Trumpf LASERCELL 1005 User manual

Operator’s manual
TRUMPF LASERCELL 1005

Operator’s manual
TRUMPF LASERCELL 1005
Edition: 07/2004

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TRUMPF Werkzeugmaschinen GmbH + Co. KG
Technische Dokumentation
Johann-Maus-Straße 2
D-71254 Ditzingen
Fon: +49 (0) 71 56/3 03-0
Fax: [phone]
Internet: http//www.trumpf.com
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This document was compiled by the Technical Documentation Dept. of
TRUMPF Werkzeugmaschinen GmbH + Co. KG
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documentation, are reserved to TRUMPF Werkzeugmaschinen GmbH + Co.
KG, even in case of patent and industrial rights applications. No part of this
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consent of TRUMPF Werkzeugmaschinen GmbH + Co. KG Subject to errors
and technical changes.
TRUMPF Werkzeugmaschinen GmbH + Co. KG
TRUMPF Werkzeugmaschinen GmbH + Co. KG cannot be held responsible
for possible mistakes in this documentation. Any warranty for direct and
indirect damages, arising in connection with the delivery or the use of this
documentation, is excluded, as far as this is in conformity with the law.

B337EN00.DOC Before You proceed... 0-5
Before You proceed...
This operator’s manual documents the numerically controlled
TRUMPF LASERCELL 1005 (TLC 1005) laser processing system.
This manual is addressed not only to the user (owner) and the
operator of the machine, but also to its maintenance personnel.
This group of persons must have access to the manual.
•Programming manual
TLC 1000, TLC 1005, TLC 6005, TLC CUT 5
•Programming manual Teach-In-Programming
TLC 1000, TLC 1005, TLC 6005, TLC CUT 5
•Spare parts list for the TLC 1005
•Spare parts list for the TLF Laser
•Wiring diadram for the TLC 1005
•Wiring diadram for the TLF Laser
•Data collection TLC 1000, TLC 1005, TLC 6005, TLC CUT 5
•Technical information Laser processing:
TLF laser: Basics, installation and use
•Vendor-supplied documentation
The documents on paper are supplemented by online help at the
control for machine operation and programming.
The entire machine documentation contains vital safety information
regarding prevention of injuries and potential hazards to life and
health. The symbol to the left calls your attention to information of
this type. Be sure to read the Safety chapter!
Complementary
Documentation
Online Help

0-6 Before You proceed... B337EN00.DOC

B337EN00.DOC Table of Contents 0-7
Table of Contents
Chapter 1 Safety
1. For your safety ...............................................................1-3
2. Terminology....................................................................1-4
3. Operating safety.............................................................1-4
3.1 Authorized use of the machine ........................................1-5
3.2 Measures to be taken by the user/operator.....................1-6
Observe information and warning plates....................1-6
Instructing personnel...................................................1-6
Care needed while operating the machine.................1-7
Eliminating malfunctions during operation................1-10
Duty of care when handling the cooling unit.............1-11
Using the appropriate spare parts and operating
materials....................................................................1-12
Water protection........................................................1-13
Fire protection...........................................................1-14
3.3 Measures taken by the manufacturer ............................1-16
Securing the danger zone of the machine................1-16
Suction unit and compact dust extractor
(filtering installation)..................................................1-18
3.4 Warnings contained in this operator’s manual...............1-19
Symbols ....................................................................1-20
Signalling words........................................................1-20
4. Overview of hazards....................................................1-21
5. Laser processing .........................................................1-23
5.1 Operating modes of the laser system............................1-23
5.2 Laser classes .................................................................1-23
5.3 Dangers due to laser radiation.......................................1-24
5.4 Protection against radiation............................................1-25
Measures to be taken by the user/owner..................1-25
Measures taken by the manufacturer .......................1-27

0-8 Table of Contents B337EN00.DOC
5.5 Hazardous substances...................................................1-30
Dust, aerosols and gases .........................................1-30
Cutting oils ................................................................1-31
Ozone........................................................................1-32
Polyethylene-coated (PE) tubes ...............................1-32
5.6 Hazards from thermal decomposition of ZnSe
lenses.............................................................................1-33
Lens characteristics ..................................................1-33
Thermal decomposition.............................................1-33
Response to accidents..............................................1-34
Disposal of lenses.....................................................1-35
5.7 Hazards caused by flash or very bright light..................1-35
5.8 Danger due to high voltage............................................1-36
5.9 Risks from electromagnetic alternating fields ................1-37
Chapter 2 Installation conditions TLC 1000 and TLC
1005
1. Installation site...............................................................2-5
1.1 Space requirements.........................................................2-5
1.2 Floor requirements...........................................................2-5
1.3 Weight loading .................................................................2-6
1.4 Ambient conditions...........................................................2-9
1.5 Exhaust air conduction for compact dust extractor........2-10
1.6 Outdoor installation of cooling unit.................................2-11
2. Gas supply....................................................................2-12
2.1 Laser gases....................................................................2-13
Purity.........................................................................2-13
Gas consumption, supply lines, pressure
reducer......................................................................2-13
Laser gas supply from cylinders ...............................2-14
Central laser gas supply (fixed piping)......................2-14
2.2 Cutting gases .................................................................2-15
Purity.........................................................................2-15
Gas consumption......................................................2-15
Supply lines to cutting gas supply.............................2-18
Cutting gas supply with cylinders or bundles............2-19
Cutting gas supply from gas tank .............................2-20
1.3 Welding gases (inert gases) ..........................................2-22
Purity.........................................................................2-22
Supply lines...............................................................2-22

B337EN00.DOC Table of Contents 0-9
3. Electrical supply...........................................................2-23
3.1 Power supply..................................................................2-24
3.2 Connected loads, fuse protection ..................................2-25
3.3 Teleservice.....................................................................2-26
3.4 Network connection........................................................2-26
4. Compressed air supply ...............................................2-27
5. Operating materials .....................................................2-29
5.1 Laser gases and cutting and inert gases.......................2-29
5.2 Cooling water .................................................................2-29
6. Transport ......................................................................2-32
1.1 On delivery: checking the system ..................................2-35
1.2 Unloading machine and transporting to the
installation site................................................................2-35
Transport of TLC 1005 basic machine......................2-36
Base for machine body.............................................2-39
Machine table............................................................2-40
Base plate.................................................................2-40
System components .................................................2-41
1.3 Installing the system.......................................................2-41
Preparing the factory floor.........................................2-42
2. Planning aid..................................................................2-43
Chapter 3 Description
1. Machine concept............................................................3-3
2. The Technical data.........................................................3-4
3. Coordinate system, zero point, working range...........3-7
3.1 Coordinate system...........................................................3-7
3.2 Zero point, working range ................................................3-8

0-10 Table of Contents B337EN00.DOC
4. The modules of the laser cutting center....................3-11
4.1 The modules of the basic machine ................................3-14
Machine body............................................................3-16
Motion unit for X, Y, Z (extension arm).....................3-17
Drives........................................................................3-18
Safety cabin ..............................................................3-18
Support table.............................................................3-19
Base plate.................................................................3-21
Rotary axis with media connection (optional)...........3-23
Back stop (optional) for rotary axis...........................3-25
Direct drive rotary axis (optional)..............................3-26
Beam guideway.........................................................3-28
Processing optics......................................................3-32
Central lubrication.....................................................3-35
Instrument panel .......................................................3-36
4.2 The laser ........................................................................3-38
Targeting laser..........................................................3-39
4.3 Electrical installation.......................................................3-40
Safety interface (optional).........................................3-40
Digital user interface (optional).................................3-42
4.4 Suction unit and compact dust extractor........................3-42
Suction......................................................................3-42
Compact dust extractor.............................................3-43
5. Control system/programming.....................................3-44
5.1 Control system ...............................................................3-44
5.2 Programming..................................................................3-45
2-D programming......................................................3-45
3-D programming......................................................3-46
6. Sensor system..............................................................3-48
6.1 TSD seam sensor system (optional)..............................3-48
6.2 DIAS distance-control system........................................3-50
7. Options..........................................................................3-51
7.1 Measuring probe (optional)............................................3-51
7.2 Welding wire feed (optional)...........................................3-52

B337EN00.DOC Table of Contents 0-11
Chapter 4 Operation
Part 1: Operating devices..........................................................4-9
1. Control elements other than on the operating
panel................................................................................4-9
1.1 Control elements of the basic machine............................4-9
1.2 Control elements of the safety door
(electrically driven sliding door)......................................4-12
1.3 Teach panel ...................................................................4-14
1.4 Control elements of the JIC version...............................4-15
1.5 Control elements on the start post of the pallet
changer .........................................................................4-17
1.6 Z axis brake switch.........................................................4-21
2. Operating panel with color display............................4-22
2.1 Control elements on the machine ..................................4-23
2.2 Control elements of the control system..........................4-30
3. ASCII keyboard.............................................................4-34
Part 2: User interface ...............................................................4-36
1. User interface layout....................................................4-36
1.1 Menu bar........................................................................4-36
1.2 Status bar.......................................................................4-37
1.3 Message line..................................................................4-38
1.4 Softkey bar.....................................................................4-38
1.5 Display area ...................................................................4-38
2. Machine submodes......................................................4-39
2.1 AUTOMATIC submode..................................................4-39
2.2 MDA submode ...............................................................4-40
2.3 JOG submode................................................................4-40
3. Control system activity fields.....................................4-40
4. PRODUCTION activity..................................................4-42
4.1 PRODUCTION Single job..............................................4-42
4.2 PRODUCTION – Machine components.........................4-51
4.3 PRODUCTION Program options ...................................4-52

0-12 Table of Contents B337EN00.DOC
4.4 PRODUCTION – Switch elements.................................4-53
Operation of the switch elements .............................4-54
Switch elements for distance control system............4-55
Switch elements in general.......................................4-57
Service switch elements ...........................................4-59
Welding switch elements ..........................................4-60
PRODUCTION Front safety door switch
elements....................................................................4-61
Safety door status display switch elements..............4-63
Left pallet changer status display switch
elements....................................................................4-64
Front pallet changer status display switch
elements....................................................................4-65
Right pallet changer status display switch
elements....................................................................4-66
Maintenance switch elements...................................4-67
Suction unit switch elements ....................................4-68
Manually movable table indexing switch
elements....................................................................4-70
Switch elements for TLF laser statuses 1.................4-73
Switch elements for TLF laser statuses 2.................4-74
4.5 PRODUCTION Tables...................................................4-75
Laser technology.......................................................4-75
Laser power cycles...................................................4-86
Welding table ............................................................4-88
Tube section technology table..................................4-93
4.6 PRODUCTION Summary production plan.....................4-96
4.7 PRODUCTION Production plan for basic machine .....4-100
5. SET-UP activity...........................................................4-103
5.1 SET-UP – Switch elements..........................................4-103
Switch elements of the distance control system.....4-104
Switch elements in general.....................................4-106
Service switch elements .........................................4-109
Welding switch elements ........................................4-111
Switch elements for maintenance...........................4-112
Left pallet changer switch elements (optional)........4-113
Front pallet changer switch elements (optional).....4-114
Right pallet changer switch elements (optional).....4-116
Left pallet changer manual function switch
elements (optional) .................................................4-117
Front pallet changer manual function switch
elements (optional) .................................................4-118
Right pallet changer manual function switch
elements (optional) .................................................4-120
Switch elements for suction unit .............................4-121

B337EN00.DOC Table of Contents 0-13
Manually movable support table indexing switch
elements (optional) .................................................4-122
Front safety door switch elements for electrically
driven sliding doors.................................................4-125
Front safety door switch elements for electrically
driven lift doors........................................................4-127
TLF laser intervention 1 switch elements ...............4-128
TLF laser intervention 2 switch elements ...............4-129
5.2 SET-UP - Jog mode.....................................................4-131
5.3 SET-UP MDA...............................................................4-132
5.4 SET-UP – Adjust laser beam.......................................4-134
6. PROGRAMMING activity............................................4-139
6.1 NC Editor......................................................................4-139
6.2 NC program management............................................4-141
6.3 File management .........................................................4-143
6.4 Outputting NC programs from the management
system..........................................................................4-145
6.5 Selecting NC programs................................................4-147
7. Tooling activity...........................................................4-149
7.1 Zero point offset...........................................................4-149
8. MAINTENANCE / INITIAL START-UP activity..........4-151
8.1 MAINTENANCE / INITIAL START-UP Data backup ...4-151
8.2 MAINTENANCE / INITIAL START-UP Display............4-152
8.3 MAINTENANCE / INITIAL START-UP Maintenance
logbook.........................................................................4-153
9. DIAGNOSTICS activity...............................................4-154
9.1 DIAGNOSTICS Error diagnostics ................................4-154
9.2 DIAGNOSTICS I/O diagnostics ...................................4-155
9.3 DIAGNOSTICS Remote diagnostics............................4-156
9.4 DIAGNOSTICS Laser ..................................................4-157
Laser RF generator.................................................4-157
Laser leak test.........................................................4-158
9.5 DIAGNOSTICS Display home position........................4-160
10. Integrated MDC activity (optional)............................4-161
10.1 MDC message texts.....................................................4-161
10.2 MDC Creating and modifying message texts...............4-162
10.3 MDC Displaying and editing machine data..................4-164
10.4 MDC Creating and modifying interruptions..................4-166
10.5 MDC Evaluating machine data ....................................4-167
10.6 MDC Display of the times in a list................................4-169
10.7 MDC Changing the time...............................................4-170

0-14 Table of Contents B337EN00.DOC
Part 3: Operating the machine..............................................4-171
Calling up the online help........................................4-171
1. Machine start-up and shutdown...............................4-174
1.1 Switching on the machine............................................4-174
1.2 Switching off the machine............................................4-175
2. Switching off the machine in the event of
malfunctions/emergencies........................................4-176
2.1 Triggering E-STOP.......................................................4-176
2.2 Cancelling E-STOP......................................................4-176
3. Eliminating malfunctions ..........................................4-177
3.1 Triggering FEED HOLD ...............................................4-177
3.2 Acknowledging FEED HOLD .......................................4-177
3.3 Acknowledging FEED HOLD after a collision
involving the nozzle......................................................4-177
3.4 Cancelling E-STOP after detecting a collision
(optional for the cutting head) ......................................4-178
3.5. Releasing the X, Y, B and C axis drive brakes............4-179
3.6. Releasing the Z axis drive brake..................................4-180
4. Executing a program .................................................4-181
4.1 Calling up and starting a program................................4-181
4.2 Stopping a program during machining.........................4-182
4.3 Aborting a program ......................................................4-182
5. Operating in marking test mode...............................4-183
6. Editing, filling and deleting the zero point
memories G54 to G57................................................4-184
6.1 Editing a zero point memory manually.........................4-185
6.2 Filling the zero point memory for all axes with the
current axis position.....................................................4-186
6.3 Filling the zero point memory for individual axes
with the current axis position........................................4-188
6.4 Deleting the zero point memory for all axes.................4-191
6.5 Deleting the zero point memory for individual axes.....4-193
7. Working with the summary production plan...........4-195
7.1 Creating a summary production plan...........................4-198
7.2 Starting a summary production plan............................4-199
7.3 Ending a summary production plan .............................4-200

B337EN00.DOC Table of Contents 0-15
8. Processing with the production plans -basic
machine.......................................................................4-201
8.1 Creating a production plan...........................................4-202
8.2 Starting production plans .............................................4-203
8.3 Ending production plans...............................................4-204
9. Moving the axes in jog mode....................................4-205
10. Support table indexing..............................................4-205
10.1 Indexing support tables................................................4-205
10.2 Undoing electrical indexing..........................................4-206
10.3 Undoing pneumatic indexing........................................4-206
11. Optional: Driving pallet changers ............................4-207
11.1 Coupling pallets............................................................4-208
11.2 Separating pallets ........................................................4-208
11.3 Moving pallets in manual mode ...................................4-209
11.4 Moving pallets in automatic mode................................4-209
11.5 Moving the pallet after actuating the axis switch
(after a collision)...........................................................4-210
12. Electrically driven safety doors................................4-210
12.1 Opening the lift door.....................................................4-211
12.2 Closing the lift door ......................................................4-211
12.3 Referencing the safety door.........................................4-212
12.4 Referencing the safety door.........................................4-213
12.5 Closing the safety door ................................................4-213
12.6 Releasing the safety door after a collision..................4-214
13. Calling up a lubrication cycle ...................................4-216
13.1 Starting a lubrication cycle...........................................4-217
13.2 Starting the Z axis lubrication cycle .............................4-218
14. Operating the laser ....................................................4-219
14.1 Switching on the laser..................................................4-219
14.2 Switching off the laser..................................................4-220
14.3 Igniting the laser beam.................................................4-220
14.4 Switching off the laser beam........................................4-221
14.5 Opening the beam trap ................................................4-221
14.6 Closing the beam trap..................................................4-221
14.7 Working in laser test mode...........................................4-222
14.8 Setting laser operation mode.......................................4-222
14.9 Setting the laser mode.................................................4-223
14.10 Setting the laser power ...............................................4-223
14.11 Carrying out a leakage test..........................................4-224

0-16 Table of Contents B337EN00.DOC
15. Diagnostic functions..................................................4-225
15.1 Error diagnostics..........................................................4-225
15.2 Displaying inputs and outputs of the machine and
laser..............................................................................4-226
15.3 Remote diagnostics via pcANYWHERE1....................4-227
15.4 Querying the software version .....................................4-227
16. Managing master files ...............................................4-228
16.1 Uploading an NC program from the disk drive............4-228
16.2 Uploading an NC program from the hard disk ............4-229
16.3 Outputting an NC program to the disk drive................4-230
16.4 Outputting an NC program on the hard disk drive .......4-231
16.5 Outputting a program part onto the disk drive..............4-232
16.6 Deleting NC programs from the program manager .....4-233
17. Managing NC programs.............................................4-234
17.1 Displaying NC text........................................................4-234
17.2 Editing NC text.............................................................4-235
Searching for a block in the NC text .......................4-235
Searching for a function in the NC text...................4-235
Searching for and replacing a function in the
NC text....................................................................4-236
Inserting an additional line......................................4-236
Copying and inserting text passages......................4-237
Deleting text passages............................................4-238
18. Editing tables based on an NC text..........................4-239
19. Acknowledging maintenance....................................4-240
20. Operating the integrated MDR..................................4-241
20.1 Creating a message text..............................................4-241
20.2 Assigning a message text............................................4-242
20.3 Splitting up an interruption period................................4-243
20.4 Evaluating machine data..............................................4-244
21. Evaluating the ODC interface ..................................4-245
21.1 Opening a LOG-file ......................................................4-245
21.2 Opening a LOG file in MS Excel ..................................4-246
22. Carrying out a back up of the PCU 50......................4-247

B337EN00.DOC Table of Contents 0-17
Chapter 5 Setting work
1. Safety information..........................................................5-4
2. Overview of setting work ..............................................5-5
3. Checking and setting B and C axes.............................5-6
3.1 Checking C axis and setting reference offset value.........5-7
3.2 Checking the B axis and setting the reference
offset value.......................................................................5-9
4. Selecting processing optics .......................................5-13
4.1 Selecting the cutting head..............................................5-14
4.2 Selecting the welding head............................................5-16
5. Cutting head setting work...........................................5-19
5.1 Dismantling the cutting head..........................................5-20
5.2 Mounting the cutting head..............................................5-20
5.3 Centering the beam........................................................5-21
5.4 Determining and setting the focus position....................5-25
Adjusting the setting on the cutting head..................5-29
Determining focus position f=0 .................................5-30
Correcting focus position ..........................................5-32
6. Adjustment work on the welding head......................5-33
6.1 Installing the welding head.............................................5-33
6.2 Centering the beam........................................................5-34
6.3 Determining and setting the focus position....................5-37
Utility program CP_FOCUS_WELD..........................5-38
Setting the welding head to the nominal
dimension..................................................................5-40
Focus search with machines without AutoLas
Plus...........................................................................5-41
Focus search with machines with AutoLas Plus......5-47
7. Determining the joint offset ........................................5-65
7.1 Determine link offset of X and Y axis.............................5-67
Determining the joint offset for cutting head.............5-67
Determining the joint offset for the welding
head..........................................................................5-69
7.2 Determining link offset of Z axis (tool length)................5-71

0-18 Table of Contents B337EN00.DOC
8. Changing the gas and air connections at the Z
center sleeve ................................................................5-74
9. Recording the DIAS characteristic curve..................5-75
10. Checking and setting the Crossjet.............................5-76
11. Setting the flow rate of the welding gas....................5-77
12. Switching over the welding gas .................................5-78
13. Measuring probe (optional).........................................5-79
13.1 Installing the measuring probe.......................................5-79
Selecting measuring probe.......................................5-80
Calibrating the measuring probe...............................5-83
14. Welding wire feed (optional).......................................5-86
14.1 Inserting welding wire.....................................................5-86
15. Setting the rotary axis (optional)................................5-90
15.1 Shifting the rotational axis horizontally in X
direction..........................................................................5-90
15.2 Adjusting the rotational axis in Z direction .....................5-91
15.3 Swivelling the rotational axis by 90°...............................5-92
16. Setting the back stop (optional) .................................5-93
16.1 Shifting the rotational axis horizontally in X
direction..........................................................................5-93
17. Further service programs............................................5-94
Program overview.....................................................5-94
17.2 Replacing LTT's in utility programs................................5-94
17.3 Performing parting cuts..................................................5-96
17.4 Cutting support slats ......................................................5-97
17.5 Cutting sacrificial plates .................................................5-99

B337EN00.DOC Table of Contents 0-19
Chapter 6 Machine maintenance
1. General guidelines.........................................................6-3
2. Maintenance overview...................................................6-4
3. System lubrication.........................................................6-7
3.1 Explanation of the symbols used in the lubrication
diagram ............................................................................6-7
3.2 Lubrication chart...............................................................6-8
3.3 Lubricant table..................................................................6-9
3.4 Notes for lubrication chart..............................................6-10
4. Maintenance of mechanical components..................6-19
4.1 Maintenance on basic machine .....................................6-19
4.2 Maintenance of compact dust extractor.........................6-23
5. Maintenance of pneumatic components and
filters..............................................................................6-30
5.1 Instrument panel ............................................................6-30
5.2 Maintenance on basic machine .....................................6-36
5.3 Maintenance for Laserpac..............................................6-43
6. Maintenance of optical components..........................6-44
6.1 General guidelines and additional equipment................6-44
6.2 Maintenance of optical components ..............................6-47
7.Maintenance of electrical components......................6-64
Safety information.....................................................6-64
8. Safety cabin maintenance...........................................6-69
9. Maintenance of seam sensor system (optional).......6-70
10. Maintenance of air-conditioning doors......................6-71

0-20 Table of Contents B337EN00.DOC
Chapter 7 Maintenance of laser
1. Maintenance overview...................................................7-3
1.1 Maintenance intervals......................................................7-4
2. Vacuum pump ................................................................7-5
2.1 Auxiliary tools and materials ............................................7-5
2.2 Maintenance work............................................................7-6
3. Compressed air filter unit..............................................7-7
4. Laser control ..................................................................7-7
5. Cooling unit ....................................................................7-8
5.1 Auxiliary tools and materials ............................................7-8
5.2 Maintenance work..........................................................7-11
6. RF generator.................................................................7-18
6.1 Notes on safety..............................................................7-18
6.2 Auxiliary tools and materials ..........................................7-19
6.3 Construction of RF generator.........................................7-19
6.4 Short-circuiting residual voltage.....................................7-20
Tube output stage.....................................................7-21
HV power supply unit................................................7-24
6.5 Maintenance work..........................................................7-26
7. Operating steps during maintenance work...............7-37
7.1 Opening the vacuum system .........................................7-37
7.2 Leak test.........................................................................7-37
7.3 Operating the cooling unit..............................................7-37
7.4 Checking generator values...................................................7-38