Operator's manual
TC L 3050
TC L 4050, TC L 6050
Operator's manual
TC L 3050, TC L 4050, TC L 6050
Edition: 10/2004
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TRUMPF Werkzeugmaschinen GmbH + Co. KG
Technische Dokumentation
Johann-Maus-Straße 2
D-71254 Ditzingen, Germany
Phone: +49 (0) 71 56/3 03-0
Fax: +49 (0) 71 56/3 03-5 40
Internet: http://www.trumpf.com
E-mail: docu.tw@de.trumpf.com
This document was c ompiled by the Technical Docum entation Department
of TRUMPF Machine Tools G mbH + Co KG.
All rights to this documentation, especially the rights of reproduction and
distribution as well as that of translation are reserved to TRUMPF
Werkzeugmaschinen GmbH + Co. KG, even in the case of notifications of
protected privilege. No part of this documentation may be reproduced,
processed, duplicated or distributed by means of electronic systems in any
form whatsoever with out the prior written c onsent of TRUMPF Machi ne Tools
GmbH + Co.KG. Subject to technical alterations. Errors except ed.
TRUMPF Werkzeugmaschinen GmbH + Co. KG
TRUMPF Werkzeugmaschinen GmbH + Co. KG cannot be made liable for
possible mistak es in this documentation. No liabili ty is accepted for dir ect or
indirect damage or injury resulting from the delivery or use of this
documentation, in so far as this is l egally permissible.
Before you read on...
Operator's manual
TC L 3050, TC L 4050
Contents of the operator's
manual
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This operator's manual documents the laser cutting machine
TRUMATIC L 3050 (T C L 3050), TRUMATIC L 4050 (TC L 4050),
TRUMATIC L 6050 (TC L 6050) with th e T RUMPF C NC c on touri ng
control system based on SINUMERIK 840D.
The operator's manual is not only intended for the user (owner)
and the operator of the machine, but also for the maintenance
personnel. It must be accessible to those people.
The operator's manual is divided into the following chapters:
Chapter 1 Safety
Chapter 2 Installation conditions
Chapter 3 Description
Chapter 4 Operation
Chapter 5 Setting work
Chapter 6 Machine maintenance
Chapter 7 Laser maintenance
Chapter 8 Noise level test certificate
Chapter 9 Alignment of the multibeam safety light barrier
Chapter 10 TRUMPF RotoLas tube cutting unit
The documents on pap er have been supplemented by the onl ine
help in the control system for machine operation and programming.
In addition to this opera tor's manual, the fol lowing form part of the
machinery documentat ion:
• Programming manual.
• Replacement parts catalogue.
• Circuit diagram.
• Folder: documents from supplier companies.
Manuals for programm ing systems and docum ents accompanying
training courses are also available.
B452EN00.DOC Before you read on... 0-5
Table of contents
Chapter 1 Safety
1. For your safety............................................................... 1-3
2. Terminology ................................................................... 1-4
3. Operating safety ............................................................ 1-4
3.1 Authorized application of the system............................... 1-5
3.2 Measures to be taken by the user/ operator.................... 1-6
3.3 Measures taken by the manufacturer............................ 1-13
Warning plates and other warnings............................ 1-6
Operator training......................................................... 1-8
Necessary diligence in operating the system.............1-8
Eliminating malfunctions during operation.................. 1-9
Using specified replacement parts and
operating materials ................................................... 1-10
Water protection ....................................................... 1-11
Fire protection........................................................... 1-12
Securing the danger zone of the machine................ 1-13
Suction equipment.................................................... 1-15
4. Overview of hazards.................................................... 1-16
5. Laser processing......................................................... 1-19
5.1 Operating modes of the laser system............................ 1-19
5.2 Laser classes................................................................. 1-19
5.3 Hazards from laser radiation.......................................... 1-20
5.4 Protection aga inst ra di ation ........................................... 1-20
Measures to be taken by the user/owner ................. 1-20
Measures taken by the manufacturer....................... 1-22
5.5 Hazardous substances .................................................. 1-25
Dust, aerosols and gases......................................... 1-25
Ozone....................................................................... 1-26
Polyethylene (PE) coated sheets ............................. 1-26
5.6 Hazards from thermal decomposition of ZnSe
lenses............................................................................. 1-28
Lens characteristics.................................................. 1-28
Thermal decomposition............................................ 1-28
0-6 Table of contents B452EN00.DOC
Responsive measures in case of accident............... 1-29
Disposal of lenses .................................................... 1-30
5.7 Danger due to high voltage............................................ 1-30
6. Danger due to alternating
electromagnetic fields................................................. 1-32
6.1 Linear drives .................................................................. 1-32
Measures taken by the manufacturer....................... 1-33
6.2 RF generators................................................................ 1-34
Chapter 2 Installation conditions
1. Installation site............................................................... 2-3
1.1 Space requirements......................................................... 2-3
1.2 Floor requirements........................................................... 2-3
1.3 Load indications............................................................... 2-5
1.4 Ambient conditions .......................................................... 2-7
1.5 Exhaust air conducti on .................................................... 2-8
2. Gas supply...................................................................... 2-9
2.1 Laser gases ..................................................................... 2-9
Purity........................................................................... 2-9
Gas consumption, supply lines, pressure
reducer...................................................................... 2-10
Laser gas supply from cylinders............................... 2-11
Central laser gas supply (fixed piping) ..................... 2-11
2.2 Cutting gases................................................................. 2- 12
Purity......................................................................... 2-12
Cutting gas consumption.......................................... 2-12
Supply lines for the cutting gas supply..................... 2-15
Cutting gas supply with cylinders or bundles ........... 2-16
Cutting gas supply with gas tank..............................2-18
2.3 Nitrogen for beam guideway ventilation ........................ 2-19
3. Electrical power supply............................................... 2-20
3.1 Power supply (grid network) .......................................... 2-21
Isolating transformer................................................. 2-22
3.2 Connected loads, fuse protection, frequency................ 2-23
3.3 Power consumption ....................................................... 2-24
3.4 Teleservice..................................................................... 2-24
3.5 Network connection ....................................................... 2-25
B452EN00.DOC Table of contents 0-7
4. Compressed air supply............................................... 2-26
5. Operating materials..................................................... 2-28
5.1 Laser gases, cutting gases, and shield gases............... 2-28
5.2 Cooling water................................................................. 2-28
6. Machine transport........................................................ 2-30
Measures to be taken by the customer .................... 2-31
TRUMPF service work.............................................. 2-32
7. Planning checklist ....................................................... 2-33
Chapter 3 Description
1. Machine concept............................................................ 3-3
2. Technical data................................................................ 3-3
2.1 Axis directions.................................................................. 3-4
3. Subassemblies of the machine .................................... 3-5
3.1 Basic machine.................................................................. 3-7
3.2 Machine frame................................................................. 3-8
3.3 Motion unit ....................................................................... 3-8
3.4 Drives............................................................................... 3-9
3.5 Suction............................................................................. 3-9
3.6 Longitudinal conveyor belt and transverse
conveyor belt.................................................................... 3-9
3.7 Instrument panel............................................................ 3-10
3.8 Cutting gas switching and pressure regulating
valve............................................................................... 3-11
3.9 Beam guideway ............................................................. 3-12
3.10 Cutting head................................................................... 3-14
3.11 APC – Advanced Process Control................................. 3-16
3.12 Pallet changer................................................................3-17
Principle of function of the pallet changer ................ 3-18
3.13 The TLF laser ................................................................ 3-20
Technical data .......................................................... 3-23
3.14 Spraying equipment.......................................................3-24
Structure of the spraying equipment ........................ 3-24
3.15 Laser pointer diode........................................................ 3-25
3.16 Clamps (optional)........................................................... 3-25
3.17 Overview of the electrical elements............................... 3-26
0-8 Table of contents B452EN00.DOC
Chapter 4 Operation
Part 1: Control elements............................................................ 4-2
1. Control elements not on the operating panel............. 4-2
2. Operating panel with color display.............................. 4-6
2.1 Machine control elements................................................ 4-7
2.2 Control system control elements ................................... 4-13
3. ASCII Keyboard............................................................ 4-17
4. Disk drive...................................................................... 4-19
Part 2: User interface............................................................... 4-20
1. Structure of the user interface ................................... 4-20
1.1 Menu bar........................................................................ 4-20
1.2 Status line ......................................................................4-21
1.3 Message line.................................................................. 4-22
1.4 Softkey bar..................................................................... 4-22
1.5 Display area................................................................... 4-22
2. Machine submodes ..................................................... 4-23
2.1 AUTOMATIC submode.................................................. 4-23
2.2 MDA submode............................................................... 4-24
2.3 JOG submode................................................................ 4-24
3. Control system activity fields..................................... 4-25
4. Diagnostics................................................................... 4-26
5. Activity - PRODUCTION .............................................. 4-27
5.1 PRODUCTION Single job.............................................. 4-27
5.2 PRODUCTION Machine components ........................... 4-31
5.3 PRODUCTION Program processing options................. 4-32
5.4 PRODUCTION Switch elements ................................... 4-34
Operation of the switch elements............................. 4-34
General switch elements.......................................... 4-35
Laser machining switch elements ............................ 4-36
Switch elements for TLF laser statuses 1 ................ 4-37
Switch elements for TLF laser statuses 2 ................ 4-38
5.5 PRODUCTION Tables.................................................. 4-39
Laser technology ...................................................... 4-39
B452EN00.DOC Table of contents 0-9
Laser power cycles................................................... 4-60
Sheet handling tables...............................................4-62
Load sheet................................................................ 4-63
Sheet technology...................................................... 4-64
Measuring table ........................................................ 4-66
Tube part technology................................................ 4-68
Tube load.................................................................. 4-73
Tube clamping method............................................. 4-81
Microjoints................................................................. 4-86
5.6 PRODUCTION Production plan..................................... 4-89
5.7 NC program management in NC................................... 4-92
6. Activity SETUP............................................................. 4-94
6.1 SETUP switch elements ................................................ 4-94
General switch elements.......................................... 4-94
Pallet change cycle switch elements........................4-96
Manual pallet change switch elements..................... 4-97
Laser machining switch elements ............................ 4-98
Service switch elements........................................... 4-99
Switch elements RotoLas....................................... 4-100
Hydraulic collet chuck switch elements.................. 4-101
TLF laser intervention 1 switch elements............... 4-102
TLF laser intervention 2 switch elements............... 4-103
6.2 SETUP Jog mode........................................................ 4-105
6.3 SET-UP MDA............................................................... 4-106
6.4 SETUP Adjust laser beam........................................... 4-108
7. PROGRAMMING Activity ........................................... 4-113
7.1 PROGRAMMING NC edit or ......................................... 4-113
7.2 PROGRAMMING Managing NC programs ................. 4-115
7.3 PROGRAMMING File management............................4-117
7.4 PROGRAMMING Issue programs from the
program manager ........................................................ 4-119
8. MAINTENANCE / START-UP Activity....................... 4-121
8.1 MAINTENANCE / START-UP Backup ........................ 4-121
8.2 MAINTENANCE / START-UP Display......................... 4-123
8.3 MAINTENANCE/START-UP Logbook,
maintenance ................................................................ 4-124
9. DIAGNOSTICS Activity.............................................. 4-125
9.1 DIAGNOSTICS Fault diagnostics................................ 4-125
9.2 DIAGNOSTICS I/O diagnostics ................................... 4-127
9.3 DIAGNOSTICS Remote diagnostics ........................... 4-128
9.4 DIAGNOSTICS Las er.................................................. 4-129
Laser RF generator.................................................................. 4-129
Laser leak test.......................................................................... 4-131
9.5 DIAGNOSTICS Displaying home position................... 4-133
0-10 Table of contents B452EN00.DOC
10. Integrated MDC activity field (optional)................... 4-134
10.1 MDC message texts .................................................... 4-134
10.2 Creating and modifying MDC message texts ..............4-135
10.3 Displaying and processing MDC machine data........... 4-137
10.4 Creating and modifying MDC interr uptions.................. 4-139
10.5 Evaluating MDC machine data .................................... 4-140
10.6 MDC display of the times in list form ...........................4-142
10.7 Modifying MDC time .................................................... 4-144
Part 3: Operating the machine.............................................. 4-145
1. Machine start-up and shutdown .............................. 4-148
1.1 Machine start-up.......................................................... 4-148
1.2 Machine shutdown during malfunctions /
emergencies ................................................................ 4-149
1.3 Machine shutdown....................................................... 4-149
2. Executing program.................................................... 4-150
2.1 Automatic program execution...................................... 4-150
2.2 Stopping a program during execution.......................... 4-151
2.3 Aborting a program...................................................... 4-151
2.4 Reentering a program.................................................. 4-152
3. Working with the production plan ........................... 4-157
3.1 Creating the production plan........................................ 4-157
3.2 Executing production plan ........................................... 4-158
3.3 Restarting execution of the production plan after a
program has been canceled........................................ 4-158
4. Moving the axes manually ........................................ 4-159
5. Releasing the drive brakes ...................................... 4-159
5.1 Release the Z axis drive brake ................................... 4-159
6. Manual lubrication cycle........................................... 4-160
7. Operating the pallet changer.................................... 4-161
7.1 Changing pallets manually.......................................... 4-161
7.2 Changing pallets automatically................................... 4-162
8. Operating the laser.................................................... 4-163
8.1 Switching on the laser.................................................. 4-163
8.2 Switching the laser off................................................. 4-163
8.3 Energizing the laser beam........................................... 4-164
8.4 Switching the laser beam off ....................................... 4-164
8.5 Opening the beam trap............................................... 4-164
8.6 Closing the beam trap.................................................. 4-165
B452EN00.DOC Table of contents 0-11
8.7 Working in laser test mode .......................................... 4-165
8.8 Setting laser operation mode....................................... 4-165
8.9 Setting laser submode................................................. 4-166
8.10 Setting laser power..................................................... 4-166
8.11 Implementation of the leak test................................... 4-167
9. Diagnostic functions ................................................. 4-168
9.1 Fault diagnos tics.......................................................... 4- 168
9.2 Displaying the laser and machine inputs and
outputs......................................................................... 4-169
9.3 Remote diagnostics via pcANYWHERE1.................... 4-170
9.4 Inquiring about software version.................................. 4-171
10. Management of master files ..................................... 4-171
10.1 Reading in NC programs from the disk drive............... 4-171
10.2 Reading in NC programs from hard disk ..................... 4-172
10.3 Issuing NC programs to disk drive............................... 4-172
10.4 Issuing NC programs to the hard drive........................ 4-173
10.5 Issuing a program part to the disk drive ...................... 4-174
10.6 Deleting NC programs from the program manager..... 4-174
11. Managing NC programs ............................................ 4-175
11.1 Display NC text............................................................ 4-175
11.2 Editing NC text.............................................................4-176
Finding block in NC text.......................................... 4-176
Searching for a function in the NC text................... 4-176
Searching for and replacing a function in an NC
text.......................................................................... 4-177
Inserting additional lines.........................................4-178
Copying and pasting text........................................ 4-178
Deleting text passages ........................................... 4-179
12. Editing tables based on an NC text ......................... 4-180
13. Using ToPs 100 lite.................................................... 4-181
13.1 Starting and ending ToPs............................................ 4-181
13.2 Overview of programming sequence........................... 4-182
13.3 Updating ToPs............................................................. 4-182
14. Operating the RotoLas tube and tube cutting
facility.......................................................................... 4-183
14.1 Preparing the machine for tube machining..................4-183
14.2 Switching the machine setting over to plane
machining..................................................................... 4-185
14.3 Selecting and deselecting the longitudinal conveyor
belt............................................................................... 4-185
14.4 Setting the work position.............................................. 4-186
14.5 Positioning the support................................................ 4-188
14.6 Carrying out tube center measurement at a point....... 4-188
0-12 Table of contents B452EN00.DOC
14.7 Resetting the coordinate displacement ....................... 4-189
14.8 Utility program CP_RLPRG......................................... 4-189
Cutting spacers....................................................... 4-190
Cutting spatter guard.............................................. 4-190
Creating mounting discs for rectangular tubes....... 4-191
14.9 Working with the automatic collet chuck (optional)...... 4-194
Clamping with the automatic collet chuck .............. 4-194
Unclamping with the automatic collet chuck........... 4-195
Notes on working with the automatic collet
chuck ...................................................................... 4-195
14.10 Changing the dead range of the clamping jaws .......... 4-196
14.11 Determining the zero point offset................................ 4-199
14.12 Running test mode...................................................... 4-201
14.13 Working examples ......................................................4-202
Machining round tubes without support.................. 4-202
Machining rectangular tube without support........... 4-203
15. Saving customer data ............................................... 4-204
16. Acknowledging maintenance ................................... 4-205
17. Activating auto-shutdown (optional)....................... 4-206
18. Operating the integrated MDC.................................. 4-207
18.1 Creating a message text.............................................. 4-207
18.2 Assigning a message text............................................ 4-208
18.3 Subdividing an interruption time period ....................... 4-209
18.4 Evaluating machine data ............................................. 4-210
19. ODC – Evaluating an interface ................................. 4-211
19.1 Opening a LOG file...................................................... 4-211
19.2 Opening a LOG file in MS – Excel............................... 4-212
Part 4: E-Shop: Acquiring replacement parts online ......... 4-213
1. Start E-Shop............................................................... 4-213
1.1 Registering................................................................... 4-213
1.2 Login ............................................................................4-214
1.3 Storing customer data.................................................. 4-214
2. Ordering replacement parts...................................... 4-215
2.1 Ordering from the Top Ten list..................................... 4-215
2.2 Direct ordering ............................................................. 4-216
B452EN00.DOC Table of contents 0-13
2.3 Editing the shopping cart ............................................. 4-217
2.4 Ordering a shopping cart ............................................. 4-218
Chapter 5 Setting work
Safety information...................................................................... 5-3
1. Replacing cutting head (fast lens replacement)......... 5-4
2. Centering the beam to the nozzle ................................ 5-6
2.1 Procedure for adhesive strips.......................................... 5-6
3. Working with AutoLas Plus.......................................... 5-8
3.1 Exceeding the automatic adjustment range .................. 5-10
4. Determining focus position ........................................ 5-10
4.1 Procedure ...................................................................... 5-10
4.2 Focus search program CP_FOCUS_COMB................. 5-12
4.3 Evaluation of the focus search program........................5-12
5. Setting work on the pallet conveyor.......................... 5-13
Replacing cam assembly.......................................... 5-14
Replacing pallet conveyor chain............................... 5-16
Checking for chain elongation.................................. 5-17
6. Setting work on the CatEye ........................................ 5-18
7. Further utility programs.............................................. 5-18
7.1 Slitting program CP_T RIM_OFF.................................... 5-18
7.2 CP_CONTOUR_CUTTING - Utility program for
parameter optimization.................................................. 5-18
7.3 Utility programs for cutting wearing parts for the
workpiece support.......................................................... 5-19
TC L 3050 standard machine................................... 5-19
TC L 3050 with LiftMaster R..................................... 5-21
TC L 3050 with LiftMaster RP................................... 5-22
TC L 3050 with LiftMaster P..................................... 5-22
TC L 3050 with SortMaster....................................... 5-23
TC L 3050 with SortMaster (auxiliary pallets)........... 5-23
TC L 3050 with PalletMaster .................................... 5-24
TC L 4050 standard machine................................... 5-24
0-14 Table of contents B452EN00.DOC
TC L 4050 with LiftMaster R..................................... 5-25
TC L 4050 with LiftMaster P..................................... 5-26
TC L 4050 with LiftMaster RP................................... 5-26
TC L 6050 standard machine................................... 5-27
TC L 6050 with LiftMaster R from the TC L 4050..... 5-27
Chapter 6 Machine maintenance
1. General guidelines......................................................... 6-3
2. Maintenance overview................................................... 6-4
2.1 Classification according to components.......................... 6-4
2.2 Classification according to maintenance intervals........... 6-5
3. System lubrication......................................................... 6-8
3.1 Lubrication chart ..............................................................6-8
3.2 Lubricant table ................................................................. 6-9
3.3 Notes for lubrication chart.............................................. 6-10
4. Maintenance of mechanical components ................. 6-17
4.1 Maintenance ov erv iew................................................... 6-17
4.2 Notes for maintenance overview ................................... 6-17
5. Maintenance of pneumatic components and
filters ............................................................................. 6-25
6. Maintenance of optical components ......................... 6-37
6.1 General guidelines and additional equipment............... 6-37
6.2 Maintenance of optical components .............................. 6-38
Notes for maintenance plan...................................... 6-39
7. Maintenance of the electrical components............... 6-48
8. Maintenance of the hydraulic system........................ 6-51
9. Maintenance of air-conditioning doors ..................... 6-53
B452EN00.DOC Table of contents 0-15
Chapter 7 Maintenance
1. General guidelines......................................................... 7-3
2. Maintenance overview................................................... 7-4
2.1 Maintenance po ints.......................................................... 7-6
3. Gas circuit ...................................................................... 7-8
3.1 Overview.......................................................................... 7-8
3.2 Maintenance ins truc ti ons................................................. 7-9
Vacuum pump ............................................................ 7-9
4. Pneumatic system ....................................................... 7-10
4.1 Maintenance ins truc ti ons............................................... 7-10
Compressed air filtering unit..................................... 7-10
5. Cooling water circuit ................................................... 7-11
5.1 Overview........................................................................ 7-11
5.2 Maintenance ins truc ti ons............................................... 7-15
Cooling unit............................................................... 7-15
6. Electrical....................................................................... 7-26
6.1 Overview........................................................................ 7-26
Notes on safety......................................................... 7-27
Short-circuiting residual voltage ............................... 7-28
6.2 Maintenance ins truc ti ons............................................... 7-34
RF generator............................................................. 7-34
Analog values IS11-IS22.......................................... 7-40
Analog values IS36/IS44.......................................... 7-41
7. Operating the laser...................................................... 7-46
7.1 Opening the vacuum system ......................................... 7-46
7.2 Conducting a leak test ................................................... 7-46
7.3 Switching on the cooling unit ......................................... 7-47
7.4 Checking the operation data fo r the RF generator........ 7-47
0-16 Table of contents B452EN00.DOC
Chapter 8 Test report – noise level
1. Test certificate................................................................ 8-2
2. Measurement result....................................................... 8-3
3. Test workpiece............................................................... 8-4
4. Position of measuring points....................................... 8-5
5. Notes on TC L 4050 and TC L 6050.............................. 8-5
Chapter 9 Aligning the MSL multi-beam safety light
barrier
1. Alignment accessories.................................................. 9-2
2. Installation example ...................................................... 9-3
3. Alignment procedure..................................................... 9-4
Chapter 10 TRUMPF RotoLas tube cutting device
1. TRUMPF RotoLas tube cutting device:
An overview.................................................................. 10-3
2. Specifications............................................................... 10-4
3. The most important components............................... 10-5
3.1 Rotation unit................................................................... 10-6
3.2 Exhaust system ............................................................. 10-6
3.3 Support .......................................................................... 10-7
3.4 NC backstop................................................................ 10-10
3.6 Catch plate (optional)................................................... 10-11
3.7 Automatic collet chuck (optional)................................. 10-12
B452EN00.DOC Table of contents 0-17
3.8 Clamping technique..................................................... 10-13
Clamping workpiece ............................................... 10- 13
Turning and clamping jaws (clamping technique
no. 1-6) ................................................................... 10-14
Basic jaws............................................................... 10-15
Bolt clamping set (clamping technique no. 7)........ 10-16
Prism clamping set (clamping technique no. 8)..... 10-17
Dead area-minimised clamping (clamping
technique no. 9)...................................................... 10-18
Clamping special shapes (clamping technique
no. >100) ................................................................ 10-19
Clamping technique table....................................... 10-20
4. Operating the RotoLas tube cutting device............ 10-21
5. Maintenance............................................................... 10-22
5.1 Maintenance Overview ................................................ 10-22
5.2 Notes on maintenance................................................. 10-22
6. ToPs 400 programming system ............................... 10-24
0-18 Table of contents B452EN00.DOC
Chapter 1
Safety
1. For your safety............................................................... 1-3
2. Terminology ................................................................... 1-4
3. Operating safety ............................................................ 1-4
3.1 Authorized application of the system............................... 1-5
3.2 Measures to be taken by the user/operator..................... 1-6
Warning plates and other warnings............................ 1-6
Operator training......................................................... 1-8
Necessary diligence in operating the system............. 1-8
Eliminating malfunctions during operation.................. 1-9
Using specified replacement parts and
operating materials ................................................... 1-10
Water protection ....................................................... 1-11
Fire protection........................................................... 1-12
3.3 Measures taken by the manufacturer............................ 1-13
Securing the danger zone of the machine................ 1-13
Suction equipment.................................................... 1-15
4. Overview of hazards.................................................... 1-16
B452EN01.DOC Safety 1-1
5. Laser processing......................................................... 1-19
5.1 Operating modes of the laser system............................ 1-19
5.2 Laser classes................................................................. 1-19
5.3 Hazards from laser radiation.......................................... 1-20
5.4 Protection aga inst ra di ation ........................................... 1-20
Measures to be taken by the user/owner ................. 1-20
Measures taken by the manufacturer....................... 1-22
5.5 Hazardous substances .................................................. 1-25
Dust, aerosols and gases......................................... 1-25
Ozone....................................................................... 1-26
Polyethylene (PE) coated sheets ............................. 1-26
5.6 Hazards from thermal decomposition of
ZnSe lenses................................................................... 1-28
Lens characteristics.................................................. 1-28
Thermal decomposition............................................ 1-28
Responsive measures in case of accident............... 1-29
Disposal of lenses .................................................... 1-30
5.7 Danger due to high voltage............................................ 1-30
6. Danger due to alternating electromagnetic
fields.............................................................................. 1-32
6.1 Linear drives .................................................................. 1-32
Measures taken by the manufacturer....................... 1-33
6.2 RF generators................................................................ 1-34
1-2 Safety B452EN01.DOC
1. For your safety
With the TRUMATIC L 3050, TRUMATIC L 4050, TRUMATIC
L 6050, you have a laser machining system which features the
latest technology and ensures safe operation.
With the declaration of EC conformity and the CE label on the
system, we confirm that the TRUMATIC L 3050, TRUMATIC
L 4050, TRUMATIC L 6050 com plies with the re levant regulati ons
on occupational health and safety stipulated in EC Machinery
Directive 98/37/EC.
Nameplate and CE label
Fig. 29892en
Together with the CE m ark ing, the nameplate is on t he right side of
the machine in the start post area.
B452EN01.DOC Safety 1-3
As the manufacturer of the m achines , we wish to acqu aint you, the
owner, with the safet y concept of the system , as wel l as t o pro vide
information about potential risks and measures by means of a
comprehensive chapter on safety.
Particular emphasis is placed upon protection against radiation and
potentially hazardous materials during laser machining.
Note
In addition to the inf ormation in this chapter, ple ase also observe
general safety and accident prevention regulations.
2. Terminology
Danger zone
User/Owner
Operator/personnel
... is the area within and peripheral to the machine where the safety
or health of persons is endangered.
... is the person on whose operating s ite the system is set up a nd
operated.
... are the persons responsible for the transportation, installation,
initial startup, operation, maintenance (including cleaning) and
elimination of malfunctions for the machine.
3. Operating safety
The system is built using the latest technology and is safe to
operate.
The system can become a source of danger if it used inappropriately or other than intended:
• Dangers to the safety of the operator.
• Impairment of the machine and other property of the user.
• Impairment of the working efficiency of the machine.
1-4 Safety B452EN01.DOC
3.1 Authorized application of the system
The TRUMATIC L 3050, TRUMATIC L 4050, TRUMATIC L 6050 is
a laser machining system for cutting flat metal materials. Tubes
and profiles can also be machined if th e TRUMPF RotoLas tube
cutting unit (optional) is used.
Authorized application also means:
• The conditions for installation specified by the manufacturer
must be observed and maintenance work must be carried out.
• The installation and operation of the machine must comply with
the respective national regulations valid in the country where
the machine is operated. The user is responsible for
compliance with these la ws.
The following is not permitted:
• Laser cutting of plastic materials.
• Unauthorized modif ication or retrofitting of the machine by the
user or operator.
• Any type of operation which can impair safety.
No liability assumed in the
event of unintended use.
Any other use is considered to be other than intended. The
manufacturer assumes no liability for any resulting damage to
property and injury to persons. T he user bears all lia bility f or risk in
such cases.
B452EN01.DOC Safety 1-5
3.2 Measures to be taken by the user/
operator
Warning plates and other warnings
Some of the tasks which must be performed while operating the
TC L 3050, TC L 4050, TC L 6050 could lead to dangerous
situations for the personnel involved. Warnings precede the
instructions for the performance of such tasks in this operator's
manual. Furthermore, corresponding warning signs are on the
system.
Note
Observe the warnings.
Adhere to the obligations and r estrictions of the warni ngs . They are
for your own safety.
The warnings contain:
• A symbol.
• A key word.
• Information on the source and type of danger.
• Instructions on how to avoid the danger.
The form and content of the warnings are described in the
following sections.
Symbols
The warnings are supplemented in the left column by symbols
indicating the type of danger.
General danger symbol; the t ype of dang er is d escribed in detai l in
the warning indicated by this symbol.
This symbol warns against dangerous electrical currents.
Furthermore danger signs with the following inscription have also
been applied to the relevant components and cables in the switch
cabinet for components of the machine, which are connected in
front of the main switch:
CAUTION! LIVE WHEN MAIN SWITCH IS SWITCHED OFF.
These components are live even if the main switch is set to OFF!
This symbol warns agains t dangerous laser beams.
For additional laser-specific danger and information plates, see
section 5.4, p. 1-20.
This symbol warns agains t electromagnetic fields.
1-6 Safety B452EN01.DOC
Key words
The warnings are indicated by one of the following key words:
• Danger
• Warning
• Caution
The key words have the following meaning:
Danger
Warning
Caution
Warning
Refers to a great danger. Death and serious injuries are the
consequence if it is not avoided.
Refers to a dangerous situation. Serious injuries or considerable
damage to property can be the consequence if they are not
avoided.
Refers to a potentially dangerous situation. Slight injuries or
damage to property can be the consequence if they are not
avoided.
Information on the source, type and how to avoid the danger
The warnings contain information on the source and type of the
danger as well as i nstructions on how t o behave in order t o avoid
dangers.
Example:
Fire hazard due to incorrectly laid gas conduits!
If a gas conduit is damaged, a short circuit in an electric
cable could cause a fire.
Do not lay gas conduits together with electric cables.
B452EN01.DOC Safety 1-7
Operator training
The machine may be operated, serviced, and repaired by
authorized, qualified, and ins tr uc te d per s onne l only.
Work on electric, pneumatic, hydraulic, and laser-specific equipment may only be carried out by specially trained expert personnel.
The following measures m ust also be c arrie d out pri or to person nel
beginning work at the machine:
• Give instructions on potential dangers.
• The user must, if necessary, ensure that the personnel wear
protective clothing and gloves. This especially applies when
heated workpieces are to be removed. If necessary, use
special tools for r emoving the wor kpiece. Suitabl e laser saf ety
glasses must always be worn in service mode (laser system
class 4). A close-fitting dus t m ask (fine dus t m ask of filter class
P3 against toxic part icles) must alwa ys be worn when wo rking
on the compact dust extractor.
• The areas of competence for maintenance, operation and
servicing must be clearly defined in order to avoid any
ambiguity concern ing responsibilities for the safety aspects of
machine operation.
• Personnel must read the technical documentation of the
system. We recommend that the user receives written
confirmation that t he personnel have re ad and un derstood the
technical documentation.
Safety devices and danger
zones of the system
Necessary diligence in operating the system
• Suitable saf ety equipment for securing the danger zone must
be installed as a prerequisite to machine operation.
• As a general rule, saf ety devices may not be removed o r put
out of operation. If, ho wever, this is required for m aintenance
or repair work, reinstall the safety devices immediately after
finishing the maintenance or repair work and put them into
operation.
• T he safety cabin and light barrier m ust be checked for proper
functioning once per shift (preferably before starting
production).
• Light barriers must also be tested for proper functioning:
– If the arrangement of light transmitter and light receiver
has been changed.
– After all maintenance and service work on the light barrier.
1-8 Safety B452EN01.DOC
• The operator must make sure nobody is within the danger
zone each time before the system is started up.
Making sure the system is in
perfect working order
Observing the shutdown
procedures
• The user or the persons authorized by the user may only
operate the machine if it is in perfect condition.
• The user must set up the system in accordance with the
installation plan and installation conditions.
• The user must ensure the wor kplace at the machine is clean
and orderly by means of appropriate instructions and
inspections.
• The us er must ens ure that suf ficient f resh air is suppli ed to the
working area.
• Changes (including chan ges in operating perf ormance) arising
at the machine which affect operating safety must be
immediately reported to the user by the operator. For this
reason the system must be checked for visible defects and
damage at least once every shift.
The prescribed shutdown procedures must be adhered to for all
work concerning the transport, installation, operation, maintenance,
and repairs as well as for putting the system into service:
• Before undertak ing any setting, maintenance or ser vice work,
the machine must be switched off using the m ain s witc h, whic h
must then be locked and t he key removed. Any exc eptions to
this rule, requiring that the system remains switched on, are
specified in the operator's manual.
• For work on the pneumatic system:
– Shut off the compressed air supply and lock it.
– Close the stopcocks of the gas supply.
– Wait for at least 5 seconds until the pressure has dr opped
after shutting off the compressed air supply.
– Check whether the operating press ure has fallen to 0 bar.
To do this, read the current operating pressure on the
relevant pressure gauge on the instrument panel.
Eliminating malfunctions duri ng operation
1. Press FEED HOLD.
2. Eliminate the malfunction using the control panel.
3. If the malfunction cannot be eliminated using the operating
panel: press E-STOP.
4. Eliminate the malfunction by intervening briefly in the machine.
B452EN01.DOC Safety 1-9
5. If there are malfunctions which need to be eliminated by
maintenance or servicing work:
– Switch off the main switch.
– Lock the main switch.
– Pull out the key.
6. Have maintenance and repair work carried out.
Using specified replacement parts and
operating materials
Original parts and
accessories
Operating materials
Original parts and accessor ies have been especially designed f or
this machine. Replacem ent parts for or iginal p arts and ac cessor ies
other than those supplied by the machine's manufac turer ha ve a lso
not been checked and approved by the manufacturer. The
installation and/or use of such products may therefore under
certain circums tances change the original des ign ch aracteristics of
the system and impair safety.
Note
The manufacturer accepts no liability for damage caused by the
use of non-original parts and accessories or by the incorrect
installation or replacement of original parts and accessories.
The instructions for using the appropriate operating materials (in
particular lubricants and cleaning agents) must be observed. If a
safety data sheet (Eur opean Directive 91/ 155/EEC, 93/112/EC) of
the manufacturer is prescribed for an operating material, the
instructions included on it must be followed, such as:
• Chemical properties.
• Physical and safety-relev ant inf or mation.
• Transport
• Regulations
• Safety measures, storage and handling.
• Measures in the event of accidents or fires.
• Toxicological information.
• Ecological information.
This also applies especially to the appropriate disposal of operating
materials. The pres cribed disposal method an d the waste key are
specified by the saf ety data sheet. The safety data sheet can be
requested from the manufacturer of the operating material.
1-10 Safety B452EN01.DOC
Water protection
The principle of precaution a pplies to systems with water-polluting
substances in the Fed eral Republic of German y. It stipulates t hat
no waterways are allowed to be polluted as a result of handling
these substances. This is the m ain statement of § 19 of the W ater
Resources Act (WRA). Plant decrees (VAwS) and administrative
regulations (VVAwS) of the federal states specify how this
precautionary principle should be followed.
Water-pollutant substances Hydraulic oil and lubricants
Water hazard class WGK 2
Hydraulic oil operati ng pressure 150 bar
Volume of the water-pollutant
substances
Pollutant level of t h e complete system A
Information on water protection
≤1000 l
Table 1-1
Cooling water
Cooling water may only be disposed of togeth er with waste water
in agreement with the local waste disposal authority.
B452EN01.DOC Safety 1-11
Fire protection
Ready availability of a hand-
held fire extinguisher
Caution
For fire protection purposes, the following hand-held fire
extinguishers are required:
• Hand-held fire exti nguisher for m etal fires (class D) due t o the
danger of ignition of hot slag created during laser machining.
• CO
Risk of fire in the compact dust extractor due to burning
objects in the workspace of the system or after changing
workpiece materials.
hand-held fire extinguisher (class B) for fires in the
2
compact dust extractor.
Do not throw cigarette ends or oth er burning objects into the
machine workspace. Otherwis e there is a risk of the objects
being sucked in b y the suction un it and enter ing the c ompact
dust extractor through the suction channel.
The following safety precautions should be observed after
changing the workpiece from aluminum/aluminum alloys to
galvanized sheets, mild steel or stainless steel, or vice versa:
– Wait for the lag time of the suc tion u nit to expir e af ter the
processing program has come to an end.
– Replace the disposable containers in the compact dust
extractor. We recommend using separate containers for
each of these material groups and labeling them
accordingly.
Measures to be taken in the
event of a fire
If there is a fire in the compact dus t extractor, the following ste ps
must be undertaken to fight the fire:
1. Switch off the main switch.
2. Close the intake opening if possible.
3. Close the exhaust opening on the top of the housing if
possible.
4. Have an extinguishing agent ready: CO
extinguisher.
5. Swing the metal sheet away from the spraying opening. The
spraying openings are in two opposite housing walls and are
both indicated with a sign.
6. Spray the extinguishing agent into the appropriate opening.
7. Only open the door of th e housing when it is possible to fight
the fire.
8. Extinguish the fire completely, if possible.
hand-held fire
2
1-12 Safety B452EN01.DOC
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