Name: Trumpf TRUPUNCH 5000
Brand: Trumpf
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4-108 Operation B380EN04.doc

10.4 DIAGNOSTICS Display original

position

Whether the active system components are at home position or not

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symbol appears next to the respective system component if it is at

home position.

Table of Contents6
For Your Safety23
Terminology24
Operational Safety25
Intended Use of the System25
Measures to be Taken by the User/Operator27
Danger Signs and Warnings27
Symbols27
Signaling Words28
Information on the Source and Type and How to Avoid the Danger28
Instructing Personnel29
Duty of Care When Handling the System29
Eliminating Malfunctions During Operation32
Using Designated Spare Parts and Operating Materials32
Water Protection33
Measures Taken by the Manufacturer34
Securing of the Danger Zone of the System34
Laser Safety36
Danger Due to Magnetic Fields37
Overview of Residual Risks38
Trupunch 5000 Installation Conditions43
Responsibilities45
Planning Aid46
Installation Site48
Space Requirements48
Floor Requirements48
Load Indications50
Ambient Conditions53
Air Purity53
Electrical Supply54
Power Supply54
Isolating Transformer55
Connected Loads/Fuse Protection57
Remote Diagnostics57
Network Connection58
Compressed Air Supply59
Operating Materials62
Operating Materials for the Hydraulic System62
Cooling Water for the Cooling Unit63
Materials63
Pallets for Sheetmaster (Optional)65
Older Tool Cartridges65
New Multitools and Tapping Tools67
Transport68
Measures to be Taken by the Customer69
Machine Delivery69
Unloading the Machine from the Truck70
Transporting the Machine to the Installation Site73
Installing the Machine74
The Machine Concept78
Technical Data81
The most Important Assemblies82
Machine Frame83
Punching Head84
Coordinate Guide with Linear Magazine85
Drives86
Part Removal87
Tools88
The Tool System88
Components of a Tool Set90
Punch90
Punch Selection92
Alignment Ring94
Die94
Stripper96
Stripper Selection97
Continuation of Table 2102
Stripper Selection Examples104
Tool Innovations107
Roller Tools107
Roller Deburring Tool and Deburring Multitool109
TRUMPF Multitools110
Tapping Tools115
Clean Cutting with TRUMPF Multishear117
Press Brake Bending with the TRUMPF Multibend118
Quick Beading119
Engraving119
Adaptive Stroke Calibration120
Maximum Output Tables122
Calculation Formulae122
Influencing Factors123
Punch125
Dies125
Stroke Rate Tables130
Influencing Factors130
Standard Tool131
Whisper Tool133
Standard Tool with Active Presser Foot134
Long Standard Tool with Active Presser Foot135
Multitool136
Forming Tool137
Standard Tool138
Whisper Tool140
Standard Tool with Active Presser Foot141
Long Standard Tool with Active Presser Foot142
Multitool143
Forming Tool144
Technical Information: Automation145
Automation Made to Measure145
Overview of Automation146
Simple Automation147
Sheetmaster148
Loading Table (Trupunch 5000 Only)152
Gripmaster153
Shearmaster (Not Trupunch 3000)155
Flexible Manufacturing Cell157
Toolmaster (Only Trupunch 3000 and Trumatic 6000)158
Cart Systems with Travel Rails161
Cart System with Toothed Belt Drive163
Characteristic Features164
Sortmaster Box165
Sortmaster Pallet166
Flexible Manufacturing Cell with TRUMPF Compact Store168
Flexible Sheet Machining System170
Control System and Administration for Connection to Storage171
Control System Technology172
Programming174
Directly at the Machine174
In the Office175
Defining Machining: What Is Done Automatically176
The most Important Options177
10.1 Active die178
10.2 die Spray Lubrication179
Brush Tables with Loading and Unloading Aid180
10.4 Height-Adjustable Clamps181
Operation183
Part 1: Control Elements189
Control Elements: Overview189
Control Panel with Color Display191
Operating Elements of the Machine192
Operating Elements of the Control System196
Keyboard200
USB Connection201
Part 2: User Interface202
Structure of the User Interface202
Menu Bar203
Status Line203
Message Bar204
Softkey Bar204
Display Area204
Machine Submodes205
AUTOMATIC Submode205
MDA Submode206
JOG Submode206
Control Areas207
Diagnostics208
PRODUCTION Operation209
PRODUCTION Single Job209
Layout of Graphics209
PRODUCTION Production Plan212
NC Program Management in the NCU214
PRODUCING Machine Components215
PRODUCTION Program Options216
PRODUCTION Switch Elements217
Operating the Switch Elements217
General Switch Elements218
Z Axis Calibration (Optional)220
Switch Elements H+L Diagnostics221
Sortmaster Box Switch Elements (Optional)222
Gripmaster Switch Elements (Optional)222
Sheetmaster Axis Switch Elements (Optional)222
Sheetmaster General Switch Elements (Optional)223
PRODUCTION: Tables224
Loading Sheets225
Sheet Unloading228
Sheet Technology236
Workpiece Removal237
Repositioning242
Tool Technology - Tapping (Optional)243
Tool Technology - Engraving (Optional)244
Tool Technology - Tapping (Optional)245
Tool Technology - Punching/General246
Tool Technology - Quick Beading (Optional)249
Tool Technology - Multishear (Optional)249
Tool Technology - Roller Tool (Optional)251
Tool Technology - Engraving (Optional)253
SETUP Operation254
SET-UP Switch Elements254
General Switch Elements254
Punching Switch Elements255
Switch Elements H+L Diagnostics255
Switch Elements H+L Diagnostics256
Sortmaster Box Switch Elements (Optional)256
Gripmaster Switch Elements (Optional)257
Support Table Switch Elements (Optional)257
Sheetmaster Switch Elements (Optional)258
Stripper Unit Switch Elements (Optional)259
Toolmaster Switch Element (Optional)259
Loading Table Switch Elements (Optional)260
SET up Jog Mode261
Mda Set-Up262
PROGRAMMING Operation263
NC Editor263
PROGRAMMING NC Program Management263
PROGRAMMING File Management265
Sending NC Programs from the Program Manager268
TOOLING Operation269
TOOLING Tool Table (Autom.)269
TOOLING Tool Table (Manual)269
Setting up Rails269
Setting up the Toolmaster (Optional)269
Set up Rail/Tool (Optional)271
Selecting NC Programs272
TOOLING Rail Allocation273
TOOLING Tool Allocation273
TOOLING Tools275
Required Tools275
Tool Change List275
General Tool Data276
Tool Master Data/Status Data277
Explanation of the Tool Data279
MAINTENANCE/START-UP Operation284
Maintenance/Start-Up Data Backup284
Changing the Configuration for a Partial Backup286
Starting a Partial Backup Manually286
DIAGNOSTICS Operation288
10.1 DIAGNOSTICS Fault Diagnostics288
10.2 DIAGNOSTICS I/O Diagnostics289
10.3 DIAGNOSTICS Remote Diagnostics289
DIAGNOSTICS Display Original Position290
Integrated MDR Operation (Optional)291
11.1 MDR Message Text291
MDR Creating and Modifying Message Texts292
MDR Displaying and Editing Machine Data294
MDR Creating and Changing Interruptions296
11.5 MDR Evaluating Machine Data297
11.6 MDR Displaying the Times in List Form298
11.7 MDR Changing the Time298
Part 3: Operating the Machine299
Switching the Machine on and off300
Switching on the Machine300
Switching off the Machine in the Event of Malfunctions or Emergencies301
Switching off the Machine301
Executing a Program302
Executing a Program Automatically302
Executing a Program with the Softpunch (Optional)303
Triggering a Single Stroke304
Changing the Forming Depth305
Program Stop During Execution306
Stopping Programs306
Reentry into a Program307
Working with the Production Plan309
Creating a Production Plan309
Executing a Production Plan310
Restarting the Execution of the Production Plan after a Program Interruption311
Moving the Axes Manually312
Releasing the Drive Brakes313
Releasing the X and y Axis Drive Brakes313
Manual Execution of the Lubrication Cycle314
Diagnostic Functions315
Fault Diagnostics315
Displaying Machine Inputs and Outputs316
Remote Diagnosis Via Pcanywhere317
Querying the Software Version318
Managing Master Files318
Uploading NC Programs from the USB Interface318
Uploading NC Programs from the Hard Disk319
Output of NC Programs Via USB Ainterface320
NC Program Output on the Hard Disk Drive321
Program Part Output Via USB Interface322
Deleting NC Programs from the Program Manager323
NC Program Management324
Displaying NC Text324
Editing NC Text325
Searching for a Block in the NC Text325
Searching for a Function in the NC Text326
Searching for and Replacing a Function in the NC Text326
Inserting an Additional Line328
Copying and Inserting Text Passages329
Deleting Text Passages330
Editing Tables Based on NC Text330
Tooling332
Creating an Automatic Tool Table and Loading the Tool Rail332
11.2 Manually Loading/Unloading Tools333
Loading a Tool from the Rail Onto the Toolmaster (Optional)334
11.3 Correcting Clamp Positions335
11.4 Removing an Active Tool336
11.5 Unloading All Tools336
Operating the Integrated MDR336
12.1 Creating a Message Text337
12.2 Assigning a Message Text337
12.3 Splitting up an Interruption Period338
12.4 Evaluating Machine Data339
Adjusting the Pressure Foot Pressure340
If Problems Arise341
Removing Stripper from Stripper Adapter341
Removing the Punch from the Punching Head343
14.3 Removing the die from the die Holder346
14.4 Replacing the Stripper Segment347
Using Shearmaster (Optional)348
Starting and Stopping Shearmaster Manually348
15.2 Change Scrap Container349
15.3 Use Shearmaster in Stacking Mode349
15.4 Technical Notes350
15.5 Correcting Malfunctions350
Release Tilted Scrap Skeleton350
Release Tilted Scrap from the Chute351
Using Height-Adjustable Clamps352
16.1 Moving Height-Adjustable Clamps352
16.2 Utilizing Height-Adjustable Clamps353
16.3 Help if Problem Arises353
General Guidelines358
Maintenance Overview359
Lubrication362
Overview362
Maintenance Instructions365
Longitudinal and Transverse Guides365
Transverse Carrier and Table Support Bearings367
Central Lubrication368
Hydraulics369
Zero Stop Sensor (Only Trupunch 5000 with Automation)374
Punch Spray Lubrication375
Die Spray Lubrication (Optional)378
Tapping Lubrication Unit (Optional)380
Die Clamping Piston Clamp384
Rail Transverse Carrier and Table Support385
Punch Holder386
Active die (Optional)386
Hydraulic System388
Overview388
Depressurizing the Accumulator System389
Maintenance Instructions391
Hydraulic Accumulator391
Hydraulics Hose Lines395
Hydraulic Unit397
Pneumatic System400
Overview400
Maintenance Instructions401
Air Cushions (Optional)401
Punch Spray Lubrication402
Mechanical Elements404
Overview404
Maintenance Instructions405
Punching Tool Adapter405
Chip Vacuum System: Side Channel Blower406
Chip Vacuum System: Vacuum Pipe408
Chip Vacuum System: Chip Flap409
Chip Vacuum System, Complete411
Tool Cartridge Support Slat413
Clamps414
Racks and Guide Rails415
Index Pin(S)415
Brush Field Segment Tables, Parts Flap and Brush Tables (Optional)416
Brush Field Segment Tables418
Compressed Air Maintenance Unit421
Control Panel422
Electrics423
Overview423
Maintenance Instructions424
Switch Cabinet: Connectors and Clamping Screw Connections424
Switch Cabinet: External Air Circuit424
Switch Cabinet: NCU Battery425
Buffer Battery Box PC427
Safety Light Barrier and Light Barrier Parts Flap (Optional)430
Inductive Proximity Switch431
Sensor System - Stripper Sensor432
Cooling Unit436
Maintenance Instructions436
Procedure after a Collision441
Handling the Setting Device442
Assigning the Punch and Alignment Ring442
10.2 Determining the Tool Length444
Regrinding Tools445
11.1 Compensating the Regrind Amount446
General Guidelines455
Maintenance Overview456
Sheetmaster and Gripmaster Maintenance Overview456
Sheetmaster and Gripmaster Maintenance456
Sortmaster Box Maintenance Overview457
Overview457
Maintenance Overview for Double Cart with Toothed Belt Drive459
Shearmaster Maintenance Overview459
Lubrication461
Lubrication Chart for Sheetmaster with Gripmaster461
Lubricant462
Maintenance Instructions463
Axis Guide Strip at the Sheetmaster463
Pick-Up Columns of the Carrier Cups at the Sheetmaster464
Stripper Unit (Optional) Guide Rod on the Sheetmaster465
Safety Device of the Suction Frame at the Sheetmaster466
Guide Rods of the Sheet Thickness Gauge at the Sheetmaster467
Central Lubrication on the Sheetmaster468
Axis Feedgear at the Sheetmaster469
Z Axis Feedgear at the Sheetmaster469
Y Axis Feedgear at the Sheetmaster (Optional)469
Guide Rails at the Gripmaster470
Stop Pins on the Movable Gripmaster470
Grippers on the Gripmaster471
Lubrication Chart for Toolmaster (40/70)472
Maintenance Instructions474
Lifting Device Bearing474
Indexing475
Shifting Unit (Toolmaster (70))476
Rotary Table477
Central Lubrication477
Drive Motor Gearbox478
Lubrication Chart for Sortmaster Box479
Lubricant480
Maintenance Instructions480
Rolling Elements of the Four-Point Bearing480
Inner Toothing of Slewing Ring482
3.10 Lubrication Chart for Sortmaster Pallet483
3.11 Lubricant484
3.12 Maintenance Instructions484
Cam484
Flange Bearing Unit485
Roller Chains and Chain Wheels485
Flat Gearbox485
Screw Joints486
Weld Joints486
Lubrication Chart for Double Unloading Cart487
3.14 Lubricant488
3.15 Maintenance Instructions488
Track Rollers488
Ball Bearings489
Flange Bearing Unit489
Roller Chains and Chain Wheels490
Flat Gearbox490
Screw Joints491
Weld Joints491
Lubrication Chart for Double Cart with Toothed Belt Drive493
3.17 Lubricant494
Running Surfaces494
Ball Bearings495
Flange Bearing Unit496
Roller Chains and Chain Wheels496
Flat Gearbox497
Screw Joints497
Weld Joints498
3.18 Lubrication Chart for Shearmaster499
3.19 Lubricant499
3.20 Maintenance Instructions500
Pneumatic Components507
Pneumatic Components on the Sheetmaster and Scissor Table507
Overview507
Maintenance Instructions508
Pressure Regulator508
Vacuum Hoses in the Suction Frame510
Filters in the Suction Cup Vacuum Connections511
Pneumatic Bellows Cylinder at the Scissor Table512
Pneumatic Hoses at the Scissor Table512
Mechanical Components513
Mechanical Components at the Sheetmaster and Gripmaster513
Overview513
Maintenance Instructions514
Dowelling of Sheetmaster, Gripmaster and Support Table with Movable Gripmaster514
Vacuum Cups on the Sheetmaster515
Axis, Z Axis, and y Axis (Optional) Cable Tow Chains at the Sheetmaster518
Mechanical Components on the Shearmaster519
Scrap Container519
Conveyor Belt520
Electrical Components521
Maintenance of the Electrical Components at the Sheetmaster and Scissor Table521
Maintenance Instructions521
Switch Cabinet of the Sheetmaster: TASC521
Control System Battery521
Light Barriers at the Scissor Table522
Test Certificate523
Measurement Result525
Reference Workpiece526
Position of the Measuring Points527

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Trumpf TRUPUNCH 5000 Specifications

General

Brand	Trumpf
Model	TRUPUNCH 5000
Category	Industrial Equipment
Language	English

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