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LASERCELL 1005
Trumpf LASERCELL 1005 User Manual
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Operator’
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TRUMPF LASERCELL 1005
2
Table of Contents
Default Chapter
7
Table of Contents
7
Chapter 1 Safety
24
For Your Safety
26
Terminology
27
Authorized Use of the Machine
28
Measures to be Taken by the User/Operator
29
Observe Information and Warning Plates
29
Instructing Personnel
29
Care Needed While Operating the Machine
30
Eliminating Malfunctions During Operation
33
Duty of Care When Handling the Cooling Unit
34
Using the Appropriate Spare Parts and Operating Materials
35
Water Protection
36
Fire Protection
37
Measures Taken by the Manufacturer
39
Securing the Danger Zone of the Machine
39
Suction Unit and Compact Dust Extractor (Filtering Installation)
41
Warnings Contained in this Operator's Manual
42
Symbols
43
Signalling Words
43
Operating Safety
27
Overview of Hazards
44
Laser Classes
46
Laser Processing
46
Operating Modes of the Laser System
46
Dangers Due to Laser Radiation
47
Protection against Radiation
48
Measures to be Taken by the User/Owner
48
Measures Taken by the Manufacturer
50
Hazardous Substances
53
Dust, Aerosols and Gases
53
Cutting Oils
54
Ozone
55
Polyethylene-Coated (PE) Tubes
55
Hazards from Thermal Decomposition of Znse Lenses
56
Lens Characteristics
56
Thermal Decomposition
56
Response to Accidents
57
Disposal of Lenses
58
Hazards Caused by Flash or very Bright Light
58
Danger Due to High Voltage
59
Risks from Electromagnetic Alternating Fields
60
Chapter 2 Installation Conditions TLC 1000 and TLC 1005
66
Installation Site
67
Space Requirements
67
Floor Requirements
67
Weight Loading
68
Ambient Conditions
71
Exhaust Air Conduction for Compact Dust Extractor
72
Outdoor Installation of Cooling Unit
73
Gas Supply
74
Laser Gases
75
Purity
75
Gas Consumption, Supply Lines, Pressure Reducer
75
Laser Gas Supply from Cylinders
76
Central Laser Gas Supply (Fixed Piping)
76
Cutting Gases
77
Purity
77
Gas Consumption
77
Supply Lines to Cutting Gas Supply
80
Cutting Gas Supply with Cylinders or Bundles
81
Cutting Gas Supply from Gas Tank
82
Welding Gases (Inert Gases)
84
Purity
84
Supply Lines
84
Electrical Supply
85
Power Supply
86
Connected Loads, Fuse Protection
87
Teleservice
88
Network Connection
88
Compressed Air Supply
89
Operating Materials
91
Laser Gases and Cutting and Inert Gases
91
Cooling Water
91
Transport
94
On Delivery: Checking the System
97
Unloading Machine and Transporting to the Installation Site
97
Transport of TLC 1005 Basic Machine
98
Base for Machine Body
101
Machine Table
102
Base Plate
102
System Components
103
Installing the System
103
Preparing the Factory Floor
104
Planning Aid
105
Chapter 3 Description
108
Machine Concept
110
The Technical Data
111
Coordinate System, Zero Point, Working Range
114
Coordinate System
114
Zero Point, Working Range
115
The Modules of the Laser Cutting Center
118
The Modules of the Basic Machine
121
Machine Body
123
Motion Unit for X, Y, Z (Extension Arm)
124
Drives
125
Safety Cabin
125
Support Table
126
Base Plate
128
Rotary Axis with Media Connection (Optional)
130
Back Stop (Optional) for Rotary Axis
132
Direct Drive Rotary Axis (Optional)
133
Beam Guideway
135
Processing Optics
139
Central Lubrication
142
Instrument Panel
143
The Laser
145
Targeting Laser
146
Electrical Installation
147
Safety Interface (Optional)
147
Digital User Interface (Optional)
149
Suction Unit and Compact Dust Extractor
149
Suction
149
Compact Dust Extractor
150
Control System/Programming
151
Control System
151
Programming
152
2-D Programming
152
3-D Programming
153
Sensor System
155
TSD Seam Sensor System (Optional)
155
DIAS Distance-Control System
157
Options
158
Measuring Probe (Optional)
158
Welding Wire Feed (Optional)
159
Chapter 4 Operation
161
Part 1: Operating Devices
169
Control Elements Other than on the Operating Panel
169
Control Elements of the Basic Machine
169
Control Elements of the Safety Door (Electrically Driven Sliding Door)
172
Control Elements of the Safety Door
172
(Electrically Driven Sliding Door)
172
Teach Panel
174
Control Elements of the JIC Version
175
Control Elements on the Start Post of the Pallet Changer
177
Z Axis Brake Switch
181
Operating Panel with Color Display
182
Control Elements on the Machine
183
Control Elements of the Control System
190
ASCII Keyboard
194
Part 2: User Interface
196
User Interface Layout
196
Menu Bar
196
Status Bar
197
Message Line
198
Softkey Bar
198
Display Area
198
Machine Submodes
199
AUTOMATIC Submode
199
MDA Submode
200
JOG Submode
200
Control System Activity Fields
200
PRODUCTION Activity
202
PRODUCTION Single Job
202
PRODUCTION - Machine Components
211
PRODUCTION Program Options
212
PRODUCTION - Switch Elements
213
Operation of the Switch Elements
214
Switch Elements for Distance Control System
215
Switch Elements in General
217
Service Switch Elements
219
Welding Switch Elements
220
PRODUCTION Front Safety Door Switch Elements
221
Safety Door Status Display Switch Elements
223
Left Pallet Changer Status Display Switch Elements
224
Front Pallet Changer Status Display Switch Elements
225
Right Pallet Changer Status Display Switch Elements
226
Maintenance Switch Elements
227
Suction Unit Switch Elements
228
Manually Movable Table Indexing Switch Elements
230
Switch Elements for TLF Laser Statuses 1
233
Switch Elements for TLF Laser Statuses 2
234
PRODUCTION Tables
235
Laser Technology
235
Laser Power Cycles
246
Welding Table
248
Tube Section Technology Table
253
PRODUCTION Summary Production Plan
256
PRODUCTION Production Plan for Basic Machine
260
SET-UP Activity
263
SET-UP - Switch Elements
263
Switch Elements of the Distance Control System
264
Switch Elements in General
266
Service Switch Elements
269
Welding Switch Elements
271
Switch Elements for Maintenance
272
Left Pallet Changer Switch Elements (Optional)
273
Front Pallet Changer Switch Elements (Optional)
274
Right Pallet Changer Switch Elements (Optional)
276
Left Pallet Changer Manual Function Switch Elements (Optional)
277
Front Pallet Changer Manual Function Switch Elements (Optional)
278
Right Pallet Changer Manual Function Switch Elements (Optional)
280
Switch Elements for Suction Unit
281
Manually Movable Support Table Indexing Switch Elements (Optional)
282
Front Safety Door Switch Elements for Electrically Driven Sliding Doors
285
Front Safety Door Switch Elements for Electrically Driven Lift Doors
287
TLF Laser Intervention 1 Switch Elements
288
TLF Laser Intervention 2 Switch Elements
289
SET-UP - Jog Mode
291
Set-Up Mda
292
Set-Up - Mda
292
SET-UP - Adjust Laser Beam
294
PROGRAMMING Activity
299
NC Editor
299
NC Program Management
301
File Management
303
Outputting NC Programs from the Management System
305
Selecting NC Programs
307
Tooling Activity
309
Zero Point Offset
309
MAINTENANCE / INITIAL START-UP Activity
311
MAINTENANCE / INITIAL START-UP Data Backup
311
MAINTENANCE / INITIAL START-UP Display
312
MAINTENANCE / INITIAL START-UP Maintenance Logbook
313
DIAGNOSTICS Activity
314
DIAGNOSTICS Error Diagnostics
314
DIAGNOSTICS I/O Diagnostics
315
DIAGNOSTICS Remote Diagnostics
316
DIAGNOSTICS Laser
317
Laser RF Generator
317
Laser Leak Test
318
DIAGNOSTICS Display Home Position
320
Integrated MDC Activity (Optional)
321
MDC Message Texts
321
MDC Creating and Modifying Message Texts
322
MDC Displaying and Editing Machine Data
324
MDC Creating and Modifying Interruptions
326
MDC Evaluating Machine Data
327
MDC Display of the Times in a List
329
MDC Changing the Time
330
Part 3: Operating the Machine
331
Calling up the Online Help
331
Machine Start-Up and Shutdown
334
Switching on the Machine
334
Switching off the Machine
335
Switching off the Machine in the Event of Malfunctions/Emergencies
336
Triggering E-STOP
336
Cancelling E-STOP
336
Eliminating Malfunctions
337
Triggering FEED HOLD
337
Acknowledging FEED HOLD
337
Acknowledging FEED HOLD after a Collision Involving the Nozzle
337
Cancelling E-STOP after Detecting a Collision (Optional for the Cutting Head)
338
Releasing the X, Y, B and C Axis Drive Brakes
339
Releasing the Z Axis Drive Brake
340
Executing a Program
341
Calling up and Starting a Program
341
Stopping a Program During Machining
342
Aborting a Program
342
Operating in Marking Test Mode
343
Editing, Filling and Deleting the Zero Point Memories G54 to G57
344
Editing a Zero Point Memory Manually
345
Filling the Zero Point Memory for All Axes with the Current Axis Position
346
Filling the Zero Point Memory for Individual Axes with the Current Axis Position
348
Deleting the Zero Point Memory for All Axes
351
Deleting the Zero Point Memory for Individual Axes
353
Working with the Summary Production Plan
355
Creating a Summary Production Plan
358
Starting a Summary Production Plan
359
Ending a Summary Production Plan
360
Processing with the Production Plans -Basic Machine
361
Creating a Production Plan
362
Starting Production Plans
363
Ending Production Plans
364
Moving the Axes in Jog Mode
365
Support Table Indexing
365
Indexing Support Tables
365
Undoing Electrical Indexing
366
Undoing Pneumatic Indexing
366
Optional: Driving Pallet Changers
367
Coupling Pallets
368
Separating Pallets
368
Moving Pallets in Manual Mode
369
Moving Pallets in Automatic Mode
369
Moving the Pallet after Actuating the Axis Switch (after a Collision)
370
Electrically Driven Safety Doors
370
Opening the Lift Door
371
Closing the Lift Door
371
Referencing the Safety Door
372
Referencing the Safety Door
373
Closing the Safety Door
373
Releasing the Safety Door after a Collision
374
Calling up a Lubrication Cycle
376
Starting a Lubrication Cycle
377
Starting the Z Axis Lubrication Cycle
378
Operating the Laser
379
Switching on the Laser
379
Switching off the Laser
380
Igniting the Laser Beam
380
Switching off the Laser Beam
381
Opening the Beam Trap
381
Closing the Beam Trap
381
Working in Laser Test Mode
382
Setting Laser Operation Mode
382
Setting the Laser Mode
383
Setting the Laser Power
383
Carrying out a Leakage Test
384
Diagnostic Functions
385
Error Diagnostics
385
Displaying Inputs and Outputs of the Machine and Laser
386
Querying the Software Version
387
Remote Diagnostics Via Pcanywhere 1
387
Managing Master Files
388
Uploading an NC Program from the Disk Drive
388
Uploading an NC Program from the Hard Disk
389
Outputting an NC Program to the Disk Drive
390
Outputting an NC Program on the Hard Disk Drive
391
Outputting a Program Part Onto the Disk Drive
392
Deleting NC Programs from the Program Manager
393
Managing NC Programs
394
Displaying NC Text
394
Editing NC Text
395
Searching for a Block in the NC Text
395
Searching for a Function in the NC Text
395
Searching for and Replacing a Function in the NC Text
396
Inserting an Additional Line
396
Copying and Inserting Text Passages
397
Deleting Text Passages
398
Editing Tables Based on an NC Text
399
Acknowledging Maintenance
400
Operating the Integrated MDR
401
Creating a Message Text
401
Assigning a Message Text
402
Splitting up an Interruption Period
403
Evaluating Machine Data
404
Evaluating the ODC Interface
405
Opening a LOG-File
405
Opening a LOG File in MS Excel
406
Carrying out a Back up of the PCU 50
407
Chapter 5 Setting Work
417
Safety Information
417
Overview of Setting Work
418
Checking and Setting B and C Axes
419
Checking C Axis and Setting Reference Offset Value
420
Checking the B Axis and Setting the Reference Offset Value
422
Selecting Processing Optics
426
Selecting the Cutting Head
427
Selecting the Welding Head
429
Cutting Head Setting Work
432
Dismantling the Cutting Head
433
Mounting the Cutting Head
433
Centering the Beam
434
Determining and Setting the Focus Position
438
Adjusting the Setting on the Cutting Head
442
Determining Focus Position F=0
443
Correcting Focus Position
445
Adjustment Work on the Welding Head
446
Installing the Welding Head
446
Centering the Beam
447
Determining and Setting the Focus Position
450
Utility Program CP_FOCUS_WELD
451
Setting the Welding Head to the Nominal Dimension
453
Focus Search with Machines Without Autolas Plus
454
Focus Search with Machines with Autolas Plus
460
Determining the Joint Offset
478
Determine Link Offset of X and y Axis
480
Determining the Joint Offset for Cutting Head
480
Determining the Joint Offset for the Welding Head
482
Determining Link Offset of Z Axis (Tool Length)
484
Changing the Gas and Air Connections at the Z Center Sleeve
487
Recording the DIAS Characteristic Curve
488
Checking and Setting the Crossjet
489
Setting the Flow Rate of the Welding Gas
490
Switching over the Welding Gas
491
Measuring Probe (Optional)
492
Installing the Measuring Probe
492
Selecting Measuring Probe
493
Calibrating the Measuring Probe
496
Welding Wire Feed (Optional)
499
Inserting Welding Wire
499
Setting the Rotary Axis (Optional)
503
Shifting the Rotational Axis Horizontally in X Direction
503
Adjusting the Rotational Axis in Z Direction
504
Swivelling the Rotational Axis by 90
505
Setting the Back Stop (Optional)
506
Shifting the Rotational Axis Horizontally in X Direction
506
Further Service Programs
507
Program Overview
507
Replacing Ltt's in Utility Programs
507
Performing Parting Cuts
509
Cutting Support Slats
510
Cutting Sacrificial Plates
512
Chapter 6 Machine Maintenance
519
General Guidelines
519
Maintenance Overview
520
System Lubrication
523
Explanation of the Symbols Used in the Lubrication Diagram
523
Lubrication Chart
524
Lubricant Table
525
Notes for Lubrication Chart
526
Maintenance of Mechanical Components
535
Maintenance on Basic Machine
535
Maintenance of Compact Dust Extractor
539
Maintenance of Pneumatic Components and Filters
546
Instrument Panel
546
Maintenance on Basic Machine
552
Maintenance for Laserpac
559
Maintenance of Optical Components
560
General Guidelines and Additional Equipment
560
Maintenance of Optical Components
563
Maintenance of Electrical Components
580
Safety Information
580
Safety Cabin Maintenance
585
Maintenance of Seam Sensor System (Optional)
586
Maintenance of Air-Conditioning Doors
587
Chapter 7 Maintenance of Laser
592
Maintenance Overview
592
Maintenance of Laser
592
Maintenance Intervals
593
Vacuum Pump
594
Auxiliary Tools and Materials
594
Maintenance Work
595
Compressed Air Filter Unit
596
Laser Control
596
Cooling Unit
597
Auxiliary Tools and Materials
597
Maintenance Work
600
RF Generator
607
Notes on Safety
607
Auxiliary Tools and Materials
608
Construction of RF Generator
608
Short-Circuiting Residual Voltage
609
Tube Output Stage
610
HV Power Supply Unit
613
Maintenance Work
615
Operating Steps During Maintenance Work
626
Opening the Vacuum System
626
Leak Test
626
Operating the Cooling Unit
626
Checking Generator Values
627
Additional Equipment for Aligning
630
Chapter 8 Aligning the MSL Multi-Beam Safety Light
630
System Example
631
Aligning the Light Beam
632
Setting Mirror
634
Cross-Hairs to Cut out
635
Chapter 9 Noise Levels - Test Certificate TLC 1005
639
Mess Test Certificate
639
Measurement Results
640
Diagram: Work Piece
641
Diagram: Location of Measuring Points
642
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Trumpf LASERCELL 1005 Specifications
General
Brand
Trumpf
Model
LASERCELL 1005
Category
Industrial Electrical
Language
English
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