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
3.3 Measures taken by the manufacturer
2
Securing the danger zone of the machine
The danger zone of the system is secured by appropriate safety
devices. The system may only be operated with these safety
devices.
1 Transmitter
2 Mirror posts
3 Receiver
4 Safety cabin
2
4
3
Fig. 29908
21
The machine is supplied, as a standard, with a safet y cabin with
two doors (including safety interlocks). One door gives access to
the workroom, while the maintenance door gives access to the
instrument panel. The s afety cabin is made of sheet st eel, with a
4 mm thick, transparent polycarbonate (makrolon) viewing window.
The danger zone aroun d the p al let c h ang er is s ec ured wi th a multibeam light barrier. If there are people in the area above the saf ety
cabin, the customer must tak e the necessary steps to secure t hat
area.
For machines equipped with automation components (optional),
the danger zone around the automation components is also
secured with a light barrier or safety fencing.
B452EN01.DOC Safety 1-13
Note
The operator must m ake s ure nobody is within the sec ured d anger
zone each time before the installation is started up.
Safety cabin
The safety cabin secures the machine's danger zone for all
operating modes of the control system.
If a door of the safety cabin is opened during operation:
• The laser beam is switched off.
• The beam trap is closed.
• The movement of the axes is stopped.
• The cutting gas supply is interrupted.
To switch the system back on after opening a door to the
safety cabin: close the door in question and press START.
Light barriers
The light barriers secur e the da nger zone in all o perat ing m odes of
the control system.
All movements of the pallet changer are stopped if the light beam
is interrupted during operation.
In order to switch the system bac k on after interrupting th e l ig ht
barrier: acknowledge th e light barr ier and press ST ART on the
system control panel.
1-14 Safety B452EN01.DOC
E-STOP impact buttons
E-STOP impact buttons are located at several points on the
machine.
1
2 3
1 Main switch
2 E-STOP on the control panel
Position of the E-STOP impact buttons and the main switch
3 E-STOP on the start post
E-STOP triggers the following machine functions:
• Po wer supp ly of the s ystem is interrupt ed (2 4 V co ntro l volt ag e
is retained at the machine and laser).
• The laser beam is switched off.
• The beam trap is closed.
• All axis motions stop.
• The cutting gas supply is interrupted.
Suction equipment
The exhaust suction a nd filtering equipment provided by T RUMPF
for this system is design ed to trap the aerosols an d dust particles
emitted, provided the machine is used correctly (see section 5.5,
p. 1-25).
Fig. 29896
B452EN01.DOC Safety 1-15
4. Overview of hazards
The following over view of hazards displays the pr incipal potential
risks to life and health arising from the machine. Danger to
personnel is excluded by the s ystem 's des ign and c onstruc t ion an d
its safety devices, in accordance with EC Machinery Directive
98/37/EC. Any measur es that can be tak en b y the m achine user to
reduce residual risk are indicated in the overview of hazards.
Type of hazard Danger point Danger Additional precautions
Mechanical hazards
• Due to crushing, shearing or
impact.
• Due to shearing. • Raising, lowering and
• Due to cutting and separating. • Sharp-edged workpieces. Risk of injury • Wear protective
• Getting caught or due to
winding.
• Due to being drawn in or
caught.
• Movement of the X, Y, Z
and U axes, pallet, conveyor
belts, energy coupl ing
(RotoLas option).
• Strong permanent magnets
of the linear drives and the
expanding magnets.
• LiftMaster (optional), loading
unit (optional).
• Loading and unloading cart
(optional).
• Storage system (optional).
moving the pallet.
• Movements of the round
table (RotoLas opti on).
• Movements of workpieces
projecting out of the
machine (RotoLas opti on).
• Chain drive of the pallet
changer.
• Pallet movement on the
upper track.
Risk of injury -
Risk of injury -
Risk of injury
Risk of injury
Risk of injury
Risk of injury -
clothing and gloves .
• Use tools to take out
the workpiece.
Securing of the danger
zone by the customer.
-
1
• Danger due to instability (item
tipping over by its own weight,
falling down due to a fracture
or due to its own weight) in the
case of the loading uni t or
LiftMaster (optional).
• Workpieces falling down.
1
Additional measures to be taken by the cust omer to prevent any risks
remaining in spite of the safety devices of the system.
Risk of injury -
1-16 Safety B452EN01.DOC
Type of hazard Danger point Danger Additional precautions
• Due to fluids and gases
expelled under high pr essure.
• Cutting gas.
• Hydraulic oil.
Risk of injury
Risk of injury
-
-
Electrical hazards
• Due to electrical contact. • Directly with normally live
Risk of fatal injury
-
parts.
• Indirectly with parts made
Risk of fatal injury
-
live due to malfunction.
• Contact with parts which
Risk of fatal injury
-
store electrical charge.
• From thermal radiation or
• Ejected slag spattering.
Risk of injury -
spurting, melted parts.
Thermal hazards
• Due to contact. • Hot workpieces. Risk of injury • Wear protective
clothing and gloves .
• Use tools to take out
the workpiece.
• Due to flames or explosions. • Burning/blowout due to
Risk of injury -
concentration of oxygen.
Hazards due to radiat ion
• Laser • Scattered radiation above
the safety cabin.
Risk of injury
Protection provided by
the customer agains t
potential exposur e of
personnel.
2
Danger due to magnetic fields
• High-frequency magnetic
fields.
• Strong magnetic field due to
permanent magnet regar dless
of switch-on status of the
machine.
• Scattered radiation after
taking off the external
protective cover on the tube
cutting unit (optional).
• Radiation during
service/maintenance/setting
work.
• RF generator
• Linear drives.
• Expanding magnets on the
loading equipment
(optional).
Risk of injury
Risk of injury
Risk of fatal injury to
persons with
pacemakers
Risk of fatal injury to
persons with
pacemakers
Risk of injury
Securing of the danger
zone by the customer.
Wear protective clothing
and laser safety gl asses.
Off limits.
Minimum distance of
30 cm to be maintained
by persons with pacemakers.
Keep a wedge and
hammer ready made of
non-magnetic material.
2
Additional measures to be taken by the cust omer to prevent any risks
remaining in spite of the safety devices of the system.
B452EN01.DOC Safety 1-17
Type of hazard Danger point Danger Additional precautions
Hazards due to substances
• Through contact with or by
inhaling toxic fluids, gases,
mist, fumes, and dust.
• Cutting gas.
• Dust, aerosols.
• Cutting oils.
• PE-coated profiles.
• Thermally decomposed
Health hazard
Health hazard
Health hazard
Health hazard
Health hazard
Adequate ventilat ion of
the workplace.
Follow all instructions in
the operator's manual .
lenses or mirrors.
3
Fire hazards • Beam guideway.
• Laser radiation reflection.
• Compact dust extractor.
Hazards caused by malfunctions
• Malfunction to the energy
supply.
• Drives
• Control voltage.
Risk of injury
Risk of injury
Risk of injury
Risk of injury
Risk of injury
-
Keep ready CO2 handheld fire extinguisher and
hand-held fire
extinguisher for metal
fires (class D).
-
-
Table 1-2
3
Additional measures to be taken by the cust omer to prevent any risks
remaining in spite of the safety devices of the system.
1-18 Safety B452EN01.DOC
5. Laser processing
2
5.1 Operating modes of the laser system
A distinction is made between two operating modes in terms of
safety. The operating mode is set via a key switch on the machine.
Normal mode
Service mode
Normal mode covers the operation of the laser in all intended
areas of function without maintenance and service (EN 60825-1).
Features:
• The machine is controlled either by a program or else manually.
• Protective devices are activated.
• When the laser beam is switched on, the laser cutting head is
above the workpiece in working position.
• No personnel are within the danger zone of the system.
Note
The danger class of the laser system in normal mode is: Class 1.
Service mode concerns laser operation for setting and main-
tenance work. This includes:
• All set-up work on optical components of the system.
• Alignm ent of the laser beam or check ing the alignment of the
laser beam.
Note
Danger class of the laser system in service mode:
Class 4.
5.2 Laser classes
Class 4 CO
Class of the targeting laser
B452EN01.DOC Safety 1-19
laser
A CO2 laser of Class 4 in term s of EN 60825-1 has been integrated
in the system.
Targeting lasers based on HeNe lasers or laser diodes may be
integrated in the system. The y correspond to t he clas ses 2 or 3b i n
terms of EN 60825-1.
5.3 Hazards from laser radiation
CO2 lasers
Targeting lasers
CO2 lasers generate i nvisible light (el ectromagnetic radiat ion) with
high energy. Both r eflected laser rad iation a nd direct r adiation c an
pose health hazards. Eyes and skin are particularly at risk.
Impairment of vision or even complete blindness can be the
consequence.
Light is absorbed in differ ent ways by biolo gical tiss ue. It is usual ly
transformed into heat, resulting in thermal damage (e.g. burns,
destruction of protein).
Targeting lasers (HeNe lasers, laser diodes), with their red light,
are used for fine-tuning work. Looking directly into the beam
source can damage the eyes. Com plete los s of v ision can result in
worst cases.
5.4 Protection against radiation
Measures to be taken by the user/owner
The basic responsibili ties of the machine owner are state d in the
European standard EN 60825-1 "Radiation safety of laser
systems" and other similar international standards. Furthermore
the regulations of the respective country apply.
Observing accident
prevention regulations
Determining a laser safety
officer
For the jurisdiction of l aws in the Federal Republic of Ger many, the
accident preventio n regulation "Laser radiation" (BGV B2) of the
employer's liability insurance association is to be strictly observed.
The owner of the machine m ust commission a las er safety off icer,
unless the owner pr ov es he/s he has the qualific at ions required and
monitors the laser system operation personally.
The duties of the laser safet y officer are defined b y BGV B 2 and
the implementation directives of this accident prevention
regulation.
Training facilities in the Federal Republic of Germany include:
• Berufsgenossenschaft für Feinmechanik und Elektrotechnik
(Trade Association for Precision Mechanics and Electrical
Engineering), Postfach 510580, Gustav-Heinemann-Ufer,
D–50968 Köln, Germany.
• Physikalisch-Technische Bundesanstalt (Federal Institute of
Technical Physics), Bundesallee 100,
D-38116 Braunschweig, Germany.
• TÜV Akademie Bayern / Hessen GmbH, Postfach 210420,
Westendstraße 199, D-80686 München, Germany.
• Technische Akademie Esslingen (Technical Academy in
Esslingen), Postfac h 1265, In den Anlagen 5,
D-73760 Esslingen, Germany.
1-20 Safety B452EN01.DOC
Training personnel
The company operating the system must ensure its personnel is
trained appropriately.
The minimum training requirements are:
• Instruction of personnel in the operational procedures of the
laser.
• Correct application of laser protection devices.
• Necessity of personal safety.
• Procedure in the event of accidents.
• Biological effect of laser radiation on eyes and skin.
Medical monitoring
Precautions for alignment
and setup work
Medical monitoring of the operating personnel is not mandatory.
Persons involved in accidents caused by laser radiation must
immediately undergo medical examinations.
All alignment and s etup work related to the laser beam may only
be performed by specially trained and equipped personnel.
During alignment and s etup work, the system 's danger zone m ust
be further secured where necessary (e.g. with steel, Plexiglas or
polycarbonate partitions).
The personnel mus t wear laser s afet y glasses to protect t heir e yes
during adjustment and set-up work in connection with laser
radiation. The laser s afet y glasses m ust com ply with the s tandards
of EN 60825-1 or EN 207.
B452EN01.DOC Safety 1-21
Measures taken by the manufacturer
The machine may only be operated if the safety devices are active.
Safety precautions for laser
units and beam guideway
Signage on the machine and
the laser (in accordance with
EN 60825-1)
• The laser units and the beam telescopes are covered with
hoods. The hoods are monitored by safety switches and
should only be opened with the appropriate tools.
• Each opening for laser r a diation emission is labeled with a si gn
in accordance with EN 60825-1.
• There are semireflecting mirrors in the laser unit (beam
generator). The laser power is meas ured b y a power sensor in
the extension of the mirror. Contact with escaping laser
radiation is impossible if the power sensor is installed properly.
• During normal operation, there is no point at whic h t he invisible
laser radiation can escape fr om the beam guidewa y on its way
from the beam generator to the cutting head.
• Scattered radiatio n caused by the laser beams reflecting from
the workpiece is effectively absorbed by the safety cabin.
The following signs indicate dangers in connection with laser
radiation:
Class 1
LASER PRODUCT
Sign 1: Labeling of the laser system in
normal operation
CAUTION, INVISIBLE LASER
RADIATION WHEN COVER OPEN
AND SAFETY INTERLOCKS OVERRIDDEN
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION
Signs 2 and 3: Laser warning symbol and instruction
plate on covers fi tted with safety locks
Fig. 3607en
Fig. 3616+3605en
1-22 Safety B452EN01.DOC
CAUTION, INVISIBLE LASER
RADIATION WHEN COV ER OPEN
AVOID EYE OR SKIN EXPOSURE TO
DIRECT OR SCATTERED RADIATION
Signs 2 and 4: Laser warning symbol and instruc tion
sign on covers without safety locks (can only be
opened using a tool)
INVISIBLE LASER RADIATION
AVOID IRRADIATION OF SKIN AND
EYES BY DIRECT OR
SCATTERED RADIATION
CLASS 4 LASER
Signs 2 and 9: Laser warni ng 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 µm
Λ
Fig. 3616+3606en
Fig. 3616+13028en
Sign 5: Identification of laser class
APERTURE FOR
LASER RADIATION
Sign 6: Information sign on the emission opening for
laser radiation on the laser and laser cutting head
CAUTION:
In case of destroyed lens press
EMERGENCY-STOP immediately
Danger of toxic fumes !
Observe operating instructions
Sign 7: Information sign for decomposed lens
Fig. 3614en
Fig. 3615en
Fig. 3604en
B452EN01.DOC Safety 1-23
Note
For additional signs, see: Measures taken by the manufacturer
(see p. 1-33).
Signage on the machine
2
3
5
7
2
9
3
2
3
Location of signs
The circled number s in t he fol lowing disp la y ind icate the num bered
signs listed in the previous sectio n.
2
4
2
4
2
2
4
3
2
4
2
2
1
4
2
4
6
7
3
Fig. 30334
1-24 Safety B452EN01.DOC
5.5 Hazardous substances
Note
With regard to hazardous substances, we would like to state
explicitly that we can only provide you with some examples of
sources of potential danger. You, as owner of the system, must
check the potential d angers associated with the specific m aterials
you are machining and undertake any necessary measures.
As a precaution, we recommend providing sufficient fresh air
supply in the working areas, in additi on to the required suc tion and
filter system and the exhaust air system (see also the technical
regulations for hazardous substances, TRGS).
Dust, aerosols and gases
The following substances are released when machining metallic
materials with a laser:
• Dust (particle size over 1 µm).
• Aerosols (particle size less than 1 µm). An aerosol is a gas
(particularly air) which contains very fine solid or liquid
substances.
• Gases
Volume of emissions
The volume of emissions during the machining of metallic materials
depends on the cutting speed and cutting gas pressure parameters. The volume of emission is at a minim um if the param eters
are set optimally.
Besides the cutting parameters, the volume of emissions is also
heavily influenced by the type of material. For this reason, the
volume of emissions when machining mild steel (6 mm sheet
thickness: 440 mg/m cutting length) is c onsid erab ly lower than with
CrNi materials or galvanized sheet steel (6 mm sheet thickness:
2000 mg/m cutting length).
Aerosols and dust particles, of which 97 % have a diameter
<5.7
µm, arise when laser cutting metallic materials.
3
Values of less than 0.1 mg/m
were recorded during measurements of the total particle and aerosol conce ntration at the control
panel of the machine. These values fall well below the m aximum
workplace concentrations (MAK values) allowed in the Federal
Republic of Germany for the total volume of dust (6 mg/m
technical concentration guidelines (TRK values) for chromates
(0.1 mg/m
3
).
3
) and the
B452EN01.DOC Safety 1-25
Depending on how the owner uses the m achine and in particular
on the material being processed, emissions may arise from
dangerous substances (especially those classified as carcinogenic)
for which the values g iven here as exam ples do not apply. If such
potential hazards exist, appropriate measurements should be
carried out by the owner and, if necessary, safety measures
provided for personnel.
When dealing with hazardous substances, please refer to the
"Technische Regeln für Gefahrstoffe" (TRGS 560) (technical
regulations for hazardous substances) applicable in the Federal
Republic of Germany. Its regulat ions c over the r ec ycling of a ir af ter
exhaust and filtering in the context of carcinogenic substances.
In the field of m etals, carcinogenic hazar dous substances incl ude
for example the following, according to TRGS 560:
• Beryllium compounds.
• Chrome/nickel compounds.
• Zinc chromates.
Ozone
By using titanium -doped dis char ge tu bes, U V radiat ion is abs orbe d
during high-frequency discharge, meaning ozone will not
accumulate outside of the dischar ge tub e.
Polyethylene (PE) coated sheets
When cutting polyethylene-coated sheets with the laser, mainly
aliphatic and olefin compounds are released:
• n-heptane, 1-heptene, heptadiene.
• n-octane, 1-octene, octadiene.
• n-nonane, 1-nonene, nonadiene.
• n-decane, 1-decene, decadiene.
• n-undecane, 1-undecene, undecadiene.
• Other n-alcane, 1-alcanes, diene pairs.
• Toluene
• Ethyl benzene.
• L-limonene.
• n-butyl benzene sulfonamide.
Measurements of exhaust air by means of a total hydrocarbon
analyzer (FID) revealed concentration values ranging between 2
and 10 ppm, measur ed as methane. This m eans that when laser-
1-26 Safety B452EN01.DOC
cutting PE-coated sheets, it is not likely that the limit values for
organic particles in the exhaust air will be exceeded. Strongsmelling scattered exhaust air particles even at very low
concentrations (ppb range) can cause minor smell irritations.
B452EN01.DOC Safety 1-27
5.6 Hazards from thermal decomposition
of ZnSe lenses
Lenses made of zinc sele nide (ZnSe) ar e inserted on the machine
in the output mirror of the las er unit and as a focusi ng lens in the
cutting head.
Lens characteristics
Cause
Chemical
composition
Form Disc (lens)
Color Orange, transparent
Odor Melting point 1520 °C
Vapor pressure Negligible
Solubility • Soluble in powerful acids and lyes.
Combustibility Special pre-
cautionary
measures
Zinc selenide (ZnSe)
Coating contains thorium fluoride (thorium content of a
lens with ∅ 1": approx. 1 mg)
• Insoluble in water.
None under normal storage and operating con ditions
Table 1-3
Thermal decomposition
Thermal decompos ition of the lens by absorpt ion of las er rad iation,
due, for example, to contamination or pits on the lens.
Note
Make absolutely sure the lens i n the cutting head is clea n. Otherwise, there is a greater likeli hood that th e lens will be destr oyed b y
power absorption.
Decomposition products
Zinc oxide, zinc hydrates, selenium, selenium oxides, hydrogen
selenide (H
Se), thorium.
2
Toxicology information
Selenium
Selenium and selen ium compounds release toxic products in the
event of thermal decomposition. These compounds are a health
hazard as selenium replaces sulfur in body substances. At room
temperature, hydrogen se lenite is a colorless gas which s tinks of
rotten vegetables. Even in low volumes (MAK value of 0.2 mg/m
3
1-28 Safety B452EN01.DOC
),
it can be very irritating to mucous membranes of the nose and
eyes ("selenium cold").
R23/25 Poisonous if inhaled or swallowed.
R33 Risk of cumulative effects.
S20/21 Do not eat, drink or smoke when working.
S28 In the event of skin c ontact, rinse off immediately with
S44 Consult a doctor if you do not feel well (give thi s
Extract from the hazardous substances regulation
GefStoffV Annex I
plenty of water.
description to your doctor for his /her information).
Table 1-4
Thorium
Warning
Cleaning work
Warning
Thorium is a radioactive substance. Absorption of its compounds
(e.g. through inhalation) must be avoided at all costs.
Responsive measures in case of accident
Danger of poisoning if the lens is thermally decomposed!
Inhaling or touching decomposition products can damage
your health.
Press E-STOP on the system.
Leave the area surrounding the machine.
Wait at least 30 minutes for the reaction to die off.
Cleaning work must be carried out after thermal decomposition of a
lens.
Health risks from inhaling or touching the decomposition
products
Always wear protective glov es and a cl osel y fitting dus t mask
during cleaning:
– Five-finger glov es with s eam les s pr ot ectiv e c ov ering m ade
of nitrile rubber or PVC are suitable protective gloves.
– Fine-dust masks of the P3 filter c lass are s uitable m asks
for protection against toxic particles.
1. Wipe the cutting head and the beam guideway with a damp
cloth.
2. Remove the destroyed lens.
3. W rap all lens com ponents, cloths etc. in pl astic, weld shut and
dispose of them.
B452EN01.DOC Safety 1-29
Note
Any work (e.g. cleaning, disassembly, etc.) around the output
mirror support or the discharge tube may only be carried out by
personnel who have been special l y trained to do this .
Disposal of lenses
Damaged or destro yed lenses can be sent in a seal ed and la beled
plastic bag to the following address for disposal:
TRUMPF Laser- und Systemtechnik GmbH
Johann-Maus-Straße 2
D-71254 Ditzingen, Germany
For the return deliver y, make sure you submit the i nvoice 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.
Safety warning signs for
high voltage
5.7 Danger due to high voltage
The radio frequenc y (RF) generator changes low frequenc y mains
energy into radio frequency electrical energy (13.56 MHz). It
serves to excite the laser medium.
Radio frequency voltages of up to 10 kV can arise during the
operation of the gen er ator . The ignition volta ges ar e abo ut twice as
high.
High voltage can be a source of danger at the following
components of the generator:
• Adaptive network in the resonator.
• Auxiliary ignition for the discharge path.
• Electrodes along the discharge path (shielded).
• Switch cabinet of the RF generator.
Safety warning signs indicating high voltage are attached to the
generator 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.
• Main power supply and main switch on the switch cabinet.
1-30 Safety B452EN01.DOC
Safety warning signs for high voltage
Fig. 23463
Work on the radio frequency
generator
• W ork on the RF generator ma y only be carried out by train ed
specialists from the laser manufacturer or by appropriately
trained employees of the user.
• The ins tructio n manual f or rad io fr equenc y generator s m ust be
followed for all work.
• Safety locks have been installed on the doors of the RF
generator. The energ y suppl y is inter rupted au tomaticall y if the
doors are opened.
• Warning signs have been applied to parts carrying high
voltage.
B452EN01.DOC Safety 1-31
Danger
Warning
6. Danger due to alternating
electromagnetic fields
6.1 Linear drives
Malfunction to pacemakers due to strong magnetic fields
around the linear drives!
Persons using a pacemak er must keep a minimum distance
of 30 cm away from the linear drives.
Point out the dangers for persons with p acem akers to visitor s
and to personnel of your own as well as from other
companies.
Risk of injury due to strong magnetic fields around the linear
drives!
Do not carry any heavy ferromagnetic parts (metal sheets,
tools) by hand near the drives.
Do not remove bellows on the linear drives.
Keep watches and magnetic storage media (disk ettes, credit
cards) away from the drives.
Magnetic flux density
If parts of the body have been caught bet ween a linear drive
and a ferromagnetic part, lev er the p arts stuc k together using
a pointed wedge (10–15°) made of non-magnetic material
(e.g. V2A) or force them apart with the wedge and a nonmagnetic hammer.
Note
Operation and maintena nce and service wor k may only be carried
out by properly instructed perso nne l.
The TC L 3050, TC L 4050, TC L 6050 is equipped with linear
motors (drives in Y and Z directions). The permanent magnets
installed in the secondary parts generate a strong magnetic field
and thus a high ferromagnetic attractive force (secondary part
attractive force 20000 N). The magnetic field and the attractive
force are always ef fec tive, r egar dless of the switch- on s tatus of the
motors (even if the main switch is switched off).
The magnetic flux densit y is the largest on the s urfac e of the line ar
motor; ca. 360 mT (milliTesla). The magnetic flux density
decreases in proportion t o the second power of the distance. At a
distance of onl y 10 cm it is already less than 1 mT. At a distanc e of
30 cm, the value is approx. 30
µT.
1
1
According to modern medical standards, values up to 100 µT, with a
permanent load and a fr equency of 50 Hz, are medic ally harmless for
persons in good healt h (DIN VDE 0848, Part 4).
1-32 Safety B452EN01.DOC
High attractive force
Due to the high attractive force, be particularly careful in the
immediate proximity (distance <50 mm) of the secondary parts
(moveable upper parts ). The magnetic at tractive forces take effect
suddenly in the immediate proximity and can accumulate to several
100 kg even for objec ts of m edium size. T his is why hea vy (>1 kg)
or plane (>1 dm ²) obj ects of steel or iron s houl d not b e c arried with
bare hands in this area.
Measures taken by the manufacturer
Signs on the machine
The following sign warns about the danger of magnetic fields:
Caution:
The linear drives of this machine are
fitted with powerful magnets-
POWERFUL MAGNETIC FIELDS+
HIGH MAGNETIC FORCES OF
ATTRACTION!
Sign 10
Fig. 19407en
The following sign indicates t he dangers for persons with a pacemaker:
Covering of the linear motors
Sign 8
The entire length of the drives of the Y and Z s lid es is co vered with
Fig. 19425
bellows.
B452EN01.DOC Safety 1-33
Warning
6.2 RF generators
Risk to health from radiation of electromagnetic alternating
fields arising from the incorrect operation of the
RF generator!
Anyone who operates the RF generator without the safety
covers or who bypasses the safety circuits is acting with
gross negligence.
Never operate the RF generator without safety covers.
Do not bypass any safety circuits.
The radiation of radio frequency electromagnetic fields poses no
danger for persons if the RF generator is operated as intended.
Compliance with the guidelines (EMC guideline for limits on
radiation, in line with EN 55011) is ensured by the design
engineering of the system.
1-34 Safety B452EN01.DOC
Chapter 2
Installation conditions
TC L 3050,
TC L 4050, TC L 6050
The TC L 3050, TC L 4050, TC L 6050 is a system for laser
cutting of metal materials. The machine is designed for machining
flat sheets. Tubes and profiles can also be machined if the
TRUMPF RotoLas tube cutting unit (optional) is used. Plastics
must not be cut using the TC L 3050, TC L 4050, TC L 6050.
Drawing No. 93618-5-2 0.EN Material No. 0351810
B452EN02.DOC Installation conditions TC L 3050, TC L 4050, TC L 6050 - Version 3 2-1
Table of contents
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
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
2-2 Table of contents TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
1. Installation site
1.1 Space requirements
The arrangement of the individual components and the space
requirements of the s ystem should be taken from the installation
plan valid in each case. The plan inc ludes the space required for
opening the doors of the control cabinets, for the RF generator,
suction unit, cooling unit, and the covering cap of the laser unit.
In the case of deviation from the standard installation plan, a
special foundation plan or installation plan is required.
The installation plan delivered with the unit is always valid.
1.2 Floor requirements
Evenness
Installation surface
• The floor on which t he system is instal led must be as flat and
level as possible.
• The variation in height across the area of the basic machine
and the pallet changer must not exceed 10 mm.
• Minor unevenness can be compensated for with adjustable
legs or wedge mounts.
• The entire installation surface for the basic machine and the
two front legs of the pallet changer must consist of one
continuous plate beneath the load-bearing points and must
have a smooth surface. This is particularly the case beneath
the wedge mounts.
• In the case of newly laid f loor/c ei li ng pl ates, it is imperative e.g.
in the drying process to avoid setting effects which would
exceed the values indicated below.
• The m aximum position shift perm itted for the two rear legs of
the pallet changer is ±1.5 mm.
• The changes resulting from tilting the machine should not
produce laser beam migration of more than ±0.5 mm on the
lens.
Note
External influences due to ch anging lo ads in the imm ediate vic init y
of the system can affect the qua lit y of cut of the work pieces . T hese
include:
• Fork lifts, industrial trucks etc.
• Assembly or disassem bly of other machines direc tly alongside
the system.
• Machines causing vibration during operation, such as punch
presses etc.
B452EN02.DOC Installation site TC L 3050, TC L 4050, TC L 6050 - Version 3 2-3
• The maxim um permitted accelerati on at the support points of
the laser (or basic machine) is 0.1x the acceleration due to
gravity.
An exact test must be conducted in some instances.
Case differentiation for floor
quality
Elastic base plate
Ceiling plate /
free span base plate
Two different cases must be differentiated regarding the specifications for the floor or ceiling plates:
• Machine without loading unit or LiftMaster.
• Machine + loading unit or LiftMaster, as well as prepared
machines which are to be equipped with a loading unit or a
LiftMaster at a later date.
Machine without loading unit or LiftMaster
• Minimum thickness 200 mm.
• Crosswise reinforcement 3.7 cm²/m, double-layered
• Concrete quality (corresponding to tensile strength C 25/30):
– Cylinder co mpressive strength
≥
20 N/mm².
• Load capacity 15 kN/m².
• Minimum thickness 200 mm (for load capacity 15 kN/m²).
• Concrete quality (corresponding to tensile strength C 25/30):
– Cylinder co mpressive strength
≥
30 N/mm².
• Multiple span girders.
If these specificati ons are not met, an evaluation m ust be carried
out by a structural analyst.
Machines with loading unit or LiftMaster and prepared
machines
Elastic base plate
• Minimum thickness 200 mm.
• Crosswise reinforcement 3.7 cm²/m, double-layered.
• Concrete quality (corresponding to tensile strength C 25/30):
– Cylinder co mpressive strength
≥
20 N/mm².
2-4 Installation site TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
Ceiling plate /
free span base plate
TC L 3050 + LiftMaster TC L 4050 + LiftMaster
Load capacity 30 kN /m² Load capacity 40 kN /m²
Minimum thickness 250 mm
(for load capaci ty 30 kN/m²)
Concrete quality (corresponding to tens ile strength C 25/30):
• Cylinder compressive s trength
Multiple span girders.
Minimum thickness 300 mm
(for load capaci ty 40 kN/m²)
≥
30 N/mm².
Table 2-1
Structural stress analysis
TC L 3050, TC L 4050,
TC L 6050
TC L 3050 + LiftMaster TC L 4050 + LiftMaster TC L 6050 + loading
Load capacity 30 kN /m² Load capaci ty 40 kN/m² Load capacity 40 kN/m²
Minimum thickness
250 mm (for load
capacity 30 kN/ m ²)
Concrete quality (corresponding to tens ile strength C 25/30):
Cylinder compress ive strength
Multiple span girders.
Minimum thickness
300 mm (for load
capacity 40 kN/ m ²)
≥
30 N/mm².
unit
Minimum thickness
300 mm (for load
capacity 40 kN/ m ²)
Table 2-2
Note
If these requirements are not met or if bear ing technolog y is used,
an evaluation must be carried out by a structural analyst.
1.3 Load indications
Prior to installation, the load capacity of the floor area must be
subjected to a structural stress analysis. The weights of the
individual system c omponents and the loa ds on the support points
are specified in the overview below.
Component Weight
Max. weight of the basic machine
incl. laser unit, pallet with all
support slats, and max.
workpiece weight
• TC L 3050
• TC L 4050
• TC L 6050
Max. weight of the pallet changer
incl. two pallets with all support
slats and (2x) max. workpiece
weight
• TC L 3050
• TC L4050
• TC L6050
[kg]
approx. 12000
approx. 14500
approx. 17500
approx. 3600
approx. 6500
approx. 8500
Distribution of
weight
Weight is dist ributed
over 8 surfaces
(TC L 3050) or
12 surfaces
(TC L 4050).
Refer to the
foundation plan for the
machine in question
for the weight load on
each surface.
Weight is dist ributed
evenly over
4 surfaces.
B452EN02.DOC Installation site TC L 3050, TC L 4050, TC L 6050 - Version 3 2-5
Component Weight
Pallets
• TC L 3050
• TC L 4050
• TC L 6050
Support slats (pallet laid out up to
50 %)
• TC L 3050
• TC L 4050
• TC L 6050
Max. workpiece weight
• TC L 3050
• TC L 4050
• TC L 6050
Machine control c abinet 700 The edges carry most
Transverse conveyor (optional) 350 The edges carry most
Compact dust extractor
• TC L 3050
• TC L 4050, TC L 6050
Laser control cabinet 750 The edges carry most
RF generator 820 The ed g e s ca r ry m o s t
Cooling unit (without cooling
water)
Isolating transformer (optional) 550 The edges carry most
Load indications for the basic ma chine and compone nt s
[kg]
2 x 250
2 x 370
2 x 490
2 x 150
2 x 320
2 x 480
900
1700
2600
850
1000
1250 The edges ca rry mo st
Distribution of
weight
of the load.
of the load.
The edges carry most
of the load.
of the load.
of the load.
of the load.
of the load.
Table 2-3
2-6 Installation site TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
1.4 Ambient conditions
Ambient temperature
Ambient air
Tropical version
of the laser
Control system cooling
The ambient temperature m ust be between + 10 °C and +4 3 °C for
the operation of the machine. The temperature at the installation
site must not be allowed to fall below +4 °C when the system is
switched off.
Note
One-sided exposure to direct sunlight and unidirectional drafts
(heat distortion) must be avoide d (e.g. with blinds if the contr ol unit
is set up at a window). The waste heat fr om the cooling unit mus t
either be conducted into the open air, or evenly distributed
throughout the room.
To prevent deterioration of beam quality, ensure that the installation site of the laser is free of particles or substances which
absorb radiation with a wave length of 10.6 µm. These inclu de e.g.
solvent fumes, wh ich are rele ased when enam eling, or f umes from
degreasing units.
If the ambient temperature is bet ween +35 °C - +4 3 °C, the s ystem
must be equipped with the tropical version of the laser.
The control system is cooled by inner air cir culation in the closed
control cabinet. This ensures that components are extensively
protected against dirt and dust.
The heat dissipation f rom the control s ystem housings is normally
performed by externa l heat exchang ers with fans which su ck in air
directly and blow it along the cooling elements. Make sure that
there is no excessive air c ontamination in the int ake region of the
fans behind the control system, as dust on the cooling elements
greatly reduces heat transfer.
Damp rooms are not suitable for the operation of the control
systems, principally because contact corrosion may develop on
contactors and relay contacts, leading to control system errors.
B452EN02.DOC Installation site TC L 3050, TC L 4050, TC L 6050 - Version 3 2-7
1.5 Exhaust air conduction
If the exhaust air is to be conducted into the open air from the
compact dust extractor, the following conditions apply.
Pipeline
The pipeline must be configured as follows:
• Max. of two 90° bends (radius = diameter x 1.5).
• Max. length: 10 m.
• Transition piece on the compact dust extractor.
– TRUMPF Mat. No.: 346476 for TC L 3050.
– TRUMPF Mat. No.: 355075 for TC L 4050, TC L 6050.
• Diameter of the pipe:
– 280 mm for TC L 3050
– 315 mm for TC L 4050, TC L 6050
Note
If any other configurat ions are used, a ventilation tech nician or the
manufacturer of the compact dust extr actor must be consulted. In
all cases, the max imum resistanc e of 10 da Pa ( = 100 Pa) m ust not
be exceeded.
2-8 Installation site TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
Warning
2. Gas supply
We strongly recomm end that the customer c onsult the gas supplier
in all cases regarding the gas supply.
Note
Attention must always be given to the relevant standards (e.g. DIN 477
No. 6, DIN EN 5 59, DIN 8541 part 3, VB G 15, VB G 62 §46 + §47 ).
Gas conduits and electrical cables laid out in the same cable
duct.
A short circuit could cause damage to a gas conduit or
cause a fire.
For all gas installations, you must ensure that the gas
conduits are not laid out together with the electrical cables.
Always la y out gas conduits separatel y up to the connect ion
point to the machine!
2.1 Laser gases
Purity
Laser gas Purity
Helium (He) 4.6 99.996 % vol.
Carbon dioxide (CO2) 4.5 99.995 % vol.
Nitrogen (N2) 5.0 99.999 % vol.
Table 2-4
B452EN02.DOC Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-9
Gas consumption, supply lines, pressure
reducer
Helium (He) Carbon dioxide (CO2) Nitrogen (N2)
Average gas consumption [l/h]:
TLF 5000, TLF 6000 13 1 6
Input pressure at gas mixer [bar] 5-7
Supply lines:
Nominal width [mm] 6 6 6
Max. length2 [m] 101010
Hose material PTFE or PE PTFE or PE PTFE or PE
Valve connection W21.80 x 1/14"
Pressure reducer specification:
Design Two stage with metal
Admission pressure [bar] 200 200 200
Back pressure range [bar] 0.5-6 0.5-6 0.5-6
Min. flowrate [Nm3/h]
Shutoff valve/purge valve before inlet before inlet before inlet
1
according to DIN 477
No. 6
membrane
555
1
5-7
W21.80 x 1/14"
according to DIN 477
No. 6
Two stage with metal
membrane
1
5-7
W21.80 x 1/14"
according to DIN 477
No. 10
Two stage with metal
membrane
Table 2-5
Laser gas connection point
• The connection point for the laser gases is to be found on the
machine's control cabinet.
• The supply lines must be installed up to the point on the
installation plan marked with the symbol shown on the left.
• The height of the connection point above the floor is
approx. 500 mm.
1
The input pressur e at the gas mixer must not exceed 7 bar .
2
In the cas e of longer distances , fixed piping made out of s tainless steel or
copper (refrigerator quality) is required.
2-10 Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
Laser gas supply from cylinders
• The safest, easiest and most economical way of supplying
laser gas is to use individual cylinders.
• The gas flow is interrupted when changing cylinders or
bundles.
• Only use clean conduits for the connecting lines (oil-free,
grease-free, and dust-free on both the inside and outside).
• Do not clean the hoses with solvent.
• Do not use lubrication when fitting the hoses.
• Take care that all maintenance work is carried out with the
utmost cleanliness.
Central laser gas supply (fixed piping)
• Cylinder bank systems are recommended for wall mounting
and for uninterrupted operation.
• The switch-over is carried out manually or automatically.
• Copper or stainless steel pipes (refrigerator quality) must be
used for the fixed piping.
• Hav e the piping ins ta ll ed b y qualif ie d prof es sio nals .
• To avoid c ontaminatio n during trans port and stor age, the ends
of the pipes must be securely sealed.
• Necess ary connection points must be m ade with forming gas.
When brazing copper pipes or orbital welding stainless steel
pipes, no residue may rem ain in the pipe inter ior (e. g. flux f rom
brazing).
• Alternativel y, clamping ring s crews made of the sam e material
can be used.
• The assembled piping must be tested for leaks before being
put into operation.
• The pipes must be subsequently purged with inert gas and
laser gas (final cleaning with nitrogen) in order to flush
moisture and residual gas from the lines.
• The gas supplier must be consulted in all cases.
B452EN02.DOC Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-11
2.2 Cutting gases
Purity
Cutting gas Purity
Oxygen (O2) 3.5 99.95 % vol.
Nitrogen (N2) 5.0 99.999 % vol.
3
Table 2-6
Note
In exceptional cases, nitroge n of purity 4.6 (99.996) or other purities can be used, as long as the following limit values are not
exceeded:
≤100 ppm
O
2
O ≤5 ppm
H
2
nHm
≤1 ppm
C
Cutting gas consumption
Estimating
gas consumption
Standard pressure cutting
The cutting gas consumption depends on:
• Nozzle diameter.
• Cutting gas pressure.
• Duration of laser cutting.
To be able to make an approximate estimation of the expected
cutting gas consumption, the consumption rate for standard and
high-pressure cutting are shown in the following. For a more
detailed estimate for certain types of material and material
thicknesses, refer to the data collection of the machine.
Standard pressure cutting m eans cutt ing at a pr essure of ≤6 bar at
the nozzle. Oxygen and/or nitrogen are required as cutting gases.
During standard pressure cutting with O
, the minimum flow
2
pressure available at t he connection point to th e machine is 8 bar
(with gas consumption of 10 Nm
3
/h, a nozzle Ø1.7 m m and 6 bar
cutting gas pressure).
3
When using nitrogen with low purity, oxygen i m purities of 100 ppm and
above can cause dis coloration of the cutting edges during high-pressure
cutting. This can be avoided only by using nitrogen with a purity of 5.0 or
by using a cutting gas supply with gas tank ( the nitrogen purity is generally
5.0 in the gas tank) .
2-12 Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
d Nozzle diameter
V/t [Nm3/h] Gas volume per time
3
unit in Nm
p [bar] Pressure in bar
Maximum gas consumption per hour at a laser duty
cycle of 100%
/h
Fig. 8809
High-pressure cutting
High-pressure cutting m eans cutting with a pressure of >6 bar at
the nozzle. Normally nitrogen is used as a cutting gas, in rare
cases also oxygen.
High-pressure cutting is of f er ed as an opt ion al f or proc es s ing sta inless steel and aluminum alloys.
• During high-pressure cutting with N
, the minimum flow
2
pressure available at the connection point to the machine is
3
27 bar (at a gas consumption of 82 Nm
/h, a ∅ 2.7 mm nozzl e
and 20 bar cutting gas pressure).
• During high-press ure cutting with O
, the minim um flow pres-
2
sure available at the c onnection point to the m achine is 15 bar
3
(at a gas consumption of 20 Nm
/h, a ∅ 1.7 mm nozzle and
12 bar cutting gas pressure).
B452EN02.DOC Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-13
0
100
80
60
40
]
h
/
³
m
N
[
t
/
V
20
d=1,4 mm
d=1.7 mm
d=2.3 mm
d=2.7 mm
0
6 8 10 12 14 16 18
p [bar]
d Nozzle diameter
V/t [Nm3/h] Gas volume per time
unit in Nm
p [bar] Pressure in bar
Maximum gas consumption per hour at a laser duty
cycle of 100%
3
/h
2
Fig. 23507
2-14 Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
Supply lines for the cutting gas supply
• The customer must provide the supply lines for the cutting
gases up to the connection point on the machine.
Cutting gas connection point
• The suppl y lines must be installed up to the connection point
on the installation p lan marked with the symbo l shown on the
left.
• The height of the connection point above the floor is approx.
300 mm.
• Pipes are to be used for all gas lines f rom the gas cylinder or
central gas tank to the machine.
• T he vaporizer must be set up to ac commodate the m ax. con-
sumption of all connected machines. In addition, the line
connecting the vaporizer to the connection point on the
machine should be as short as possible.
• The external gas lines mus t be ar range d i n s uch a way that the
supply lines to the connection point on the machine and the
connection point itself cannot ic e up.
• Stopc ock s m ust be bui lt in to ever y sup ply lin e to the indi vidua l
machines. This allows the supply lines, for example, to be
blocked off and bled during servicing using the purge valves on
their connection points at the machine.
Note
The gas temperature m ust not exceed 50 °C. This is of par ticular
importance when th e required gas pressure is gener ated using a
pressure booster system.
Pipes
• Oil and grease-free pipes made of copper tubing in special
quality ("refrigerator qualit y", inert-sol dered with sim ple form ing
gas) are adequate for the cutting gases.
• Stainless steel pipes are not required.
• To avoid im puriti es during transpor t and storag e, the p ipe en ds
must be securely sealed.
Pipe
dimensions
½"
or
15 x 1
⅜
" or
12 x 1
⅝
" or
18 x 1.5
¾" or
22 x 1.5
Nominal
width
[mm]
13 From the tapping point to the connection point
10 Up to 10 bar; preferably O
16 Over 10 bar; preferably N
19 For ring pipelines supplying up to two laser
Applications/comments
on the machine, changeover with clamping
ring screw joints for 12 mm connection
diameter for N
for O
2
units and for lines from vaporizer to ri ng
pipeline
or 8 mm connection diameter
2
2
2
B452EN02.DOC Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-15
Pipe
dimensions
1" or
28 x 1.5
Nominal
width
[mm]
25 For ring pipelines supplying more than two
Applications/comments
laser units and f or lines from vaporizer to ring
pipeline
Table 2-7
Note
For ring pipelines : stopcocks must be fitted be tween all stub lines
that branch off, in order to be able to shut off the lines s ection by
section.
For notes on installation and on pressure and leakage tests, see
point "Central laser gas supply".
Cutting gas supply with cylinders or
bundles
Cylinders or bundles
Cylinder banks or cylinder
bundle banks
• Cutting gas supplies with pressure reducers for cylinders or
bundles is the easiest and most economical wa y of supplying
gas; handling requirements are greater, however, due to the
volume of consumption. 1 bundle contains 12 cylinders =
3
approx. 120 Nm
gas.
• The gas flow is interrupted when changing cylinders or
bundles.
• This method of supply is only suitable in c ertain cases for N
high-pressure cutting.
• Switch-over devices are required for uninterrupted operation
with cylinder or bundle banks and also for changing cylinders.
• The switch-over is carried out manually or automatically
4
.
• Cylinder banks or banks of cylinder bundles are frequently
installed some dis tance away from the laser machine. F or this
reason the use of a ta pping point pressure r educer c los e to the
laser system is recommended.
2
4
In the case of automatic switch-over, use of a signaling unit is recommen-
ded. Without it, the bank of cylinders or cylinder bundles coul d be drained
empty on both sides wi thout this being detected.
2-16 Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
Pressure control
specification
O2 N
2
high pressure
Admission press ure
[bar] 0 – 200 0 – 200
Max. permissible bac k
pressure [bar] 25 40
Min. flow rate [Nm3/h] 30 90
Other requirements Suitable for oxygen; oil
Oil and grease-free
and grease-free
Table 2-8
Note
A pressure monitor in the form of the pressur e regulators spec ified
must be installed on the supply unit. Pressure regulators must be
secured against the max. input pressure (intrinsically safe).
Requirements at the
connection point on the
machine
Min. input pressure
O
2
standard
81527
O
2
high
pressure
N
high
pressure
[flow pressure in bar]
Max. input pressure ( stat.)
5
[bar]
21 21 33
Max. cutting gas pressure [bar] 6 12 20
Volume rate of flow6 [Nm³/h] 10 20 82
Nozzle diameter6 [mm]
∅ 1.7 ∅ 1.7 ∅ 2.7
Table 2-9
2
5
The machine is equipped with blow-off valves that respond when there is
high input pressure, thereby creating a whistling sound.
6
The volume rate of flow depends on the maximum cutting gas pressure
selected and the nozzl e diameter specified.
B452EN02.DOC Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-17
Cutting gas supply with gas tank
Tank system
Specification pressure
control
• Tanks are suitable for supplying gas safely if the gas consump-
3
tion is at least about 200 Nm
/week.
• The optimal tank size can be calculated according to the
quantity and to the local regulations.
• The gas supplier must be consulted in all cases.
• Requirements for high-pressure cutting with nitrogen:
– Do not use a tapping point pressure regu lator bet ween the
gas tank and the machine after the pressure regulating
station.
– A stopcock must be install ed bet ween the gas t ank and the
machine.
O
2
standard
Nominal pressure [bar] 18 36 36
Max. tapping pressure [bar] 14 16 30
O
2
standard
1st pressure stage (tank)
Safety pressure r egulating
8
system
Optional Optional Recom-
2nd pressure stage
(tapping point):
Tapping point pressure
regulator
Recom-
mended
Back pressure [bar] 0-16 4-25 Other requirements Suitable for
oxygen;
free of oil
and grease
O
2
high
pressure
O
2
high
pressure
Recommended
Suitable for
oxygen;
free of oil
and grease
7
N
2
high
pressure
Table 2-10
N
2
high
pressure
mended
Not recom-
mended
Oil and
grease-free
Table 2-11
7
Only necessary for special applicat ions i.e. laser cutting with oxygen highpressure.
8
The safety pressure regulation s ystem is installed close to the tank.
It provides for uniform pressure in t he network. The built-in pressure relief
valve ensures that gases are blown away into the open air in the cas e of
malfunction. In this way, possible risk s arising in the area of the machine
from a concentrat ion of oxygen (O
) or a depletion of o xygen (N2) are
2
avoided.
2-18 Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
Requirements at the
connection point on the
machine
O
2
standard
Min. input pressure
[line pressur e in bar]
Max. input pressure ( stat.)
9
[bar]
Max. cutting gas pressure [bar] 6 12 20
Volume rate of flow10 [Nm³/h] 10 20 82
10
Nozzle diameter
10
[mm] ∅ 1.7 ∅ 1.7 ∅ 2.7
81527
21 21 33
O
2
high
pressure
N
2
high
pressure
Table 2-12
2.3 Nitrogen for beam guideway ventilation
Purity
Input pressure
Nitrogen consumption
Nitrogen (N2) 5.0, i.e. 99.999% b y vol.
An input pressure of at least 11 bar must be ensured for beam
guideway ventilation with nitrogen, regardless of the cutting gas.
Beam guideway ventilation consumes nitrogen at the following
rates:
TC L 3050, TC L 4050 ca. 3.0 Nm³/h
TC L 6050 approx. 3.6 Nm³/h
Note
It is recommended not to switch the nitrogen supply off after the
machine has been s witched off , so that n itrog en also f lows thr ough
the beam guideway when the machine is off (consumption: ca.
1 Nm³/h). This creates a constant light pressure burden in the
beam guideway, which prevents particl es of dirt bei ng abl e to ent er
the beam guideway from the ambient air. If a gas tank is being
used for the nitrogen supply, the pressure burden which would
otherwise be regularly blown of f can be used for beam guide way
ventilation.
9
The machine is equippe d with blow-off valves t hat respond when there is
high input pressure, thereby creating a whistling sound.
10
The volume rate of flow dep ends on the maximum cutting gas pressure
selected and the nozzl e diameter specified.
B452EN02.DOC Gas supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-19
3. Electrical power supply
The machine is designed for the following nominal voltages:
Nominal voltage Frequency
400 V ±10% 50 Hz ±1%
460 V +10 %/ 5% 60 Hz ±1%
Table 2-13
If the available nominal voltage varies from the nominal voltage
specified above (400 V or 460 V), an iso lating tr ansform er m ust be
installed.
The electrical power supply of the system requires a 4-pole
connection with copper cable (L1, L2, L3 in clockwise phase
rotation; PE).
11
Electrical connection
Requirement:
According to
DIN EN 60204-1/4.3.1
The electrical supply is connected to the control cabinet on the
machine at the connection point marked on the installation plan
with the symbol shown on the left. T he other system components
(suction unit, cooling unit) receive supply via this connection.
Connecting lineElectrical power supply
Cable Cross-section Ground wire
Requirement:
• 4-pole copper cable
(L1, L2, L3, PE)
• Single strand or
multistrand with wi re
end ferrules
• Connection must be
protected against direct
touch contact
• Clockwise phase
rotation
According to VDE 0100
Section 430
(IEC 364-4-47)
According to VDE 0100
part 540
(IEC 364-5-54)
Table 2-14
11
If the nominal voltage i s 380 V or 415 V at 50 Hz, the tolerance of the
network must be deter mined. If the tolerance is between 360 V – 440 V, an
isolating transformer will not be neces sary.
2-20 Electrical power supply TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
3.1 Power supply (grid network)
Fault current protective
device
Network structures
If a fault current protec tion device is used on the netwo rk side to
protect from direct or indirec t cont act, on l y type B is perm itted. Se e
EN 50178 pt. 5.2.11.2 (VDE 0160, edition of April 1998).
If, when using a fault current cir cuit bre aker, the l eakage cur rent of
the machine is larg er than the set fault curr ent, the mac hine must
be separated from the network us ing an iso lating trans form er. See
EN 50178 pt. 5.2.11.1 (VDE 0160).
For IT and TT network structures as well as for asymmetrical
networks (one phase gr ounded), the machine m ust be connected
via an isolating transformer.
B452EN02.DOC Electrical power supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-21
Isolating transformer
1050
750
1
2
The following m ust be o bserve d if the m achine is equ ipped with an
isolating transformer:
• The cable from the isola ting transformer to the control cabinet
must be provided by and laid by the customer.
• The customer must decide where the isolating transformer
should be positione d. T he isolat ing tr ansf orm er is not ind icate d
on the installation plan.
• The dimensions of the isolating transformer are:
• Length: 1050 mm
• Width: 750 mm
• Height: 1400 mm
• The isol ating tr ansform er mus t be posit ioned in such a way that
access via the door hung on the front side (door with nameplate)
remains free. The required safety distance according to IEC is
800 mm; accor din g to N EC 1 100 m m . 100 mm saf ety cl earanc e
must be maintained both behind and next to the transformer.
800
1 Isolating tr ansformer 2 Safety distance
Fig. 22107
The manufacturer's documentation applies for the isolating
transformer: "Series transformer MD 125000", Roller and Fischer,
Mat No.: 349623. The documentation is available in German,
English, and French.
2-22 Electrical power supply TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
3.2 Connected loads, fuse protection,
frequency
Connected loads
Tank heating (optional)
TLF 5000 TLF 6000
Total connected load incl. all possi ble options
and cooling unit [kVA]
Maximum fuse protection of the complete
system at 400 V and 460 V [A]
Total connected load incl. all possi ble options
without cooling unit [kVA]
Maximal fuse protect ion of the complete system
without cooling unit at 400 V and 460 V [kVA]
Maximum acceptable interruption of nominal
voltage [ms]
Connected loads of t he cooling unit [kVA] 44
Fuse protection of the cooling unit [A] 80
105 109
160 160
61 65
80 80
See EN 60204, Part 1,
Point 4.3.2, Alter nating
current supply.
Table 2-15
The following applies if the installation is equipped with the tank
heating option on the cooling unit:
• The cooling unit power supply must be provided by the
customer via a separate connection to the cooling unit.
• In this case, the connected load of the com plete system can be
reduced by the connected load of the cooling unit.
• The cable for this connection must be provided by the
customer. It can be fed through the cooling unit pedestal.
B452EN02.DOC Electrical power supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-23
3.3 Power consumption
100
P[KW]
P[%]
The power consumption of the machine depends on the laser
output. When the machine is on stand-b y, the power consum ption
is 23 KW.
Power consumption including suction unit and cooling unit with
ambient temperature 25 °C:
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 102030405060708090
Telephone modem
connection
P [kW]
P [%]
Power consumption of mac hine and laser
Laser power as % of maximum laser power
Fig. 33134
3.4 Teleservice
TRUMPF has made the follo wing i nterf aces av aila ble in the contro l
cabinet of the machine:
• Interface for telephone: TAE6-N coupling.
• Network interface: either BNC or RJ45, according t o customer
requirements.
The connection point for a telephone modem is marked on the
installation plan with the symbol shown on the left.
The customer must arrange for the following work:
• Installation of a telephone s ocket by the customer 's telephone
company.
• Direct outward dialing via number code must be possible for
the modem.
• It must be possible to reach the modem with a direct dialing
number. Otherwise, a separate exchange line is necessary.
2-24 Electrical power supply TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
3.5 Network connection
Depending on the customer's requirements, either a BNC plug
RG 58 or a line with RJ 45 plug is ins talled i n the m achine's switc h
cabinet for linking the mach ine control to a network ( e.g. to con nec t
it with a programming system).
If more than one machine is included in the network, a personal
hub (network distributor) is needed. This is located in the switch
cabinet of the m achine and must be supplied with AC cur rent by
the customer, because the d istributor must als o function when the
machine is switched off. The power supply must be provided as
described in the following production control technology projects.
For production control technology in connection with CELL
SERVER, the customer needs to provide vo lta ge s u pply a par t f r om
the PC cabinet:
Network tolerance
• Voltage supply
grounded outlet socket. Grounded coupling is delivered with
the machine.
• Po wer supply in the USA and Cana da: 115 V with stand ard US
socket.
The same tolerances for nominal voltage and frequency as
described in Point 3 apply to both power supplies.
(except in the USA and Canada): 230 V with
B452EN02.DOC Electrical power supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-25
4. Compressed air supply
Compressed air connection
Connected loads for
compressed air
The connection point for compressed air is marked on the
installation plan with the symbol shown on the left.
• The compress ed air connection ma y be flexible or co nsist of a
fixed pipeline to the machine.
• The compressed air connection must be equipped with a hand-
operated 3/2 directional valve with bleeding on the machine
side.
Required network press ure [bar]
Without optional compressed-air cut ti ng
With optional compr essed-air cutting
∅ Consumption (required volume rate of flow acc ording to
ISO 1217 or DIN 1945) [Nm3/h]
Minimum nominal width of the supply pipelines ½" (DN13)
Ring pipeline length [m] Max. 50
Ring pipeline diameter At least 1"
Length of the connecting line from ring pipeline to the
connection point on t he machine [m] max. 5
7-14
12
7–9
Approx. 31
= 516 l/min
(due to water
condensation)
(26 mm)
13
Table 2-16
The compressed air must have the following properties at its
tapping point:
Characteristic Requirements ISO°8573-1
Free of
condensate
Free of dust Max. particle
Free of oil Max. oil content:
12
If a nozzle with ø 2.7 mm is used for compressed-air cutting (optional),
a minimum network pressure of 7.5 bar is required.
13
For compressed-air cutting (opt ional), the average consumption rises from
20 Nm³/h to 51 Nm³/h = 850 l/min.
Cooled to
+3 °C (pressure
dew point)
size: 40 µm
Max. particle
density:
10 mg/Nm
5 mg Nm
3
3
quality class
4 Cold dryer
7 Air filter on the
4 Oil-free
Equipment to
install
(recommended)
compressor
compacting
screw-type
compressor
Table 2-17
2-26 Compressed air supply TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
Compressor
A suitable compressor must be provided if the compressed air
supply to the system is not adequate. Due to the risk of
condensation build-up, the maximum distance between the
compressor and the basic machine should not exceed 50 m.
B452EN02.DOC Compressed air supply TC L 3050, TC L 4050, TC L 6050 - Version 3 2-27
5. Operating materials
Note
The following operating m aterials must be made available by the
customer before the machine is delivered.
5.1 Laser gases, cutting gases, and shield
gases
Note
Gas types, their purity and con nec ti ons , h os es, etc . ar e s pecified in
section 2, "Gas supply".
5.2 Cooling water
Water is needed to cool the las er unit, RF generator, and optical
components on the machine. Cooli ng is performed via two cooling
circuits, a copper cooling circuit and an aluminum cooling circuit.
Requirements
for the cooling water
For cooling water, demineralized, de-ionized, or distilled water is
mandatory. Cooling water must be provided by the customer at
system start-up.
Cooling water Copper
Cooling water quantity approx. [l] 85 470
Conductivity of freshly replaced water
[µS/cm]
Conductivity l imit of cooling water dur ing
operation [µS/cm]
Max. permissible carbonate content [mg/l]
Color Colorless Colorless
Cloudiness None None
Odor Odorless Odorless
cooling
circuit
≤10
≤200
M < 100 M < 100
Aluminum
cooling
circuit
≤10
≤200
Table 2-18
Note
The cooling circuit of the laser will have been cleaned with "high
purity ethylene gl ycol" before being transported to the c ustomer, if
the following applies:
• The system is delivered between October 1 and April 30.
• The system is transported via ship or airplane.
2-28 Operating materials TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
The system's cooling circuit m ust therefore be f lushed onsite prior
to start-up. Here, the cust omer mus t provide 60% more dem ineralized, de-ionized, or distilled water.
Storage
Handling
Color / cloudiness
Odor
• Deminerali zed water may only be stored for a short perio d of
time in order to avoid impairment of the water quality.
• The water must be transported in clean plastic containers
(without deposits, no odors).
• Avoid all unnec essary contact with the water (e.g. with hands) .
Contact with foreign materials, except those specified by
TRUMPF, affects the water quality.
• Additional water-filling equipment such as pumps, hoses, or
stopcocks should be used excl usivel y for handlin g the water of
the system.
• The demineralized water must undergo a simple inspection
regarding color, cloudiness, and odor before filling.
Any cloudiness (e.g. from suspended matter, threads, flakes,
particles) represents a water impurity. In such cases, the s ystem
should not be filled with this water.
Any deviation from a neutral o dor us u al l y in dic at es that the wat er is
biologically contam inated. In suc h cases , the system should not be
filled with this water.
Note
The chemical/physica l charact eristic s s pecif ied m us t be adhered to
without exception. Consult your supplier regarding this subject.
Algae inhibitors and
anticorrosives
Outdoor installation of
cooling unit
Algae inhibitors and anticorrosives for copper and aluminum
cooling circuits are delivered with the machine. The mixing of these
components with the cooling water must be carried out in
accordance with the regulations in the operator's manual for the
TLF la ser.
If cooling units are installed outside in areas with a risk of frost,
cooling water is mixed with the antifreeze agent "purest ethylene
glycol". The mixing r atio depends o n the temper ature condi tions at
the actual installation site:
Temperature [°C] to -15 up to -24
Percent of weight [%] 30 40
Percent of volume [%] 27 35
Mix proportions
Table 2-19
Note
Once the cooling water in a co oling un it has bee n mix ed with "high
purity ethylene gl ycol" once, the cooling unit must always be f illed
with this antifreeze agent, even in sum mer.
B452EN02.DOC Operating materials TC L 3050, TC L 4050, TC L 6050 - Version 3 2-29
6. Machine transport
All machine components are to be examined upon receipt for
damage incurred during transit. Any visible dam age caused during
transit must be recor ded on the b ill of lading a nd countersi gned by
the truck driver. Hidden damage cause d during transport must be
reported to the insura nce company and to T RUMPF within 6 days
at the latest.
The customer must make the necessar y arr angem ents and c onve y
the machinery from the truck to its final installation site.
The transport route to the machine's installation site must be
clarified in good time prior to the machine's delivery. Especially
gates, header heights, cable rack heights, ground conditions for
armored rollers etc. need to be checked.
The transport route m ust take into account the dimens ions of the
machine as per the installation plan.
Component Length ( mm) Width (mm) Height (mm)
3050 4050 6050 3050 4050 6050 3050 4050 6050
Machine body incl.
laser unit
Pallet changer 3500 4400 6700 2800 3350 3350 1000
Control cabinet of the
machine
RF generator 800 800 800 800 800 800 2100 2100 2100
Laser control cabinet 1400 1200 1200 800 1000 1000 2100 2100 2100
Laser cooling unit 2500 2500 2500 800 800 800 2105 2105 2105
Compact dust
extractor
Isolating transfor mer 1050 1050 1050 750 750 750 1400 1400 1400
Dimensions of system components incl. transport devices
5800 8100 10300 3050 3800 3820 2400
1200 1200 1200 1100 1100 1100 2100 2100 2100
1350 1550 1550 1280 1280 1280 2000 2200 2200
14
2400142550
15
1000151000
Table 2-20
14
15
Weight
The basic machine, the most heavy component to carry, weighs
the following together with the crane girder:
TC L 3050 10000 kg
TC L 4050 14000 kg
TC L 6050 16500 kg
14
This dimension goes up by approx. 350 mm with the transport bars and
armored rollers.
15
Incl. armored r ollers during transport.
2-30 Machine transport TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
Additional equipment and
transport equipment
The customer must supply:
• To transport the basic machine and pallet changer, a crane
girder must be purchased; TC L 3050 - Mat. No. 351238;
TC L 4050 - Mat. No. 3548 17; TC L 6050 – Mat. No. 3584 30.
When it is handed back, the customer will receive a
corresponding credit note.
• Crane truck for machine, pallet changer, and accessory
systems. We recomm end using a hydraul ic crane truck with at
least 80 t of hoisting power; if a larger lever arm is neede d due
to local conditions , a crane truck with a greater hoisting power
must be used.
• Forklift (carrying capacity 2.5 t).
• Gantry crane (if available; otherwise armored rollers must be
used)
– Carrying capacity 10 t for TC L 3050
– Carrying capacity 15 t for TC L 4050
– Carrying capacity 17 t for TC L 6050 or
• armored rollers (1 steerable and 2 fixed).
• At least 2
(minimum adjustable height: ≤30 mm).
• Hoisting iron (1 m) and extension.
h ydraulic hois ting jack s of at leas t 5 t lifting c apacit y
Transport regulations
Please note
Detailed rules for transporting the system are provided in the
TC L 3050 Transport regulations - Draw ing No. 93618-8-10, TC
L 4050 Transport regulations - Drawing No. 93678-8-10 and.
TC L 6050 Transport regulations - Drawing No. 93688-8-10
A copy of the transport r egu lat io ns is i nc lud ed with the de li very in a
clear plastic envelope on the machine.
Measures to be taken by the customer
• All transport work must be carried out according to the
transport regulations.
• The machine must not be lowered onto the ground without
supports. Otherwise t he lower side of various com ponents will
be damaged. The dista nce from machine beari ng plates to the
floor should be ≥100 mm. This distance f rom the floor/ground
must also be maintained dur ing transportation to the m achine
installation site.
• The floor requirements at the installation site must be determined according to the requirements of these installation
conditions. Cutouts, bore holes, etc. in the factory floor must be
prepared by the customer in accordance with the foundation
plan prior to installation of the machine.
Unloading the machine from
the truck
B452EN02.DOC Machine transport TC L 3050, TC L 4050, TC L 6050 - Version 3 2-31
• Unload the machine from the truck with a crane truck of
suitable hoisting po wer.
• Control cabinets, cooling unit, suction unit, and RF generator
can be transported directly from the truck to the inst allat ion site
of the machine using a forklift.
Transportation of the
machine from the yard to the
installation site
Installing the machine on the
installation site
• Transport the machine from the yard into the factory hall on
armored rollers.
• For transpor tation on wards to the actu al installati on site, eit her
a gantry crane of sufficient car rying ca pacity or armor ed rollers
can be used.
• Hydraul ic hoisting jacks are r equired to position and a lign the
machine at the installation site when using armored rollers.
• Position m achine + pallet changer on armored rollers next to
the actual installation site.
If site conditions do not permit this, inf orm TRUMPF cust omer
service (tel. +49 ( 0)7156/303-476 or fax +49 (0)7156/303-613
or 695) as soon as possible. In this case, the m achine can be
placed on the instal lation elem ents d elivered with it at the f inal
installation site following consultation.
• As long as t his d oes n ot hind er ins tallat ion, the contr ol c abin et,
cooling unit, and compact dust extractor can be set down at
the final installation site.
TRUMPF service work
Leveling the machine
System start-up
The leveling of the machine is carried out by TRUMPF service
technicians.
The machine is put into service by TRUMPF service technicians.
This comprises instal ling the com ponents ac cor ding the i nstallat ion
plan, connecting the machine to the supply circuits as well as
giving initial i nstructions to personnel and checking the m achine's
functioning.
2-32 Machine transport TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
30 31
7. Planning checklist
The planning check list is inte nded to pro vide you with an overvie w
of the measures and preparations to be undertaken by the
customer.
You will find deta iled inf ormation in the re levant subc hapter s of the
installation conditions.
Time before machine
Planning criterion Action
delivery
15 weeks Personnel and training
14 weeks,
but no later than calendar
Conditions at the installation
site
week ...
20
12 weeks,
Electrical power supp l y
but no later than calendar
week ...
Appoint a staff member to be
responsible for the machine
commissioning prepar ati ons.
Appoint the operating and m aintenance staff as well as programmers and arrange a training schedule for your specialists.
Appoint a laser safety officer, in
accordance with EN 60825-1
(VBG 93).
Determine the machine's final
position. Take into consid eration
space requirements using
installation plan.
Check the floor requirements
(floor quality, evenness, oilproof floor without expansion
joints). Take the weight and
dimensions of the machine into
account.
Check that the requirem ents for
ambient conditions are met
(ambient temperature, ex posure
to sunlight, purity of ambient
air).
Check the transport route ( gateway dimensions, overhead
clearance, cable rack heights,
room to negotiate around
corners, etc.).
Have the electrical connections
fitted at the installation site. T he
conductor cross section and
fuse protection should be set
out in accordance with the app licable legal requirem ents .
B452EN02.DOC Planning checklist TC L 3050, TC L 4050, TC L 6050 - Version 3 2-33
Time before machine
delivery
12 weeks,
but no later than
calendar week ...
12 weeks,
but no later than
calendar week ...
Planning criterion Action
Gas supply
Compressed air supply
Arrange for installation of the
laser and cutting gas supply at
the installation site .
Decide on the gas s upp l y meth od
(cylinders, cylinder banks, gas
tank).
Note the valves and fittings
required (e.g. two-stage pressure
reducer).
Consult your gas supplier to arrange the layout of the gas line s.
Install supply of c ompressed air
at the installation site (connection, purity, compressed air
requirements).
4 weeks,
but no later than
calendar week ...
4 weeks,
but no later than
calendar week ...
4 weeks,
but no later than
calendar week ...
At installation and start-up Ensure electricians are
Operating materials Acquire stocks of operating
Transport Make sure that the transportation
Laser safety gl asses Order laser safety glasses for
available
materials:
laser gases, cutting gases, and
operating materials for the
cooling unit.
aids required are available .
service work.
Connect the machine to the
electrical supply.
Table 2–21
2-34 Planning checklist TC L 3050, TC L 4050, TC L 6050 - Version 3 B452EN02.DOC
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
B452EN03.DOC Description 3-1
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
3-2 Description B452EN03.DOC
1. Machine concept
The TC L 3050, TC L 4050, TC L 6050 is a high-speed laser
cutting machine for machining plane components with high
precision. The precision is achieved b y a high degree of structural
stiffness.
The TC L 3050, TC L 4050, TC L 6050 works according to the
proven principle of "f lying opt ics ": the work piec e is s tation ar y, while
the laser cutting he ad moves. The CO
tool. It is guided via the mirror from the laser unit to the cutting
head and focused onto the workpiece. The sheet table and the
pieces are not moved. This ensures machining free of scratches.
Furthermore, the flatb ed machine with the T RUMPF RotoLas tub e
cutting unit (optional) can be used for machining tubes and profiles.
A pallet changer is standard equipment on the TC L 3050,
TC L 4050, TC L 6050. It replaces the pallet with the machined
metal sheet with a pallet with an unmachined s heet. The loading
and unloading of pallets can proceed at the same time as
machining. As a result, machine downtimes are reduced to a
minimum.
laser beam ser ves as the
2
Machine Working range
• (X x Y).
• Z axis.
Max. workpiece weight 900 kg 1800 kg 2800 kg
Max. axis speed
• Axially parallel.
• Simultaneous approx.
Max. axis acceleration 17 m/s² 16 m/s² 16 m/s²
Accuracy
• Smallest programmable increment.
• Positioning accuracy.
• Central positioning variation.
2
2. Technical data
TC L 3050 TC L 4050 TC L 6050
3000 x 1500 mm
115 mm
Mild steel Stainless steel AluminumMax. sheet thickness
25 mm 20 mm 12 mm
200 m/min
300 m/min
0.001 mm
0.05 mm
0.03 mm
1
The working range in Z direction is 90 mm on the TC L 3050 wit h
automation.
2
The accuracy achieved in the workpiece depends on factors including the
type of workpiece, its pretreatment, t he sheet size and its position in the
working area. The measur ing length was 1 m, as prescribed by
VDI/DGQ 3441.
1
4000 x 2000 mm
115 mm
6000 x 2000 mm
115 mm
B452EN03.DOC Description 3-3
TRUMPF CNC control
• Color monitor.
• Hard disk memory.
• Disk drive.
• Platform
Laser Laser type
Max. laser power,
programmable in 1% steps
Wavelength
Beam mode
Laser consumption values
Laser gas CO
Laser cooling Closed cooling system
Complete
system
Dimensions and weight
• Length
• Width
• Height
• Weight
Rated output 33-72 kW (TLF 5000)
TC L 3050 TC L 4050 TC L 6050
Based on Siemens SINUMERIK 840D
12" TFT display
500 MB for NC programs
3.5"
PC with Windows NT 4.0
TRUMPF TLF 5000
5000 W
10.6 µm
TEM
01*
2
N
2
He
3
4
1 l/min
6 l/min
13 l/min
11250 mm
4600 mm
2400 mm
12500 kg
13000 mm
5400 mm
2400 mm
14000 kg
TRUMPF TLF 6000
6000 W
10.6 µm
TEM
01*
16950 mm
5550 mm
2550 mm
16000 kg
37-76 kW (TLF 6000)
Further information on dimensions, weights, consumption values
and ambient conditions are provided in the "Installation requirements" chapter.
2.1 Axis directions
Axis directions
3
Approximate values. The exact specifications are to be found in the
applicable installation plan.
4
Approximate values; incl. suction uni t, control cabinet, RF generator, and
Fig. 29894
cooling unit.
3-4 Description B452EN03.DOC
123
14
4
13
12
3. Subassemblies of the machine
1 Control cabinet with
RF generator
2 Switch cabinet of the machine
3 Cooling unit
4 Compact dust extractor
5 Pallet changer
6 Start post
Subassemblies of the machine
Position
Designation
1
Basic machine with safety cabin
2
Pallet (2 pieces)
3
Transverse conveyor belt (optional)
4
Tube cutting unit TRUMPF RotoLas
(optional for TC L 3050/4050)
5
Pallet changer
6
Automatic loading unit (optional)
1011
7 Transverse convey or belt with
scrap bucket (optional)
8Pallet
9 Longitudinal conveyor belt
10 Basic machine
11 Operating panel
Function Description
Machining of the stationary workpiece with the
focused laser beam serving as a moving tool
(flying optics principle)
Workpiece support with slats of mild or
stainless steel
Disposal of cut out pieces and slag which fall
through the pallet support
Machining of tubes and profiles with the l aser
beam
Pallet-changing system with two pallets
makes it possibl e to load and unload during
the cutting proc ess
Automatic loading of sheets into the machine Loading unit operator's
8
9
76
12 Safety cabin with door
13 RotoLas tube cutting unit
(optional)
14 TLF laser
Chapter Description
Chapter Description
Chapter "RotoLas tube c utting
unit"
Chapter Description
manual
5
Fig. 29895
B452EN03.DOC Description 3-5
Position
Designation
7
Compact dust extractor
8
Cooling unit
9
Switch cabinet
10
TLF 5000 / TLF 6000
11
Control cabinet wit h RF generator
12
Safety cabin with door
13
Machine and laser control panel
14
Start post for pallet changer and
automation component s (optional)
15
Longitudinal conveyor belt
Function Description
Environmentally-friendly exhaust suction of
fumes and airborne par ticles
Cooling of the laser unit and the deflection
mirrors in the beam guideway
CNC control system, logic and power section,
electrical supply to the drives, etc.
Generates the laser radiation Chapter Description
Excites the laser gases Chapter Descript ion
Secures the machine' s working area
Central operating position of the machine Chapter "Operation" and
Operating posit ion for pallet changer and
automation component s (optional)
Disposal of cut out pieces and slag which fall
through the pallet support
Chapter 3 and vendorsupplied documentation
Chapter Description
Electrical circuit diagram,
manufacturer documentation
"Online help for operation"
Chapter Operation
Chapter "Description" and
"Supplier documentation"
Table 3-1
3-6 Description B452EN03.DOC
3.1 Basic machine
6
7
The main components of the basic machine are:
1 3 4 5
2
Flexible usage
1 Laser unit
2 Motion unit
3 Instrument panel
4Pallet
Components of the bas ic machine
5 Longitudinal conveyor belt
6 Machine frame
7 Control panel
Fig. 28598
• Closed machine frame with integrat ed laser unit and operating
panel.
• Motion unit (consisting of the cross member and the Y slide
with integrated Z axis).
• Several suction chambers, separated by removable bulkheads.
• Instrument plate for installing central lubrication and the
pneumatic components.
• Longitudinal conveyor belt for transporting slag and waste
parts under the working area of the machine.
The machine's work ing range can be used in a flex ible way, e.g.:
machining of bulky workpieces, working with a fixture). For this
purpose, the easy-to-remove bulkheads which separate the s uction
chambers must be taken out.
B452EN03.DOC Description 3-7
3.2 Machine frame
2325654
Closed machine frame
Safety cabin
The highest possible parts
precision with very high
machine dynamics
The machine has a compact, clos ed C-frame. Protecti ve paneling,
a safety door, energ y guides, suc tion and ventilat ion s ystems have
been fitted to the machine frame.
No special foundat ion is required for the TC L 3 050, TC L 4050,
TC L 6050. The machine and the automation components are
simply doweled to the floor.
Machining takes place within a closed safety cabin.
The sheet metal is placed on a pallet in the pallet changer. The
pallet moves into the cabin at working he ight. The laser beam will
only be ignited if the door is completely closed.
3.3 Motion unit
The TC L 3050, TC L 4050, TC L 6050 works according to the
principle of "fl ying optics": workpiece s tationary, tools m oving over
it. This guarantees high processing precision.
The motion unit is based on a highly stable, FEM-calculated
transverse support, which has a lightweight welded steel design.
Design features and manufacturing methods enabling extremely
lightweight construction were deliberately selected for this purpose.
The motion unit cov ers the entire working range in Y direction. It
consists of the cros s member and the Y axis with the integrated Z
axis. The cutting head is mounted on the Z axis. The c utti ng hea d' s
Y and Z drives are integrated in the Y slide.
1 1
1 Drive motor of the X axis
2 Guides of the X sli de
3 Cutting head
4 Y/Z drive ("prim ary part")
Motion unit of the basi c machine
5 Guides of the Y sli de
6 Magnetic Y drive ("secondary
part")
Fig. 28588
3-8 Description B452EN03.DOC
3.4 Drives
Drive in X direction
Drive in Y and Z directions
Multi-chamber suction
system
Removable bulkheads
Optimum suction power
The motion unit is driven both on the left and right by a modern
integral axis. The drives have been designed as gantry axes.
The Y and Z axes have b een designed as linear d irect drives. A
combination motor is used here; i.e. both motors are in one
housing and have been provided with a joint cooling system.
3.5 Suction
There is a suction system under the working range of the laser
cutting machine, consisting of several suction chambers. Each
suction chamber is opened and closed via a pneumaticallyoperated flap and is connected to the central suction channel.
The suction chambers are separated by vertically inserted
bulkheads. To m achine shee ts which c over on l y a sm all par t of the
working range (especial ly in the Y direction), the se parating plates
inserted in the X direction can be repositioned. This substantially
increases the suction power in that area.
For work with a fixture or a similar flexible use, the separating
plates can be removed.
During the cutting operation, onl y the flap of the suct ion chamber
below the cutting he ad is op ened. As a r esult, th e suctio n p ower is
concentrated on only one chamber at a time, ensuring optimum
suction of the fumes and floating particles. The suction unit
ensures that the particle concentrations fall well within the limit
values permitted at the workplace.
Compact dust extractor
Continuous purging cycle
Principle of conveyor belt
function
The compact dust extractor with surface filter removes particles
from the exhaust gases produced during laser cutting.
A continuous purging cycle provides optimal use of the filters'
capacity.
3.6 Longitudinal conve yor belt and
transverse conveyor belt
The machine has one longitudinal and one transverse conveyor
belt (optional) for transporting small parts (
of the machine in the X direction or in the Y direction (optional).
The longitudinal and/or transverse conveyors run continuously in
cutting mode.
The belt speed is about 2.8 m/min.
<100 mm x 100 mm ) out
B452EN03.DOC Description 3-9
3.7 Instrument panel
1234567
The machine's pneumatic diagram can be found in the
replacement parts list of the TC L 3050, T C L 4050, TC L 6050.
The entire gas supply to the machine is provided via the i ns tr ument
panel on the left lateral carrier on the basic machine.
98 10 1111 12 13
1 Beam guideway press ure reducer
2 Microfilter
3 Activated carbon filter
4 Beam guide ventilat ion pressure
reducer
5 Electrical lubricator for chain on
the longitudinal conveyor belt
Instrument panel Fig. 33221
6 Single piston pump and low-
viscosity grease reservoir for
central lubri cation
7 Reservoir for spraying
equipment
8 Pressure relief valve
9 Purge valve input
10 Cutting gas filter (O2 and N2)
11 Purge valve output
12 Compressed air mai ntenance
unit
13 Compressed air pressure gauge
3-10 Description B452EN03.DOC
The following machine elements are supplied or controlled pneumatically:
Machine element Function of the compressed air
Laser cutting head Nozzle cooling, cutting air as the
Z slide Checking whether the cutting head is
cutting gas (opt ional; as alternative to
oxygen or nitrogen) and for blowing
slag away after piercing thick sheets.
present or not
Vacuum flaps Opens and closes the flaps in t he
Pallet indexing For pallet indexing in the basic
Cateye (optional) Feed motion of the "Cat Eye" optical
Central lubric ation Connection for spray lubrication
Tube cutting unit (optional for
TC L 3050/TC L 4050)
Spraying equipment ( optional) Compressed air for spray pulse
Compact dust extrac tor Supply connect ion
exhaust chambers
machine
sensor
elements; connect ion for lubricating
pump
Shifting the support
Table 3-2
3.8 Cutting gas switching and pressure
regulating valve
Programmable cutting gas
pressure
The combination proportional valve with ASI activation for
switching and regulating the cutting gas is found on the Z axis,
under a cover plate. It enables step-by-step programming of the
cutting gas pressure from 0.25 bar to 20 bar. Very fast gas
regulation is possib le du e to t he c lose prox im it y to the cut tin g h ead
and therefore also the cutting process.
Potentiometer for cutting gas
pressure
In addition, each pres sure level can be m odified, even duri ng the
cutting process, by
±20% via a potentiometer integrated in the
control panel.
Digital gas pressure display
A digital display likewise installed in the control panel makes it
possible to control the current gas pressure with an accuracy of
±0.1 bar.
The gas type has no ef f ect on the c ontrol acc urac y of the val ve, as
long as the required purities are maintained.
B452EN03.DOC Description 3-11
3.9 Beam guideway
Completely encapsulated
beam guideway
Traveling mirror carrier
The laser beam is completely encapsulated on its way from the
beam generator to the cutting head of the basic machine; this
means that no laser ra diation can escape and no f umes from the
cutting process can infiltrate the beam guideway.
After the invisible l aser rad iation has been r eleased f rom the beam
generator, the beam initially runs via the optical e lements on the
left lateral carr ier of the machine. In do ing so, central functi ons of
the beam guideway are realized:
• The com ponents of the be am guidewa y ensure the be am path
and hence the beam form and also the beam quality are
maintained optimally over the entire working range of the
machine for the respective machining situations.
• Phase shifter (ECQ).
The entire beam guideway is ventilated with nitrogen. Gas-tight
beam guideway ventilati on ensures a constant pres sure burden in
the beam guideway under all working conditions.
The traveling mirror carrier ensures that beam character istics are
even over the ent ire working range of the machine. Ther e are two
deflection mirrors on the traveling m irror carrier. Dep ending on the
position of the cutting head in the working range, the traveling
mirror carrier moves to a defined position in X direction (U axis);
this means that the beam path is always more or les s exactly the
same length, regardless of the processing point in the working
range.
Cooled deflection mirror
Autofocus function
AutoLas Plus
Lens monitoring
sensor system
All deflection mirrors are cooled by the cooling unit of the laser.
AutoLas
position of laser m achines. AutoLas
focus position to suit the type and thick ness of the material. The
main component is the automatic focusing mirror, with its surf ace
specifically shaped b y the cooling water pressure. In t his way, the
angle of divergence of the laser beam is changed, enabling
systematically repositioning of the focus upwards or downwards.
The machine's standard equipment includes a lens monitoring
sensor system. The high laser output p laces high dem ands on the
machine components, particularly the focusing lens. Any
contamination on the lens leads to increased absorption of the
laser radiation. The absorbed laser radiation results in the lens
being heated and, in the worst case, to th ermal decomposition of
the lens.
The lens monitoring sensor s ystem prevents the focusin g l ens from
evaporating completely, by switching off the laser within a few
milliseconds of the thermal decomposition of the lens beginning.
The flashing of the lens, which pr ecedes the beginning of thermal
decomposition, is identified via a photodiode, while an integrated
light barrier detect s any development of fum es in the area above
the lens. For further information: Technical telegram, lens
monitoring sensor system.
Plus is a device used to automatically set the focus
Plus automatically adjusts the
3-12 Description B452EN03.DOC
2
1
5
8
3
4
1 Output mirror
2 Adaptive deflection mirror
3 Deflection mirr or
Beam guideway
6
7
9
4 Beam bending mirror
5 Phase shifter
6 Deflection mirr or
7 Deflection mirr or
8 AutoLas Plus mirror
9 Lens
Fig. 30197
B452EN03.DOC Description 3-13
3.10 Cutting head
The laser cutting head is a central component of the system.
The lens adapter tube with the optical c omponents and th e cutting
head housing with cutting nozzle, distance control system and
adjusting screws are essential components of the laser cutting
head.
The lens (ZnSe) ref r ac ts the para l lel laser beams and c onc e ntr ates
them in the focus where the energ y densit y of the rad iation is at its
highest. Depending on the lens type, the focal length is 3. 75", 5",
7.5", 9", or 10". For optimum work res ults, the focus must be set to
a defined point on th e workpiece surface. T he le ns is c oo led by the
cutting gas flow, which is f ed coaxially to the laser beam into the
hollow space under the lens.
For machining, the ra diation and the cutting g as are directed o nto
the workpiece through the cutting nozzle which is additionally
cooled with purified compressed air.
The sensor system for distance control is located in the cutting
head, protected by a cover plate.
The capacitive distance control system keeps the distance from the
nozzle to the sheet constant throughout the cutting process.
The entire cutting head is fastened to the Z ax is, whic h is driven b y
a linear motor.
Lens monitoring sensor
system
The TC L 3050, TC L 4050, TC L 6050 is equipped with a lens
monitoring sensor system as standard. The light intensity in the
cutting head is monitored by a light-sensitive component. The
machine is switched off as soon as the sensor system detects a
flash of light. Sinc e the l ens gives off a flash before it is destro yed,
this prevents it from being completely destroyed.
After the lens monitoring sensor system has responded, check
whether the sensor system was triggered by:
• The start of thermal decomposition, or
• Process light
has triggered the sensor system.
If the start of therm al decomposition is the c ause, the lens can not
be used anymore and must be r eplaced. However, t his avoids the
time-consuming work of cleaning the beam guideway, which is
required after full thermal decomposition of a lens.
3-14 Description B452EN03.DOC
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