wear The sacrificial plates should be replaced when they show signs of wear 308 1 X...

Page 513: ...laser cutting The cutting optics have been installed set up and selected Master file is split Additional equipment tools material Utility program CP_93918_445_120_SACRIFIC LST for sacrifi cial plate 1...

Page 514: ...mm 24 Support table for pallet changer working height 700 mm 4000 mm divided 18 6 Number of sacrificial plates Note A sacrificial plate will be cut with every program start 1 Position the cutting hea...

Page 515: ...5 102 Further service programs B337EN05 DOC...

Page 516: ...6...

Page 517: ...rication diagram 6 7 3 2 Lubrication chart 6 8 3 3 Lubricant table 6 9 3 4 Notes for lubrication chart 6 10 4 Maintenance of mechanical components 6 19 4 1 Maintenance on basic machine 6 19 4 2 Mainte...

Page 518: ...eral guidelines and additional equipment 6 44 6 2 Maintenance of optical components 6 47 7 Maintenance of electrical components 6 64 Safety information 6 64 8 Safety cabin maintenance 6 69 9 Maintenan...

Page 519: ...dirty parts or vacuum with an industrial vacuum cleaner Notes on lubrication When lubricating the machine refer to the lubrication chart and the maintenance instructions In addition the following poi...

Page 520: ...arrester Check and clean 40 27 26 Coarse material collector Clean 40 27 30 Compressed air gauge for operating pressure Inspection 40 31 31 Compressed air gauge for beam guideway ventilation Inspection...

Page 521: ...e Inspection 1000 20 53 Deflection mirror for B C angular gear Check and clean 1000 57 54 AutoLas Plus mirror 1 Check and clean 1000 58 55 56 Deflection mirror adjustable Check and clean 1000 60 57 60...

Page 522: ...23 Filter insert seal Check and replace Every 3 years 25 72 Battery fan NC CPU Replace battery Every 3 years 66 73 Buffer batteries PCU 50 Replace battery Every 3 years 67 51 Welding head parabolic m...

Page 523: ...rvals in operatinghours S ee operator s manual for information on lubrication points andnecessary action Lubrication by means of grease gun General lubrication using an oil can or spray can Check oil...

Page 524: ...6 8 Machine maintenance B337EN06 doc 3 2 Lubrication chart h 9 5000 2000 500 6 1 7 8 2 3 4 160 5 Lubrication diagram Fig 31761...

Page 525: ...Mobilgear 627 629 SHELL Omala Oil 100 150 CLP ISO VG 100 150 0108758 5 Bearing frames on rotary axis and on back stop optional ARAL Aralub HLP2 BP Energrease LS EP2 CASTROL LZV EP ELF EPEXA 2 ESSO BEA...

Page 526: ...nce note Procedure 1 X axis gearbox Fig 31719 5000 Change oil Drain oil 1 Open oil filler plug and oil drain plug 2 Drain the oil while it is at working temperature Refill with oil 1 Close drain plug...

Page 527: ...5000 Change oil Drain oil 1 Open oil filler plug and oil drain plug The oil filler plug is located on the opposite rear side of the gearbox 2 Drain the oil while it is at working temperature Refill wi...

Page 528: ...nge oil Drain oil 1 Open oil filler plug and oil drain plug 2 Drain the oil while it is at working temperature Refill with oil 1 Close drain plug 2 Fill with oil amount approx 0 5 l 3 Close filler plu...

Page 529: ...otary axis gearbox A axis Fig 31718 5000 Change oil Drain oil 1 Open oil filler plug and oil drain plug 2 Drain the oil while it is at working temperature Refill with oil 1 Close drain plug 2 Fill wit...

Page 530: ...nipples 4 each on the rear sides of the bearing frames with a grease gun until the grease comes out on the bearing frames Fill the height adjustment grease nipple 1 with a grease gun 6 Tap hole plate...

Page 531: ...rews 2 to the left and the right of the two drive motors 1 3 Check grease level the gearwheel must be at least half covered but no more than fully covered Note the gearbox is filled with a synthetic g...

Page 532: ...g hours Maintenance note Procedure 8 B and C axis motor intermediate gears Fig 22963 5000 Lubricate 1 Remove the casing on the Z center sleeve 2 Fill the grease nipples 2 using a grease gun B and C ax...

Page 533: ...message Fill low viscosity grease reservoir once the minimum filling level is reached When message appears 1 Filling low viscosity grease reservoir remove cover Pour the low viscosity grease in slowl...

Page 534: ...the pressure is less than 30 bar An error message is issued Causes of the error can include Air in the line A broken hose Low viscosity grease reservoir is empty The refill quantity should be such th...

Page 535: ...B337EN06 doc Machine maintenance 6 19 4 Maintenance of mechanical components 4 1 Maintenance on basic machine 10 13 12 11 15 17 16 14 Maintenance points Fig 31721...

Page 536: ...ndle oil 2 Afterwards cover the points which have been cleaned with a thin film of oil 3 Check dirt wipers for wear and replace them if needed 14 Cable connections and quick release couplings Z center...

Page 537: ...h an activated carbon filter There is a sacrificial plate set into every drawer The sacrificial plate prevents the drawer from being deformed by thermal stresses 1 Pull the drawer out by hand 2 Remove...

Page 538: ...e safety information in the Safety chapter Make sure you do not stir up any dust while cleaning Use a vacuum cleaner with an activated carbon filter There is a flap on each side of the basic table whi...

Page 539: ...om aluminum processing LAGA code 35304 aluminum waste or EAK Code 120103 chips and cuttings containing metals other than iron EAK group waste from mechanical shaping incl welding cutting Warning Dange...

Page 540: ...extremely fine metal dust The dust container disposable container in the compact dust extractor must be replaced after changing the working material from aluminum aluminum alloy to galvanized sheet me...

Page 541: ...itch off the MAIN SWITCH 2 Open the upper door on the filtering installation and check the cleanliness of the clean gas space 3 If there is any contamination clean the clean gas space with an industri...

Page 542: ...itch off the MAIN SWITCH 2 Open the lower door on the filtering installation 3 Open the cover The hoses meanwhile remain attached to the lid 4 Visually inspect the container to determine the remaining...

Page 543: ...ge Check for deposits and if needed sweep and vacuum clean its upper and lower sides 4 Insert the cartridge Close the doors 26 Drawer Coarse material collector Fig 27732 40 Clean 1 Switch off the MAIN...

Page 544: ...he lower door 3 Remove the quick clamping device 4 Pull spiral hose off and clean with a ring brush 5 Check spiral hose for points of leakage visual inspection Replace if damaged 6 Put the spiral hose...

Page 545: ...0 Inspection 1 Switch off the MAIN SWITCH 2 Check the functioning of the final position switch Small fire message cell detection horn manual release mechanism 2000 Inspection 1 Switch off the MAIN SWI...

Page 546: ...6 30 Machine maintenance B337EN06 doc 5 Maintenance of pneumatic components and filters 5 1 Instrument panel Fig 39484...

Page 547: ...al operating hours Maintenance note Procedure 30 Compressed air gauge for operating pressure 40 Inspection Check operating pressure Nominal value 6 1 bar 31 Compressed air gauge for beam guideway vent...

Page 548: ...e filter cartridge The filter cartridge must be replaced after 5000 operating hours at the latest 34 Activated carbon filter for beam guideway ventilation 1 35 Active charcoal filter for Crossjet Weld...

Page 549: ...ote Procedure 36 Disposable filter in beam guideway ventilation 500 Check and replace If the filter is clearly dirty replace filter insert 37 Condensate precipitation collecting tank Fig 35118 40 Insp...

Page 550: ...s conduit if there is a drop in pressure Note To maintain the pressure in the sealing gas conduit over a lengthy period in which the machine is standing idle a nitrogen cylinder should be attached to...

Page 551: ...te Procedure Sealing gas conduit on Z center sleeve Fig 22975 When message appears Emptying water from the sealing gas conduit 1 Remove the plugs 1 on the Z center sleeve Allow air to escape until wat...

Page 552: ...place If the filter is clearly dirty replace filter insert 45 Filter in cutting gas conduit on cutting head Fig 22971 500 Check and replace If the filter is clearly dirty replace filter insert Note en...

Page 553: ...t along the longest beam path with the axes immobile 1 Move axes to Z 0 Y 1500 and X 2000 3000 or 4000 2 Fill the U tube manometer with measuring fluid up to the 0 marking 3 Remove connection screw 1...

Page 554: ...ning the opening needs to be smaller If the pressure differential is larger than 0 4 0 1 mbar then the pressure in the beam guideway is too high Move the flap away from the opening the opening needs t...

Page 555: ...us water filter 3 and check filter insert for contamination 3 Replace filter insert if very dirty If the filter insert is replaced clean the filter container 4 Screw the filter container back in 5 Ope...

Page 556: ...40 Machine maintenance B337EN06 doc Maintenance point no Interval operating hours Maintenance note Procedure Water filter Fig 22977 3 2 1 1 1 Stopcock 2 x 3 AutoLas Plus water filter 2 Full flow filte...

Page 557: ...500 Check and clean The laser beam must be switched off 1 Remove panelling on the rear side of the Y extension arm 2 Pull off filter housing and open 3 Clean filter screen If the filter screen is dam...

Page 558: ...Adaptive telescope filter Fig 31725 500 Inspection The laser beam must be switched off 1 Remove panelling 2 Pull off filter housing and open 3 Clean filter screen If the filter screen is damaged it mu...

Page 559: ...ines with high laser power and or a long beam path The Laserpac has the task of filtering dust oil and CO2 out of the compressed air used to ventilate the beam guideway Note For description of the mai...

Page 560: ...A clean environment a clean work place and clean additional equipment are absolutely essential All work involving the removal installation and cleaning of optical components as well as adjusting of th...

Page 561: ...es 1 Moisten a pad of surgical cotton with plenty of Topol 2 2 Carefully clean the mirror surface with the moistened cotton applying light pressure Regularly change the piece of cotton you use since t...

Page 562: ...no 078952 Cleaning kit compel TRUMPF part no 069431 Bellows Lens cleaning paper Kodak TRUMPF part no 086452 Aluminum foil Lint free base cloth and gloves Pure cotton wool TRUMPF Mat No 096 751 must no...

Page 563: ...X Y axis 59 Adaptive telescopic mirror Cu 53 Beam bending mirror Si for cutting head 57 Beam bending mirror Si for X Y axis 60 Phase shifter Si 54 AutoLas Plus mirror1 Cu 58 Beam bending mirror Si 61...

Page 564: ...head 55 Beam bending mirror Cu for Y Z axis 62 Beam bending mirror Cu 53 Beam bending mirror Si for cutting head 56 Beam bending mirror Cu for X Y axis laser machine 54 AutoLas Plus mirror1 Cu Beam gu...

Page 565: ...be replaced if it is damaged Remove the cutting head if necessary Fig 31109 Dismantling lens adapter 1 Undo DIAS connection cable Remove protective cover 2 Undo the cap screws on the flange of the cu...

Page 566: ...ty chapter Note Only touch lens with your fingers along its outer edge Do not touch the surface of the lens Oil grease and dust must not be allowed to get onto the lens Grease and sweat from the skin...

Page 567: ...otion applying light pressure Never rub the lens dry 5 Allow Topol to dry until a white layer has formed 6 Carefully dust off the dried Topol with cotton 7 Sprinkle a few drops of acetone on the lens...

Page 568: ...moistened with acetone 2 Blow off lens lens adapter and threaded sleeve using bellows 3 Place the spring in the threaded sleeve 4 Fit the lens correctly in position on the spring with the convex side...

Page 569: ...crew the threaded sleeve in until it aligns evenly with the lens adapter without protruding Do not screw in the threaded sleeve too tightly 6 Lightly shake the lens adapter in the axis direction while...

Page 570: ...screwed in so far that none of its thread is visible 2 Join the cutting insert to the housing align on the cylindrical pin 3 Tighten the cap screws until hand tight approx 3 6 Nm Note After dismantlin...

Page 571: ...tamination The parabolic mirror in the laser welding head is coated with molybdenum The surface of the mirror must not be touched with the fingers Water and solvents must not be allowed onto the coati...

Page 572: ...urface of coarse contaminants 2 Clean the mirror surface with a circular motion using surgical cotton and Wenol applying light pressure Repeat this procedure if needed 3 Dry polish with a new piece of...

Page 573: ...lly take out the mirror holder The mirror remains in the mirror holder for cleaning 4 Blow the mirror clean using oil free compressed air or nitrogen 5 Clean the mirror surface with lens cleaning pape...

Page 574: ...le doing so hold the mirror Caution The mirror might fall down 5 Carefully pull out the mirror 6 Blow the mirror clean using oil free compressed air or nitrogen 7 Clean the mirror surface with lens cl...

Page 575: ...B337EN06 doc Machine maintenance 6 59 Maintenance point no Interval operating hours Maintenance note Procedure AutoLas Plus mirror Fig 36763 1 2x 2 4x 3 1 Water connection 3 Mirror 2 Fixing screws...

Page 576: ...w the mirror clean using oil free compressed air or nitrogen 5 Clean the mirror surface with lens cleaning paper and acetone Repeat this procedure several times if necessary Only use each piece of cle...

Page 577: ...mains in the mirror holder for cleaning 3 Blow the mirror clean using oil free compressed air or nitrogen 4 Clean the mirror surface with lens cleaning paper and acetone Repeat this procedure several...

Page 578: ...o the cap screws on the phase shifter 2 Lift out the cooling element using an auxiliary tool so that the mirror cannot fall out of the bottom 3 Draw the mirror out of its mount using a suction cup and...

Page 579: ...der for cleaning 4 Blow the mirror clean using oil free compressed air or nitrogen 5 Clean the mirror surface with lens cleaning paper and acetone Repeat this procedure several times if necessary Only...

Page 580: ...cabinet which have not been de energized continue to carry a charge for four minutes after MAIN SWITCH OFF Risk of fatal injury Maintenance work on the electrical system may only be performed once th...

Page 581: ...nce note Procedure 70 Connectors and screw type connections in the switch cabinet 2000 Inspection Make sure the connectors are in perfect condition 71 Switch cabinet fan 19426 500 Clean Use compressed...

Page 582: ...om Siemens delivery date Battery replacement Caution loss of data The battery must be replaced within 15 minutes to avoid loss of data 1 Switch off the MAIN SWITCH 2 Open the switch cabinet of the mac...

Page 583: ...y only be replaced when the machine control system is switched on If the battery is changed with the MAIN SWITCH off the data stored on the hard drive of the MMC are lost 1 Switch on MAIN SWITCH 2 Rem...

Page 584: ...ing unit control panel Fig 39439 2000 h Clean Note it is not permitted to change the settings 1 Switch off the MAIN SWITCH 2 Remove the protective cover 3 Remove panelling 4 Vacuum clean the interior...

Page 585: ...Check viewing window for pits or holes Warning Invisible high energy laser radiation Severe skin burns and eye injuries may occur Replace the viewing window if 1 mm deep pits or holes are discovered d...

Page 586: ...nction with precision when the protective glass is in a perfect and clean condition When removing the protective glass make sure that no dust gets inside the sensor body Protective glass TSD 2 Mat No...

Page 587: ...cooling power the inner space of the air conditioning door must be cleaned 1 Switch off the MAIN SWITCH 2 Remove the upper hood fastening from the air conditioning door 3 Push the outer hood of the ai...

Page 588: ...ance note Procedure 1 Clean the inside area condenser fins external fans compressor and transformer with a vacuum cleaner 2 Clean the fins with compressed air Remove stubborn oil impregnated dirt usin...

Page 589: ...7...

Page 590: ...Maintenance overview 7 3 1 1 Maintenance intervals 7 4 2 Vacuum pump 7 5 2 1 Auxiliary tools and materials 7 5 2 2 Maintenance work 7 6 3 Compressed air filter unit 7 7 4 Laser control 7 7 5 Cooling u...

Page 591: ...Construction of RF generator 7 19 6 4 Short circuiting residual voltage 7 20 Tube output stage 7 21 HV power supply unit 7 24 6 5 Maintenance work 7 26 7 Operating steps during maintenance work 7 37...

Page 592: ...ork and the person to carry it out The occupation and professional training of the persons working on the TLF lasers is taken into consideration when deciding who is authorised to carry out maintenanc...

Page 593: ...s 3 30 1000 RF generator Generator tube Check operating values of the generator tube 2 31 10000 Vacuum pump Vacuum pump Hyco Replace pump 3 6 5000 8000 RF generator Generator tube As required Replace...

Page 594: ...e Material Mat no Vacuum pump Hyco 10 000 Replace pump Conversion kit with outdated vacuum pump 0946052 Open and close laser cap 1 Lock for small cap 2 Locks for large cap Open laser caps using the fo...

Page 595: ...an outdated vacuum pump mat no 0946052 is recommended The interval for pump replacement can be checked at the operating hours display on the control system 1 2 3 1 Connection for air hose 3 Mounting...

Page 596: ...doc Maintenance of laser 7 7 3 Compressed air filter unit For maintenance of the compressed air filter unit see Chapter Machine Maintenance 4 Laser control Note The TASC 3 control system is maintenan...

Page 597: ...al key 0146152 0144154 Strainer in Cu circulation 6 months Clean strainer Cooling water 6 months Replace water Demineralized water Conductivity measuring device Water pump Fuel measure Cooling water a...

Page 598: ...quipment used for filling must not be used for any other purpose Maintenance intervals evaporative cooling Detailed information on maintenance can be found in the supplied instruction manual Cooling w...

Page 599: ...hen filling up cooling water 5 ml 100 l water 5 ml 100 l water Volume at completed cooling water change 4 5 ml 18 24 ml Mat no 0344669 0344669 Protection against bacteria and algae NALCO 2594 NALCO 25...

Page 600: ...tenance information Water tank 100 h Check water level Cooling unit Fig 24028 1 2 3 1 Cooling unit 3 display Cu TLF 4000t 2 display Al Read water level on the display If the water level does not corre...

Page 601: ...e quality and cleanliness of the cooling unit s surrounding air This means that the maintenance interval after the first inspection 100 hours is determined by the user through regular checks Clean or...

Page 602: ...er additives Observe instructions on products and product packaging When measuring different cooling circuits do not mix the contents of the containers so as to avoid falsifying the results For handli...

Page 603: ...perated whilst the filter is being changed Filter for aluminium circuit Fig 24029 1 2 3 4 1 Special key for Al filter 3 Shutoff valve for KK2 Al pre flow hidden 2 Filter housing 4 Shutoff valve for KK...

Page 604: ...cuit Fig 24030 Cooling unit only for the TLF 4000 5000 The strainer consolidates impurities in the copper cooling circuit Switch system off Remove front right cover at the cooling unit 1 1 Strainer Cl...

Page 605: ...one cooling water tank The replacement of water at the second tank is to be carried out in the same way Water pump Fig 24031 Caution Dry run causes pump damage The cooling unit pump must not be used f...

Page 606: ...aning cycle and unscrew a screw connection on the laser so that the cooling water will flow into the water tank Cleaning cycle Completely empty the water tank Clean the water tank with rags or with a...

Page 607: ...ice work is acting with gross negligence Safe maintenance work Work on the generator must only be carried out by suitably qualified persons You must for your own safety observe the described safety in...

Page 608: ...22660 Teflon hoses 1000 Check teflon hoses Potential hose 0078846 Screw joint 0132044 Clamping ring 0147604 Group cathodes 1000 Clean and check group cathode Group cathode Gasket 0094289 0134673 Gener...

Page 609: ...uiting The grounding rod is already connected to the generator cabinet It must only be used for discharging the components of the generator cabinet The grounding rod can be lifted out of its mounting...

Page 610: ...he following parts by short circuiting with the grounding rod to safely eliminate any residual voltage which is present Isolate the generator and safeguard against unintentional restarting Wait for th...

Page 611: ...7 22 Maintenance of laser B337EN07 doc Discharging the bushing type capacitor Fig 29828 Discharging grid resistance Fig 29829...

Page 612: ...B337EN07 doc Maintenance of laser 7 23 Discharging the grid voltage resistance of capacitors at X2 Fig 29830 Discharging the grid voltage resistance of capacitors at X4 Fig 29831...

Page 613: ...supply unit Discharging the HV capacitor Fig 29832 Discharging the power line filter Fig 29833 Isolate generator and safeguard against unintentional restarting Observe the discharge time for the gener...

Page 614: ...RF output stage Fig 30824 HV power supply unit HV power supply unit Fig 29834 Hanging up the grounding rod on hook After you have short circuited all residual voltage from the particular module hang t...

Page 615: ...mminent failure of the fans When an error message is issued because of excess temperature a defective fan could be the cause RF generator Fig 29835 Should operation noises eminate from the fans please...

Page 616: ...the Teflon hoses The sacrificial anodes wear out in the course of time Fig 29836 1 Sacrificial anodes Switch off laser unit at main switch and safeguard against unintentional restarting Wait for disch...

Page 617: ...Cut off cooling water supply to the generator Open cap nuts on the teflon water hoses Wipe up the overflow water allow the wet parts to dry Pull teflon hoses from the reactive anodes Unscrew old react...

Page 618: ...ged Teflon hoses RF potential hoses Loosen union nut 2 Remove old Teflon hoses Mount new Teflon hoses with new clamping rings Push the Teflon hoses onto the sacrificial anodes making sure that these d...

Page 619: ...g 29838 Danger Lethal voltage at seal caps when the earthing bracket plate is removed Do not under any circumstances remove the earthing bracket plate When operating the laser unit without bracket pla...

Page 620: ...output PI begins to decrease as soon as the limit values have been reached If the generator tube is not replaced before de energization of PI then the power output of the laser unit will be reduced Da...

Page 621: ...lue of power output NVPi V Operating current of exciter stage power amplifier IB1 A Operating current of exciter stage power amplifier IB2 A Operating current of exciter stage power amplifier IB3 A Op...

Page 622: ...the wet parts The following work must also be carried out when replacing the generator tube The replacement set for the generator tube includes the required parts Replacement of sacrificial anodes Re...

Page 623: ...enerator tube Fig 29839 1 Union nuts 2 Fixing screws Unscrew Teflon screws joints at water cooled resistor Loosen the union nuts on the sacrificial anode and remove the sacrificial anodes and Teflon h...

Page 624: ...rator tube When installing pay attention to the layout of the screws If the generator tube is locked do not twist Before installing check the generator tube for visible damage Prior to installation ch...

Page 625: ...ling water flow is against the direction of the arrow Teflon hoses onto the sacrificial anodes and into the clamps designed to secure the hoses First finger tighten the union nuts Then use two revolut...

Page 626: ...ching elements by switching to on Switch vacuum system to on Prerequisites Resonator is filled to 1100 hPa Select the Focus button Select 2 Diagnostics 6 Laser 2 Leak test in the menu bar Confirm with...

Page 627: ...at the machining head To determine the operating values perform the following steps only Switch to service mode using the key switch Select the Focus button Select 2 Diagnostics 6 Laser 1 RF generato...

Page 628: ...8...

Page 629: ...ing 8 1 Chapter 8 Aligning the MSL multi beam safety light barrier1 1 Additional equipment for aligning 8 2 2 System example 8 3 3 Aligning the light beam 8 4 4 Setting mirror 8 6 5 Cross hairs to cut...

Page 630: ...ight barrier to function TRUMPF supplies an alignment device for this purpose 1 2 1 Adapter 2 Alignment device AR 60 Alignment device The alignment device is to be used with a cross hair pattern made...

Page 631: ...m example The illustration below offers an example for installing the transmitter mirror posts and receiver E 2 1 S S Transmitter post E Receiver post 1 Mirror post 1 2 Mirror post 2 Installing the mu...

Page 632: ...itting 3 Mount heavy duty anchors Fasten the posts 4 Align posts vertically in the cover plates using the bubble level 5 Remove cover plates and sheet metal shielding from all posts 6 Clean the mirror...

Page 633: ...e way as described for steps 1 4 Step 6 1 Remove the cross hairs from the mirror on the mirror post 2 Clean the mirror again if necessary 3 Switch on the machine 4 Acknowledge the safety light barrier...

Page 634: ...8 6 Setting mirror B337EN08 DOC 4 Setting mirror Mirror on mirror post 1 Loosen screws at pos 1 somewhat 2 Align mirror 3 Tighten the screws hand tight again Fig 6309...

Page 635: ...B337EN08 DOC Cross hairs to cut out 8 7 5 Cross hairs to cut out Cross hairs to cut out Fig 6310...

Page 636: ...8 8 Cross hairs to cut out B337EN08 DOC...

Page 637: ...9...

Page 638: ...Chapter 9 Noise levels Test certificate TLC 1005 1 Mess Test certificate 9 2 2 Measurement Results 9 3 3 Diagram Work piece 9 4 4 Diagram Location of measuring points 9 5 Edition 01 1998 Reference num...

Page 639: ...ikrofon Free field microphone 4155 Measuring points Measuring point layout In accordance with DIN 45635 part 1 5 sided measuring surfaces Dimensions of reference cube Length l1 6 600 m Width l2 6 100...

Page 640: ...Aeq 68 0 dB LpAeq L pAeq K1 K2 Idling noise Cooling system OFF LpAeq 63 3 dB LpAeq L pAeq K1 K2 Workplace specific values with low pressure cutting O2 pressure 2 bar Emission value LpAeq 63 4 dB LpAeq...

Page 641: ...CHEN 2 bar Einstechzeit 0 7 sec Ausblaszeit nach Einstechen 0 1 sec Bearbeitungszeit f r Einzelteil 62 sec Parameter 1500 250 1250 3000 forward feet 2 3 m min reduced forward feed for first cut 1 6 m...

Page 642: ...N09 DOC Diagram Location of measuring points 9 5 4 Diagram Location of measuring points Measuring points v Measuring point corresponds to operator s position Diagram Location of measuring points Fig 1...

Page 643: ...9 6 Diagram Location of measuring points B337EN09 DOC...

Page 644: ...10...

Page 645: ...Maquinaria S A Gro britannien President Way Spanien Avenida de Valdelaparra 13 Great Britain Airport Executive Park Spain E 28100 Alcobendas Madrid Grande Bretagne GB Luton Beds LU2 9NL Espagne 91 6 5...

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