Manual TruDisk (4C)

Operator's manual
TruDisk 2001, TruDisk 2002,

TruDisk 4002, TruDisk 4006
Operator's manual

Original operator's manual

Edition 2012-10
Order Information Please specify when ordering this document:
Operator's manual
TruDisk 2001, TruDisk 2002, TruDisk 2004, TruDisk 2501,
TruDisk 2602, TruDisk 3001, TruDisk 3302, TruDisk 3306,
Edition 2012-10
Document number 20-10-02-A3-CR02
TRUMPF Laser GmbH

Address for orders Vertrieb
Aichhalder Straße 39
78713 Schramberg
Fon: +49 7422 515 - 0
Fax: +49 7422 515 - 436
Internet: http://www.trumpf-laser.com
E-Mail: [email protected]
TRUMPF Laser GmbH

Address for service Technischer Kundendienst
Aichhalder Straße 39
78713 Schramberg, Germany
Fon: +49 7422 515 - 550 CW lasers
Fon: +49 7422 515 - 560 Pulsed lasers
Fon: +49 7422 515 - 540 Short-pulse laser
Fon: +49 7422 515 - 570 Marking lasers
Fon: +49 7422 515 - 585 Laser machines
Fon: +49 7422 515 - 580 Spare parts
Fax: +49 7422 515 - 148
Internet: http://www.trumpf-laser.com
For "partly completed machinery" in accordance with the EC

Machinery Directive, this document corresponds to the
assembly instructions.
© TRUMPF Laser GmbH

Before you proceed ...
What do the operating These operating instructions contain important information on

instructions contain? your laser device, its functions, operation and maintenance. This
information will allow you to operate the laser device safely,
avoid any risks, reduce service costs and break-down times and
increase its reliability and life.
Other regulations In addition to the operating instructions, also observe the

regional regulations regarding accident prevention, especially
laser safety, and environmental protection.
Who are the operating The laser device operator’s manual must be read and observed
instructions for? by any person who is commissioned with work on the laser
device, for example with:
■ Operation
■ Maintenance
■ Transport.
Safety In chapter 1, you will find general safety instructions for the
laser device.
Installation, transport Chapter 2 contains information required for preparing the instal-
lation site of the laser device and safely transporting the laser
device.
Description The components of the laser device and their functions are
described in chapter 3.
Operation The operating instructions are found in chapter 4. It describes

the basic operating steps. Further information on the operation
by means of software can be found in the TruControl 1000 oper-
ating program manual, which forms part of the documentation for
your laser device.
Maintenance Chapter 5 informs you on maintenance work that you, as the

user, can carry out yourself. In case of further repair and mainte-
nance work, our Service Department will assist you.
Interruptions of operation Chapter 6 describes finally how to proceed in case of interrup-

tions of operation caused by technical reasons. This information
is supplemented by messages which are displayed if required on
the user interface.
20-10-02-A3-CR02 2012-10 Before you proceed ... I

II Before you proceed ... 2012-10 20-10-02-A3-CR02
Table of contents
Chapter 1 Safety
1 General notes 1‐3

1.1 Safety of the laser device 1‐3
1.2 Safety instructions for certain operating 1‐4
stages
Normal operation 1‐4
Upkeep 1‐4
1.3 Selection and qualification of staff 1‐4
1.4 Organizational measures 1‐4
1.5 Documents 1‐5
Standards and regulations 1‐5
Enclosed documents 1‐6
2 Information on special risks 1‐7

2.1 Laser light 1‐7
Protective measures against laser light 1‐8
Safety circuit 1‐10
2.2 Hazardous materials 1‐10
Dust, aerosols and gases 1‐11
Cutting oils 1‐12
2.3 Electrical energy 1‐13
3 Warning instructions 1‐15
4 Designated use of the laser device 1‐16
5 Laser beam exit ports 1‐17
6 Location and function of the safety devi- 1‐19

ces
6.1 EMERGENCY STOP pushbutton 1‐19
6.2 Safety circuits 1‐20
6.3 Laser warning lamp 1‐22
6.4 Key-operated switch 1‐22
6.5 Conduct in case of emergency 1‐23
20-10-02-A3-CR02 2012-10 Table of contents 0‐1

7 Labels and warning signs 1‐24
7.1 Required signs 1‐24
7.2 Labels on the laser device 1‐27
7.3 Labels in the area of the focusing optics 1‐29
Chapter 2 Installation conditions, transport
1 Scope of delivery 2‐4

1.1 Components of the laser device 2‐4
1.2 Further accessories 2‐5
1.3 Documents 2‐5
2 Dimensions 2‐7
2.1 Laser device 2‐7
Type 4 C/4 2‐7
Type 4 C/6 2‐9
2.2 Free spaces for service work 2‐10
2.3 Operating panel 2‐11
2.4 Laser light cable 2‐11
2.5 Focusing optics 2‐12
3 Weight, floor at the installation site 2‐14
4 Connections 2‐15
4.1 External connections 2‐15
4.2 Electrical interfaces 2‐15
5 Electrical connected loads 2‐19

5.1 Electrical connection 2‐21
5.2 Electromagnetic compatibility 2‐21
5.3 Insulation resistance 2‐21
6 Cooling unit 2‐23

6.1 External cooling circuit TruDisk 2001, Tru- 2‐23
Disk 2002, TruDisk 2004
Cooling water requirement for the tube 2‐24
dimensioning
0‐2 Table of contents 2012-10 20-10-02-A3-CR02

Disk 2602
dimensioning
dimensioning
Disk 4006
dimensioning
6.5 Cooling water connections 2‐35
6.6 Data for chillers 2‐36
6.7 Laser cooling circuit 2‐37
7 Ambient conditions 2‐38
8 Emissions 2‐40
9 Position of the user 2‐41

9.1 Position for switching on and off 2‐41
9.2 Position for operating the laser device 2‐41
9.3 Position for setting the focusing optics 2‐42
9.4 Position for maintenance work 2‐43
10 First measures to be taken after receipt of 2‐44

the laser device
10.1 Delivery of the laser device 2‐44
10.2 Commissioning 2‐44
Adjusting the level difference 2‐44
Removing the shipping brace of the com- 2‐45
pressor
11 Transport 2‐47
11.1 Transport by means of pallet jack 2‐47
11.2 Transport by fork lift truck 2‐49
11.3 Transport by means of a crane 2‐51
11.4 Moving the laser device on casters 2‐53
11.5 Packing the laser device 2‐55

Chapter 3 Description
1 Overview 3‐3
2 Laser 3‐4
2.1 Design 3‐4
2.2 Specifications 3‐4
3 Optical arrangement 3‐7

3.1 Components of the optical arrangement 3‐9
Central shutter (VZ) 3‐9
Shutter (V1, V2, ...) 3‐10
Shutter switch left 3‐11
Shutter switch (VW1, VW2, ...) with pilot 3‐12
laser
Physical splitter with fixed splitting 3‐15
ratio
Deflection (U1, U2, ...) 3‐15
LEM deflection 3‐16
Power and energy measuring sensor 3‐16
(LEM)
3.2 Selecting light path 3‐17
3.3 Wedge beam switch (option) 3‐18
3.4 Incoupling optics 3‐20
Incoupling optics LLK-D 3‐21
Incoupling optics LLK-B 3‐21

4 Laser light cable 3‐22
5 Focusing optics 3‐25
6 Control 3‐27
7 Mains distribution 3‐29
8 Laser cooler 3‐31
9 Cabinet cooler 3‐33
10 Air cleaner 3‐34
11 Diode current supply 3‐36
12 Operating panel 3‐37
13 Panel computer (Option) 3‐38
14 Control panel (Option) 3‐39
15 Telepresence 3‐40
15.1 Direct connection over an analog modem 3‐40
15.2 Connection via VPN 3‐41
15.3 Connection via SSH 3‐41
Chapter 4 Operation
1 Operating elements and indicators 4‐3

1.1 Case 4‐3
2 Switching the laser device on and off 4‐7

2.1 Switching on by means of the operating 4‐7
panel

2.2 Switching on by means of the panel com- 4‐7
puter and the operating panel (option)
2.3 Switching off in case of malfunction and 4‐8
emergencies
2.4 Switching on after E-Stop 4‐9
2.5 Switching off after work completion by means 4‐9
of the operating panel
of the panel computer and the control panel
(option)
3 Operating the laser device using TruCon- 4‐11

trol 1000
Select the light path in the parameter set 4‐11
Change the light path name 4‐13
3.2 Activating and deactivating the laser 4‐14
Switching the laser on and off 4‐14
Open or close the central shutter (VZ) in 4‐15
the parameter set
3.3 Responding to messages 4‐15
Resetting the message 4‐16
3.4 Generating pulse shapes 4‐17
3.5 Creating laser programs 4‐18
3.6 Programming light paths 4‐19
3.7 Pilot laser (option) 4‐19
Switching the switching functions of pilot 4‐20
laser on and off
Setting the pilot laser mode 4‐20
Switching the pilot laser in the light path 4‐22
on and off
4 External control of the laser device 4‐25

4.1 TRUMPF LaserNetwork (option) 4‐25

Chapter 5 Maintaining the laser device
2 Material 5‐5
2.1 Wearing parts 5‐5
2.2 Cooling water additives 5‐5
2.3 Tools and auxiliaries 5‐5
Blow-out device 5‐7
Compressed air quality class 2 according 5‐7
to DIN ISO 8573-1
2.4 Consumables 5‐8
2.5 Disposal 5‐8
3 Opening and closing the laser device 5‐9

3.1 Opening and closing doors 5‐9
3.2 Remove covers 5‐9
3.3 Open and close hood 5‐10
3.4 Open the hood to the user's compartment 5‐11
4 Hose connections 5‐12

4.1 Connecting the hose 5‐12
4.2 Disconnecting the hose 5‐12
5 Removing the securing device from the 5‐13

stop valve
6 Maintenance list 5‐14
7 Laser 5‐16
7.1 Identifying the pump module 5‐16
7.2 Replacing the pump module 5‐18

8.1 Dismounting and Mounting of Laser Light 5‐26
Cable
Removing LLK-D 5‐27
Mounting the LLK-D 5‐35

Removing an LLK-B 5‐51
8.2 Maintaining laser light cable 5‐57
Cleaning the protective sleeve along with 5‐57
the cover slide on the LLK-D
Replacing the protection bushing with pro- 5‐58
tective glass at the LLK-D
Clean protective sleeve along with cover 5‐60
slide on LLK-B
Replacing the protective sleeve along with 5‐61
the cover slide on the LLK-B

9.1 Replacing the diode power supply 5‐63

10.1 Topping up cooling water 5‐69
10.2 Cleaning the cooling circuit 5‐70
Cleaning procedure and change of cool- 5‐72
ing water
10.3 Replacing filter element in the fine filter 5‐84
10.4 Cleaning the contamination filter 5‐86
10.5 Checking the cooling unit for tightness 5‐89
10.6 Emptying and filling the cooling unit 5‐90
Emptying the cooling unit of the laser 5‐90
device
Filling the cooling unit 5‐99

11.1 Completely replacing the air cleaner 5‐107
11.2 Replace the filter cartridge for water separa- 5‐108
tor and microfilter
11.3 Filter cartridge in the intake filter 5‐109
11.4 Replacing filter cartridge in the activated car- 5‐111
bon filter
11.5 Changing the filter mat 5‐113
12 Electrical system 5‐114

12.1 Identifying blown electrical fuses 5‐114
12.2 Replacing a microfuse 5‐116
12.3 Switch on Circuit breaker 5‐117

13.1 Clean the screen of the operating panel 5‐118

Chapter 6 Conduct in case of service
interruptions
1 Service interruptions 6‐2

1.1 Measures in case of service interruptions 6‐2
2 Identifying causes 6‐3
3 Monitoring and faults 6‐4

3.1 Monitoring 6‐4
3.2 Fault 6‐5
4 Dealing with messages 6‐7

4.1 Structure of a message 6‐7
4.2 Message history 6‐9
Display the message history 6‐9
Setting the message filter 6‐9
Searching message 6‐10
Type of message 6‐11

Chapter 1
Safety

1.1 Safety of the laser device 1‐3
1.2 Safety instructions for certain operating 1‐4
stages
Normal operation 1‐4
Upkeep 1‐4
1.3 Selection and qualification of staff 1‐4
1.4 Organizational measures 1‐4
1.5 Documents 1‐5
Standards and regulations 1‐5
Enclosed documents 1‐6
2 Information on special risks 1‐7

2.1 Laser light 1‐7
Protective measures against laser light 1‐8
Safety circuit 1‐10
2.2 Hazardous materials 1‐10
Dust, aerosols and gases 1‐11
20-10-02-A3-CR02 2012-10 Safety 1‐1

Cutting oils 1‐12
2.3 Electrical energy 1‐13
3 Warning instructions 1‐15
4 Designated use of the laser device 1‐16
5 Laser beam exit ports 1‐17
6 Location and function of the safety devi- 1‐19

ces
6.1 EMERGENCY STOP pushbutton 1‐19
6.2 Safety circuits 1‐20
6.3 Laser warning lamp 1‐22
6.4 Key-operated switch 1‐22
6.5 Conduct in case of emergency 1‐23
7 Labels and warning signs 1‐24

7.1 Required signs 1‐24
7.2 Labels on the laser device 1‐27
7.3 Labels in the area of the focusing optics 1‐29
1‐2 Safety 2012-10 20-10-02-A3-CR02

1. General notes
This chapter contains important information about devices and

measures which serve your safety. Carefully read this informa-
tion before you start working with the laser device. Carefully
observe the instructions stated in this chapter. They are for your
own safety.
In the following sections, you will find information on the follow-

ing subjects:
■ Safety of the laser device
■ Safety instructions for certain operating stages
■ Organizational measures
■ Selection and qualification of staff
■ Standards and regulations
■ Information on special risks
■ Warning instructions in this manual
■ Designated use
■ Safety devices
■ Conduct in case of emergency
■ Labels and warning signs
Warning hints to special activities which you carry out in the
laser device are to be found in chapters 2, 4, 5 and 6. They pre-
cede each action step from which a danger may arise.
1.1 Safety of the laser device
The laser device has been built in accordance with state-of-the-

art standards and the recognized safety rules.Nevertheless its
use may constitute danger to life and limb of the user or third
parties. It can also cause impairment of the laser device and
other property.
The laser device may only be used if:

■ it is in technically perfect condition.
■ in accordance with its designated use (see "Designated use
of the laser device", pg. 1‐16).
■ if the user is aware of the safety regulations and risks
involved.
■ if the instructions set out in these operating instructions are
observed.
Any faults, especially those affecting the safety of the unit,
should be rectified immediately!
20-10-02-A3-CR02 2012-10 General notes 1‐3

1.2 Safety instructions for certain
operating stages
Normal operation
Operate the laser device only when all protective and safety rel-
evant devices, e.g. removable safety devices, E-Stop equipment,
exhausters, are in place and fully operative.
Immediately switch off the laser device in case of malfunctions
and secure it against unintentional restart. Have any defects rec-
tified immediately.
Upkeep
Observe the configuration, maintenance and inspection intervals

and their deadlines stated in the operating instructions. Observe
information regarding the replacement of parts.
Service work may be carried out by trained personnel only.
Check the correct functioning of laser safety devices regularly.
1.3 Selection and qualification of staff
User’s obligation The user must only entrust trained and instructed staff with oper-
ation, setup, maintenance and upkeep of the laser device . Set
out clearly the individual responsibilities of the persons for opera-
tion, setup, maintenance and upkeep.
Skilled electrician Any work on the electrical equipment of the laser device must be
carried out only by a skilled electrician or by instructed persons
under the supervision and guidance of a skilled electrician and in
accordance with electrical engineering rules and regulations.
1.4 Organizational measures
These operating instructions must always be at hand at the

place where the laser device is used.
Accident prevention, In addition to the operating instructions, observe all other gener-
environmental protection ally applicable legal and other mandatory regulations relevant to
accident prevention and environment protection and instruct all
persons commissioned with this work correspondingly. Some
1‐4 Safety instructions for certain operating stages 2012-10 20-10-02-A3-CR02

important standards and regulations are listed in this chapter
(see "Standards and regulations").
Reading the operating Before starting the work, the personnel entrusted with work on
instructions the laser device must have read the operator’s manual and
chapter 1 "Safety" in particular. This applies especially to per-
sons working only occasionally on the laser device, e.g. during
maintenance.
Safety goggles As far as required or stipulated by instructions, use laser safety

goggles.
Labels Observe all safety instructions and warning indications attached

to the laser device. Ensure that these are complete and in a
legible state.
Modifications Never make any modifications, additions or conversions on the

laser device which may affect safety without approval of
TRUMPF. TRUMPF cannot be held liable for any damage result-
ing from such modifications. The risk lies entirely with the user.
Spare parts Spare parts must comply with the technical requirements speci-
fied by TRUMPF. This is always guaranteed with original spare
parts.
Software installation Do not install a software which is not explicitly approved for
installation by TRUMPF. TRUMPF cannot be held liable for dam-
age resulting from the installation or operation of software not
approved by TRUMPF.
1.5 Documents
Standards and regulations
Some important standards and regulations which you have to

observe when operating a laser unit are listed below. This list is,
however, purely informative. TRUMPF does not assume any
responsibility for the completeness of this list.
International standards Standard Name

IEC 60825 Radiation safety of laser products
EN 207 Filter and safety goggles against laser radiation
(laser safety goggles)
EN 13849 -1 Safety-related parts of control systems
EN 60204 Electrical equipment of machines
EN 60825 Safety of laser products
Tab. 1-1
20-10-02-A3-CR02 2012-10 Documents 1‐5

Enclosed documents
The following documents concerning "safety" are attached to this

manual:
■ Interface descriptions.
■ Supplementary laser warning signs.
1‐6 Documents 2012-10 20-10-02-A3-CR02

2. Information on special risks
This sections deals with the special risks involved in using the
laser device:
■ Risks involved by laser light
■ Hazard generated by gas and particle emission
■ Risks involved by electrical energy
You will learn how to protect yourself against these risks.
2.1 Laser light
YAG lasers generate an intensive radiation in the invisible, near

infrared spectral range. This light may be hazardous to eyes and
skin.
Important protective measures regarding the handling of laser
light are indicated in the accident prevention regulations applica-
ble for your region. In Germany the accident prevention regula-
tions "Laser radiation" (BGV B 2) is applicable. These accident
prevention regulations refer to the standard EN 60825 "Safety of
laser products", available as international harmonized standard
IEC 60825.
Laser classes An important aspect of the regulations is the classification of

laser equipment into certain laser classes, dependent on the
hazards generated by the emitted laser radiation.
The definition of the laser classes is described briefly below. The
precise definition listing limit values can be found in EN 60825.
Class 1 Class 1 means that the laser device does not show any danger
regarding laser light in normal operation. If observing laser light
through optical instruments is dangerous, then the laser is classi-
fied as class 1M.
TRUMPF achieves class 1 for laser devices by assembling suita-
ble protective cases and protective covers. The laser is classi-
fied as class 4 during maintenance and service work with open
protective casing and with bridged safety switch.
Class 2 Class 2 means that the laser emits light in the visible wave-
length region (400 – 700 nm). The radiation is not harmful to the
human eye, even when observing it through optical instruments.
Avoid looking directly into the beam. If observing laser light
through optical instruments is dangerous, then the laser is classi-
fied as class 2M.
Class 3R Class 3R means that the laser emits radiation in the wavelength
range from 302.5 nm to 106 nm. A direct look into the beam may
20-10-02-A3-CR02 2012-10 Information on special risks 1‐7

be dangerous. The risk is, however, less than with Class 3B
lasers.
Class 3B Class 3B means that the direct or mirrored beam is dangerous.

The observation of diffuse reflections is usually not dangerous.
Class 4 Class 4 means that the radiation is dangerous to eyes and skin.
Appropriate precautions must be taken, especially a sufficient
eye protection by means of special laser safety goggles, when
operating Class 4 laser devices.
Laser devices, laser machines and accessories are assigned to
the laser classes as follows:
Device, component Laser class

Laser device with closed hood 1
Laser device with open hood 4
Laser light cable 1
Focusing optics under a closedprotective cover 1
Focusing optics withoutprotective cover 4
Laser machines with protective cover 1
Laser machines without protective cover 4
Pilot laser at the exit port (switch, deflection) 3R
Pilot laser at the exit of the focusing optics 2
Tab. 1-2
Protective measures against laser light
Eyes and skin may be exposed to laser radiation, if the

WARNING laser light is not placed under a protective cover!
Laser light can burn the skin. Direct or scattered laser light
can permanently damage the eyes.
Ø Take the necessary protective measures as specified below,
depending on the laser class.
Comply with laws and regulations

Proceed in accordance with the laws and regulations applicable in your
region, when operating laser devices.
Tab. 1-3
1‐8 Laser light 2012-10 20-10-02-A3-CR02

Classes 4 and 3B Labeling the workstation
As the operator, you are responsible for the labeling of the workstation.
The following picture illustrates as an example the labeling of a class 4
laser device.
Tab. 1-4
Laser safety officers Summon the laser safety officer

Furthermore you have to appoint in writing experts as laser safety offi-
cers when operating classes 3B and 4 laser devices. Upkeep also forms
part of operation.
Tab. 1-5
Operator’s obligations Wear adjustment goggles

The laser safety goggles protect against diffuse scattered light only.
Thus, never look into the direct beam or reflected beam even when wear-
ing laser safety goggles!
Tab. 1-6
Keep body parts away from the beam guideway in the area of the
laser exit opening
High-power laser light can cause serious burns on the skin or clothing.
Tab. 1-7
Secure the laser area against the entry of unprotected people

Secure the processing point against the entry of unprotected people by
introducing appropriate safety measures, e.g. card readers or barrier sys-
tems.
Tab. 1-8
Registering the laser unit

As operator you are obliged to report the operation of laser devices of
classes 3B and 4 to the authorities responsible for working safety.
If you have any questions about this, please contact TRUMPF or a local
agency of TRUMPF GmbH + Co. KG.
Tab. 1-9
Class 3R Wear adjustment goggles

When working at laser installation, wear adjustment goggles protecting
yourself against the wave length of the laser light in use.
Tab. 1-10
20-10-02-A3-CR02 2012-10 Laser light 1‐9

Secure the area against the access of unprotected persons
Prevent the access of unprotected persons to the processing spot by
appropriate safety measures, e.g. by card readers or barrier systems.
Tab. 1-11
Class 2 Do not look into the laser beam on purpose

The incidence of laser light on the unprotected eye may damage the ret-
ina irreparably.
Tab. 1-12
Class 1
According to definition, class 1 laser units are harmless. Persons are not
required to take protective measures.
Tab. 1-13
Safety circuit
If you have integrated the laser device into a unit with laser
shielding cover, ensure that the laser shielding cover is included
in the safety circuit of the laser device. The safety circuit
ensures that laser light can only be emitted from the focusing
lens if the laser protective cover is closed.
The corresponding information is to be found in section "Safety
circuits" of this chapter and in the interface description of the
ASV.
If you operate the laser device without laser protective cover, the
workstation is assigned to the laser class 4. In that case, please
take the necessary protective measures in the danger area of
the laser device.
2.2 Hazardous materials
Especially when handling hazardous materials, we expressly

point out that we can only give examples of danger sources. As
the operator of the unit, you have to estimate the possible dan-
ger potential of the materials to be processed and to check and
introduce necessary measures.
For precautionary reasons and independently of the necessary
extraction and filtering devices of the exhaust air duct, it is rec-
ommended to make provisions for a sufficient supply of fresh air
in the working area. In this connection we refer to the standards
and directives applicable for your region. In Germany, the "Tech-
nical regulations for hazardous substances" (TRGS) is applicable.
1‐10 Hazardous materials 2012-10 20-10-02-A3-CR02

Emission of particles when the extraction system is not
WARNING operational!
Harmful gases and particles can enter the respiratory tract
if the laser device is operated without an operational
extraction system.
Ø Do not inhale gas or particles.
Ø Only work with a properly working extraction system.
Ø Position the exhaust funnel as near to the processing point
as possible.
Ø Avoid bent or squeezed exhaust hoses.
Dust, aerosols and gases
The following substances are released when processing metallic

materials with the laser:
■ Dust (particle size over 1 µm).
■ Aerosols (particle size below 1 µm). An aerosol is a gas
(particularly air) that contains solid or liquid substances in
dispersed form. During laser welding, weld smoke is devel-
oped, which mainly consists of iron and iron oxide.
■ Gases.
Note
If the designated use allows the processing of non-metallic mate-
rials such as semiconductor and synthetic (dielectric) materials,
the gases generated during machining of the these materials
must be observed.
Emission The emission during the machining of metallic materials depends

on the (processing) speed and the cutting gas pressure, if appli-
cable. The emission is minimal in case of optimum parameters.
In addition to the cutting parameters, the type of material has a
strong influence on the emission.
When processing mild steel, the emission is remarkably lower
than with Cr-Ni materials or galvanized steel sheets. When pro-
cessing metals using a laser, aerosols and dusts 97 % of which
having a diameter < 5.7 μm are produced.
Note
Depending on the utilization of the laser device, carcinogenic
substances can be emitted, depending on the materials pro-
cessed. If there is such a risk, the operator has to carry out his
own measurements and to take protective measures for the per-
sonnel, if required.
20-10-02-A3-CR02 2012-10 Hazardous materials 1‐11

Cutting oils
When treating metallic materials with cutting oils, hydrocarbons

and aldehydes may be released during laser cutting. When using
the cutting oils recommended by TRUMPF, the following thresh-
old limit values at place of work (TLV) were for example meas-
ured:
Galvanized steel Aluminum alloy TLV

sheet (mg/m3) (mg/m3)
(mg/m3)
Acetaldehyde 0,007 0,005 90
Acetone 0,111 0,204 2400
Butanol 0,334 0,022 300
Butyl acetate 0,081 0,007 950
Decane 0,060 0,004 no limit value
Ethyl acetate 0,237 0,002 1400
Ethylbenzene 0,034 0,004 440
Formaldehyde 0,021 0,013 0,6
All hydrocarbons 2,600 1,875 no limit value
Toluene 0,057 0,12 380
Xylene 0,113 0,013 440
Cutting oils Tab. 1-14
In these cases, the values fall distinctly short of the maximum

allowable concentrations (MAC values) (examples of the use of
other cutting oils are not directly applicable).
Cutting oils for aluminum processing – such as the oil of the
company Wisura recommended by TRUMPF – contain amine
components so that nitrosamines could theoretically be formed
during laser processing.
However, investigations to that effect showed a negative result in
all tests: Nitrosamines could not be detected.
When using the cutting oils on a chlorine-free basis, recommen-
ded by TRUMPF, the generation of polychlorinated biphenylene
(PCB) and dioxins can be excluded.
Polyethylene-coated sheets When sheets coated with polyethylene films are cut by laser,
mainly aliphatic and olefinic 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
■ further n-alkane, 1-alkene, diene pairs
■ Toluene
■ Ethylbenzene
1‐12 Hazardous materials 2012-10 20-10-02-A3-CR02

■ L-limonene
■ N-butylbenzenesulfonamide
During measurements in the extracted air flow by means of a
total hydrocarbon analyzer (FID), methane concentrations
between 2 and 10 ppm were found.
Therefore, it is not to be expected that limits are exceeded by
organic exhaust air components when polyethylene-coated
sheets are processed by laser. Bad smell may be caused by
individual very low concentrations (ppb range) of odor-intensive
exhaust air components.
2.3 Electrical energy
While carrying out upkeep work, you can come into contact
DANGER with dangerous live parts!
Touching live electric parts can be extremely dangerous.
Ø Any work on the electric equipment must be carried out only
by a trained electrician.
Ø Switch off the laser device prior to any upkeep work.
Ø Secure the laser device against restart.
Ø Before touching electric parts, first check if they are de-ener-
gized.
Faults Switch the laser device off immediately if troubles occur in the
electrical system, turn the main switch to position OFF.
Stationary device According to the safety regulations for protection from electrical
energy, this laser device is considered a fixed device. The
regionally enacted safety standards and accident prevention reg-
ulations apply accordingly.
For you, as user of the laser device, this means:

■ The laser device may not be moved while switched on.
Regular check The electrical safety of the device must be checked regularly, at
least every 4 years. The basis for the check is the German
standard DIN VDE 0702. Outside the scope of this standard, the
regulations relevant in the respective region are applicable.
20-10-02-A3-CR02 2012-10 Electrical energy 1‐13

The check must be carried out by a skilled electrician. It con-
tains among other things the following actions:
■ visual check, e.g. state of the ground wire and its connection
point.
■ checking the ground wire resistance.
■ measurement of the insulation resistance is technically not
possible.
− Due to EMC measures the values are below the value
demanded in the standard DIN VDE 0702
(see chapter "Installation conditions, transport", section
"Electrical connected loads").
− A measurement of the ground wire current (however no
subsistuted measurement of leakage current) must be
carried out alternatively instead of the measurement of
the insulation resistance.
Fuses Use only original fuses with the specified characteristics and cur-
rent rating.
Voltage when main switch is Some components are still under dangerous voltage, even if the
off main switch is in position OFF. Therefore check first that the
parts that you will touch are dead.
Energy storages The discharge time of energy storages (capacitors) may be more
than 1 minute. Check the parts which are live during operation
for the presence of voltage, also after having switched off the
machine. Start the work on live parts only after you have
checked that their power supply has been cut off.
1‐14 Electrical energy 2012-10 20-10-02-A3-CR02

3. Warning instructions
A warning instruction is information that:

■ Names the type and source of a danger.
■ Indicates possible consequences in case the danger is not
avoided.
■ Gives instructions for how to avoid any damage.
One of the signal words "Danger", "Warning", "Caution", or
"Attention" indicates the severity of the possible consequences in
case the instructions are not observed.
"Danger" warns against a great danger. If not avoided, it leads
to death or serious injuries.
"Warning" warns against a danger that may cause medium or
serious injuries with permanent damage.
"Caution" warns against a danger that may cause light or
medium injuries without permanent damage.
"Attention" warns against possible material damage.
Example of a warning instruction:

Ø Take the necessary protective measures as specified below,
depending on the laser class.
It is absolutely necessary to observe and follow the warning

instructions!
20-10-02-A3-CR02 2012-10 Warning instructions 1‐15

4. Designated use of the laser device
The laser device is intended exclusively for processing solid met-

als or metal alloys.
Operating the device within the limits of its designated use

requires you to:
■ observe the instructions set out in this operating manual.
■ wire and connect electric lines to the laser device in compli-
ance with the regulations regarding electromagnetic compati-
bility (EMC).
■ not to move the laser device when it is switched on.
■ carry out necessary inspections and maintenance work.
Exceptions The laser device is not intended for processing metal or metal
alloys in connection with inflammable or explosive materials
(example: containers filled with inflammable gases or fuel;
ammunition).
The laser device must not be operated in an explosion-prone
environment.
The manufacturer cannot be held liable for any damage resulting
from such use. The risk lies entirely with the user.
1‐16 Designated use of the laser device 2012-10 20-10-02-A3-CR02

5. Laser beam exit ports
Fig. 1-1
The figure shows a laser device with focusing optics. The arrow
marks the place where the laser light is emitted.
Focusing optics are assembled by modules, your application
requires. The appearance may differ from the optics shown in
the picture. More than one laser light cable and focusing optics
can be connected to a laser device. In any case, the laser light
is emitted from the lenses of the focusing optics.
Laser light cannot be emitted from other places of the laser
device if all protective covers are closed.
Under special conditions, the workpiece may reflect scattered
radiation up to a wave length of up to 1100 nm.
Conditions (examples):
■ Laser light cable with a minimum length of approx. 75 m and
a fiber core diameter ≤ 100 µm.
■ Laser power higher than 3 kW.
Scattered radiation with a wave length of up to 1100 nm

WARNING reflected by the workpiece!
Risk of eye injuries!
Ø The laser safety goggles or the safety glass for observation
windows must be selected with regard to the wave length of
the scattered radiation of the laser.
Wavelengths Laser Wavelength Spectral range

Yb: YAG 1030 nm near infrared
possible scattered up to 1100 nm near infrared
laser radiation
20-10-02-A3-CR02 2012-10 Laser beam exit ports 1‐17

Wavelengths Laser Wavelength Spectral range
pilot laser 630 - 680 nm visible, red
Tab. 1-15
If you operate the focusing optics with detached protective cover

(class 4), you must take the required protective measures:
■ The focusing optics must be operated in a closed cabin.
■ The door contact switches are included in the safety circuit.
■ Warning instructions.
■ Laser warning lamps.
■ Training
■ Laser safety goggles: All persons in the danger area have to
wear safety goggles. The laser safety goggles must be
equipped with filtering glasses suitable for the wave length of
the laser light.
1‐18 Laser beam exit ports 2012-10 20-10-02-A3-CR02

6. Location and function of the safety
devices
Safety devices at the laser device are:

■ EMERGENCY STOP pushbutton.
■ Optical shutters, shutter switches and the corresponding
safety circuits
■ Laser warning lamps.
■ Key-operated switch.
6.1 EMERGENCY STOP pushbutton
E-Stop pushbuttons are located:

■ on the operating panel.
■ on the control panel (option).
■ on the front of the laser device.
EMERGENCY STOP pushbutton (arrows) Fig. 1-2
Operating the "E-Stop" pushbutton immediately stops all compo-

nents of the laser device which can be dangerous. In particular,
no laser light may be emitted any longer after having operated
the E-Stop pushbutton.
Note
The operating panel should be attached in a place, where it can
easily be reached from the operator's position. This guarantees
that the EMERGENCY STOP pushbutton can be pressed imme-
diately in case of an emergency situation.
Further pushbuttons Further E-Stop pushbuttons can be additionally connected to the

laser device. Integration of the E-Stop circuit of the laser device
20-10-02-A3-CR02 2012-10 Location and function of the safety devices 1‐19

in an E-Stop circuit of the system is also possible. For further
information, see the interface description for E-Stop.
Checking the function Check the function of the EMERGENCY STOP push buttons if
you have modified the EMERGENCY STOP circuit of the laser
device. TRUMPF cannot be held liable for any damage resulting
from the incorrect wiring of the EMERGENCY STOP circuit.
Operating panel without Do not connect an operating panel with pushbutton E-STOP
pushbutton E-STOP to the laser device if the laser device was previously oper-
ated by means of an operating panel without E-STOP push-
button. In this case, the E-STOP pushbutton has no func-
tion.
6.2 Safety circuits
The control of the laser device contains interfaces for safety cir-
cuits (SIK).
What is a safety circuit? A safety circuit is an electric circuit used for monitoring the pro-
tective covers and safety doors. Under the protective cover moni-
tored by the safety circuit, laser light can only be emitted from
the focusing lens if the laser protective cover is closed.
Purpose Safety circuits allow entire systems to be operated as class 1

laser devices.
ASV board Each safety circuit is connected to an ASV board, which is loca-
ted in the control of the laser device. The ASV board controls
the optical shutter, which prevents the emission of laser light
when the safety circuit is open.
ASV: Operating and safety shutter (German for: Arbeits- und
Sicherheits-Verschluss.)
Function The following picture shows the basic function of a safety circuit.
1‐20 Safety circuits 2012-10 20-10-02-A3-CR02

WS-00101
1 Laser control unit 3 Door contact closed 4 Door contact open
2 Shutter
Safety circuit, principle Fig. 1-3
Work function In the picture above the safety circuit is closed. The laser
operates according to the running laser program or is controlled
manually by the operator.
Safety function In the figure below, the safety circuit is open because the door
of the protective cabin was opened. The shutter is changed to
CLOSED position via the ASV board in the control unit. No laser
light is emitted at the processing point anymore.
20-10-02-A3-CR02 2012-10 Safety circuits 1‐21

6.3 Laser warning lamp
Fig. 1-4
Laser warning lamp The laser warning lamp is lit when:

■ laser light is emitted at the processing point.
■ the laser is ready for emitting laser light, even if no laser
light is emitted at the processing point yet ("laser on" status).
External laser warning lamp A further laser warning lamp can be connected to the laser
device and attached, e.g. near the workstation.
Further information can be found in the interface description for
E-STOP and ASV.
6.4 Key-operated switch
Fig. 1-5
1‐22 Laser warning lamp 2012-10 20-10-02-A3-CR02

Key-operated switch
0 0
I
WS-00016
A B
Fig. 1-6
Activation of the laser by an unauthorized person can be preven-

ted by means of the key-operated switch. To do so, turn the key
to the position 0 (chart A) and be withdrawn.
The key has to be inserted for operation. The key-operated
switch has to be turned to the right.
6.5 Conduct in case of emergency
2 3
1 Pushbutton EMERGENCY 3 EMERGENCY STOP push-

STOP on the operating panel button on the front of the
2 Main switch laser device
Fig. 1-7
1. Immediately press one E-Stop push-button (1 or 3).

2. If you are not sure that all dangers have been averted: Turn
main switch to the OFF position (2).
If the laser device is integrated in a system there may be more
devices for switching off. Please refer to the documents included
in the delivery of the system.
20-10-02-A3-CR02 2012-10 Key-operated switch 1‐23

7. Labels and warning signs
Labels concerning safety and identification, attached to the laser

device and in the area of the focusing optics, are described in
this section. Each label indicates the place where it is located.
7.1 Required signs
Warning against dangerous electric voltage Fig. 1-8
Warning against hot surface Fig. 1-9
Hochspannung ! Lebensgefahr !
High voltage ! Danger to Live !
Haute tension ! Danger de mort !
1‐24 Labels and warning signs 2012-10 20-10-02-A3-CR02

D
Warning against high leakage current in the protective Fig. 1-11

grounding conductor
Note: "In case of frost risk drain cooling water", instruction: Fig. 1-12
See operator’s manual
Reference to laser product class Fig. 1-13
Warning against dangerous laser radiation Fig. 1-14
20-10-02-A3-CR02 2012-10 Required signs 1‐25

H
Type plate of the laser device (example) Fig. 1-15
K
7000 W
12000 W
Po 5 mW
Notes regarding power and wavelength of the laser Fig. 1-18
Rating plate of the laser device (example) Fig. 1-19
1‐26 Required signs 2012-10 20-10-02-A3-CR02

M
Notes regarding power and wavelength of the pilot laser Fig. 1-20
Warning against touching the surfaces of the pump module Fig. 1-21
Notes regarding power and wavelength of the pilot laser Fig. 1-23
7.2 Labels on the laser device
The following pictures show the location of the labels on the

laser devices. The letters show the assignment of the section
"Required labels".
20-10-02-A3-CR02 2012-10 Labels on the laser device 1‐27

Fig. 1-24
1‐28 Labels on the laser device 2012-10 20-10-02-A3-CR02

Fig. 1-25
7.3 Labels in the area of the focusing

optics
Upon delivery, the label "Avoid Exposure" is enclosed in tripli-

cate.
The labels are adhesive lables with removable protective film.
The labels will not be attached yet, as the arrangement of the
station where the focusing optics are to be fitted to, is normally
not known at the time of delivery.
Obligation to identify As user of the laser device you are obliged to attach labels near
the focusing optics, so that they can be seen by the persons
staying within this area.
20-10-02-A3-CR02 2012-10 Labels in the area of the focusing optics 1‐29

1‐30 Labels in the area of the focusing optics 2012-10 20-10-02-A3-CR02
Chapter 2
Installation conditions,
transport
1 Scope of delivery 2‐4

1.1 Components of the laser device 2‐4
1.2 Further accessories 2‐5
1.3 Documents 2‐5
2 Dimensions 2‐7
2.1 Laser device 2‐7
Type 4 C/4 2‐7
Type 4 C/6 2‐9
2.2 Free spaces for service work 2‐10
2.4 Laser light cable 2‐11
2.5 Focusing optics 2‐12
20-10-02-A3-CR02 2012-10 Installation conditions, transport 2‐1

3 Weight, floor at the installation site 2‐14
4 Connections 2‐15
4.1 External connections 2‐15
4.2 Electrical interfaces 2‐15
5 Electrical connected loads 2‐19

5.1 Electrical connection 2‐21
5.2 Electromagnetic compatibility 2‐21
5.3 Insulation resistance 2‐21
6 Cooling unit 2‐23

dimensioning
Disk 2602
dimensioning
dimensioning
Disk 4006
dimensioning
6.5 Cooling water connections 2‐35
6.6 Data for chillers 2‐36
6.7 Laser cooling circuit 2‐37
7 Ambient conditions 2‐38
8 Emissions 2‐40
9 Position of the user 2‐41

9.1 Position for switching on and off 2‐41
9.2 Position for operating the laser device 2‐41
9.3 Position for setting the focusing optics 2‐42
9.4 Position for maintenance work 2‐43
2‐2 Installation conditions, transport 2012-10 20-10-02-A3-CR02

10 First measures to be taken after receipt of 2‐44
the laser device
10.1 Delivery of the laser device 2‐44
10.2 Commissioning 2‐44
Adjusting the level difference 2‐44
Removing the shipping brace of the com- 2‐45
pressor
11 Transport 2‐47
11.1 Transport by means of pallet jack 2‐47
11.2 Transport by fork lift truck 2‐49
11.3 Transport by means of a crane 2‐51
11.4 Moving the laser device on casters 2‐53
11.5 Packing the laser device 2‐55
20-10-02-A3-CR02 2012-10 Installation conditions, transport 2‐3

1. Scope of delivery
Laser devices from TRUMPF are configured, equipped with

accessories and delivered according to the user’s requirements.
Therefore, each delivery is specifically assembled.
The following pages give information on

■ the basic scope of delivery.
■ important optional components.
■ documents which are included in the delivery.
The total scope of delivery is listed on the delivery note. This
note contains additional information which can be important for
the identification of components, e.g. material numbers.
The components are described in the chapter "Description".
1.1 Components of the laser device
1 Operating panel 2 Laser device

Fig. 2-1
Operating panel The scope of delivery includes an operating panel. If desired, a

panel computer may be delivered. Information regarding the
Panel Computer can be found in the chapter "Description".
It allows installing the TruControl 1000 operating software on any
PC. The PC must meet the requirements specified by TRUMPF.
Furthermore, a control panel is necessary. The operating panel
is not included in the delivery. Further information can be
obtained from TRUMPF upon request.
2‐4 Scope of delivery 2012-10 20-10-02-A3-CR02

1.2 Further accessories
1 Laser light cable 2 Focusing optics

Fig. 2-2
Laser light cable Number and length of the laser light cables depend on the appli-
cation of the laser device.
Focusing optics Number and arrangement of the focusing optics depend on the
processing task the laser device has to carry out.
Also included in the delivery are:

■ documentation for laser device and accessories (see "Docu-
ments", pg. 2‐5).
■ further components for special purposes according to your
requirements (e.g. series transformer).
Pay attention to delivery Detailed specification to the supplied articles including material
note! numbers and number of pieces are to be found on the delivery
note.
1.3 Documents
The following documents are included in the delivery:

■ Operator's manual.
■ Software manual.
■ Interface descriptions.
■ Dimensional drawing, e.g. focusing optics.
■ Manufacturer’s declaration or declaration of conformity.
■ Acceptance certificate.
■ Circuit documents for the TRUMPF Service Department.
20-10-02-A3-CR02 2012-10 Further accessories 2‐5

■ Labels and warning signs which have to be attached to the
workstation.
■ Optional: Documentation of externally-bought components
for example:
− operating instructions for a CCD camera which is oper-
ated on a focusing optics.
− documentation of the chiller.
2‐6 Documents 2012-10 20-10-02-A3-CR02

2. Dimensions
All dimensions in millimeters [mm].
2.1 Laser device
Type 4 C/4
2000
1550
DW-81005
1600 950 70
Front view and left side view Fig. 2-3
20-10-02-A3-CR02 2012-10 Dimensions 2‐7

Top view Fig. 2-4
Top view, position and size of the adjustable legs Fig. 2-5
2‐8 Laser device 2012-10 20-10-02-A3-CR02

Type 4 C/6
2400
1550
DW-81067
1600 240 950 70
Front view and left side view Fig. 2-6
Top view Fig. 2-7
20-10-02-A3-CR02 2012-10 Laser device 2‐9

Top view, position and size of the adjustable legs Fig. 2-8
2.2 Free spaces for service work

470
1000
10
Y 00
1000
X
3600
DW-81001
Design 4 C/4: X = 2950 / Y = 1000 Design 4 C/6: X = 3250 / Y = 1300

Fig. 2-9
2‐10 Free spaces for service work 2012-10 20-10-02-A3-CR02

The laser device must be accessible from all sides for service
work. Furthermore space for tools and measuring instruments is
required in most cases.
The indicated spaces show the minimum spaces that must be
free around the laser device.
2.3 Operating panel
155
WS-75001
270 292
Fig. 2-10
2.4 Laser light cable
DW-82003
Fig. 2-11
Length The length of the laser light cable depends on the distance
between laser device and focusing optics.
The documents for the laser device contain specifications on the
dimensions of the laser light cable.
20-10-02-A3-CR02 2012-10 Operating panel 2‐11

Bending radius The bending radius of the laser cable must not be smaller
than 200 mm.
Installation Corresponding ways and surfaces must be prepared for the

installation of the laser light cable.
Laser light cables must be laid without traction, kinks and tor-
sion.
2.5 Focusing optics
Focusing optics are made up of modules as required by the pro-

cessing task.
Dimensions The dimensions are determined by the components used for pro-
ducing your focusing optics.
Free space Space has to be kept free around the focusing optics, especially
for:
■ unhindered emission of laser light.
■ adjustment work.
■ maintenance and service work.
Documents Information on dimensions, fastening and space to be kept free

can be found in the following documentation:
■ operating manual of your focusing optics.
■ dimensional drawing of your focusing optics.
■ installation directive.
These documents have been delivered together with your laser
device or with the separately delivered focusing optics.
Dimensional drawing and The dimensional drawing contains:

installation directive ■ all dimensions in millimeters [mm].
■ letters as a reference to the installation directive.
How to use the dimensional drawing and the installation instruc-
tions is illustrated on the next page.
2‐12 Focusing optics 2012-10 20-10-02-A3-CR02

371,5 134,5
Kamerama ße
37 54,5 ±3 abh ä ngig vom Typ
10
k p
360 °
drehbar
8 Schr a ube 7,5
f M5 (4x)
h b a
Seriennu mm er CFO
7 9 1 min Biegeradius R200 Identnum m er CFO
6
Brennweiten-
e 2
kennzeichnung
Objektiv
C 11
r
3
130 ±0,01 2,3,4
Ansic h t C Kü hlwasser
r Zulauf
4x90 °
12
drehbar
Zuluft 22
Crossjet 13
14
4x90 °
5 drehbar
Loch - 19
6
<1 15 8x45 °
drehbar
X 0,2
Schutzgas / Sp ü lgas
37 37
Kü hlwasser
Y 0,2
Z
Rü cklauf 77 ±0,20
39 52 ±0,20 d 1 1237676 22-43-29-00 Steckeraufnah m e CFO 8 0778143 22-27-04-00 Beobachtung drehbar
2 1285521 22-47-05-00 Kollim ation CFO 200 AQ mit Defok. 9 0778149 22-27-06-00 Adapter fuer Ka mera
3 0781581 22-24-78-00 Kuehlring 3 10 Ka m era
4 1235049 22-43-20-00 Abdeckung CFO 90 ° 11 Objektiv 200
5 1233290 22-43-17-00 Versorgungsschnittstelle 12 1231656 22-43-06-00 Kassetten m odul CFO 50
6 0766534 22-24-03-00 Wuerfel 90 ° fuer Beobachtung 13 Schutzglas
7 0778800 22-24-57-00 Flansch mit Schutzfilter 14 1225300 22-43-04-00 Crossjet 200 CM TL
15 1231600 22-43-28-00 Schutzgaszufuhr 200
Brennweite Schutzver m erk nach CFO

f=200 DIN 34 beachten! (mit LLK dargestellt)
A bbildungs- Gewicht ohne LLK TRUMPF Laser Blatt 1
verh ä ltnis
a bis z siehe Einbaur ichtlinie XX-XX-XX-DH 1:1 ca. 5 ,5 kg Gm bH + Co. KG
D - 78713
von 1 Bl.
Index Da tum bearb. gepr. freigg. Schra m berg
Dimensional drawing of a focusing optics (example) Fig. 2-12
In addition to the dimensions, you will also find letters on the

drawing. The arrow points to the letter e.
Under "e" you will find in the installation directive the dimen-
sional drawing for the holes "Würfel 90°".
Dimensional drawing for "Würfel 90°" in the installation direc- Fig. 2-13
tive
20-10-02-A3-CR02 2012-10 Focusing optics 2‐13

3. Weight, floor at the installation site
Weight Weight laser device Type 4 C/4: 8,2 kN (820 kg)

Type 4 C/6: 8,8 kN (880 kg)
distributed on 4 adjustable legs Ø 80 mm
Charge per adjustable 4 C/4: 2,05 kN (205 kg)
leg:
4 C/6: 2,2 kN (220 kg)
Tab. 2-1
Height difference at the floor Place the laser device as horizontally as possible! Height differ-
ences at the installation site can be compensated with adjusta-
ble legs.
Vibrating charge Maxiumum vibration acceleration in vertical and horizontal direc-

tion: 0,01 g ≙ 100 mm/s²
If there is a higher vibrating charge at the installation site, vibra-
tion dampers must be used. For the dimensioning of the vibra-
tion dampers, a vibration measurement is required at the installa-
tion site.
2‐14 Weight, floor at the installation site 2012-10 20-10-02-A3-CR02

4. Connections
4.1 External connections
1 2 3 4 6
1 Cooling water return 3 Cooling water drain hose (sup- 5 Cable entry of mains cable
2 Cooling water drain hose ply) 6 Operating panel cable
(return) 4 Cooling water supply
External connections Fig. 2-14
Cooling water connections The cooling water hoses are mounted on a hose gland fastend
by means of a knurled nut at the laser device.
Further information for the connection and the hose and thread
measurements: (see "Cooling water connections", pg. 2‐35)
Electrical connection The mains cable is firmly connected to the laser device.
Further information for the electrical connection: (see "Electrical
connected loads", pg. 2‐19)
4.2 Electrical interfaces
This chapter describes the electrical interfaces that can be used

to connect the laser device to other equipment. Further informa-
tion can be found in the interface description.
20-10-02-A3-CR02 2012-10 Connections 2‐15

1 Peripheral bus interface 6 Interface for external laser warn- 11 E-Stop interface
2 USB ports ing lamp 12 Modem interface
3 Parallel and realtime interface 7 Focusing optics interface 13 Space for fieldbus interfaces
4 Analog output 8 Safety circuit interface 14 Interface for operating panel
5 Analog input 9 CPX/control panel interface 15 Ethernet interfaces
10 Switch-on interface
Control and part of the mains distribution Fig. 2-15
Parallel interface or fieldbus The laser device can be controlled by an external control unit
interface (e.g. PLC) via parallel or fieldbus interfaces.
The external control unit can be connected to the parallel or real-
time interface. For further information about this topic see the
operating instructions and the interface description for the laser
device.
2‐16 Electrical interfaces 2012-10 20-10-02-A3-CR02

You can control the laser device as well via one of the following
fieldbuses:
■ Profibus-DP
■ DeviceNet
In this case, the board of the chosen fieldbus system is installed
in one of the free spaces for the fieldbus modules. Information
about pin assignment and data format is to be found in the inter-
face description of the chosen fieldbus system.
Analog input The optional interface "Analog input" enables the definition of the
laser power, pulse duration and frequency as analog quantity
externally by voltage or current.
Safety circuit interface The safety circuit interface of the laser device allows:
■ external safety devices to be integrated into the safety circuit
of the laser device
■ status signals to be displayed externally.
A shutter switch releases the respective light path when the
safety circuit of the shutter switch is closed.
Further information is to be found in the interface description of
the ASV.
Interface for the control The control panel for switching the control on and off can be
panel connected optionally to interface X3.
Start-up interface The contacts which are necessary to activate the function ”Con-
trol ON", ”Control OFF" from an external device (for example a
PLC) are provided on the interface X2. In addition to that, the
interface has contacts for connecting an external laser warning
lamp and an external monitoring lamp.
E-Stop interface Via the E-Stop interface you can:

■ connect further E-Stop push-buttons to the laser device.
or
■ integrate the laser device into a higher-ranking E-Stop circuit.
The higher-ranking E-Stop circuit can belong to a plant of which
the laser device is a part.
Note
Lay the cables to the external E-Stop devices in such a way that
they are not exposed to any danger, e.g. by crushing or being
run over.
Peripheral bus interface The TRUMPF Peripheral Bus is a fieldbus system based on real-
time Ethernet. The TRUMPF Peripheral Bus components are
designed for mounting on DIN mounting rails (35 mm) according
to EN 50022.
20-10-02-A3-CR02 2012-10 Electrical interfaces 2‐17

For connection of the TRUMPF Peripheral Bus stations commer-
cial Ethernet cables can be used.
More information can be found in the interface description
"TRUMPF Peripheral Bus interfaces".
Analog output The front plate of the DLC board is provided with 2 analog out-
puts. For each output, the user can select via software which
signal is to be scanned at a connector for measuring purposes.
Measuring instruments (such as an oscillograph) can be connec-
ted directly to the output signals.
More information can be found in the interface description "Ana-
log output of the DLC board".
2‐18 Electrical interfaces 2012-10 20-10-02-A3-CR02

5. Electrical connected loads
Mains 380 V (-10 %) ... 460 V (+10 %)

50 Hz (-3 Hz) ... 60 Hz (+3 Hz)
A clockwise rotating field is required at the
mains connection.
Further data according to EN 60204-1, TN
net according to IEC 60364-1
cos φ (DPF) at nominal 0.96
power
λ at nominal power (total 0.96
power factor)
Insulation resistance 200 kΩ
Back-up fuse TruDisk 2001, TruDisk 2002, Tru-
Mains dimensioning! Disk 2004: 25 A
TruDisk 2501, TruDisk 2602: 35 A
TruDisk 3001, TruDisk 3302, Tru-
Disk 3306: 40 A
TruDisk 4002, TruDisk 4006: 50 A
Operating class gl/gG fuse
Tab. 2-2

TruDisk 2004
Operating condition Power [kW] Power [kVA] Current at 400 V [A] Use
Electric power at nomi- 11 12 17 Consumption data
nal laser power at the
workpiece
Maximum power con- 12,5 13 19 Case of service
sumption
Tab. 2-3
TruDisk 2501
Electric power at nomi- 15 16,5 23,5 Consumption data
workpiece
Maximum power con- 17 18,5 27 Case of service
sumption
Tab. 2-4
20-10-02-A3-CR02 2012-10 Electrical connected loads 2‐19

TruDisk 2602
Electric power at nomi- 14 15 21,5 Consumption data
workpiece
Maximum power con- 15,5 16,5 23,5 Case of service
sumption
Tab. 2-5
TruDisk 3001
Electric power at nomi- 17,5 19 27,5 Consumption data
workpiece
Maximum power con- 19,5 21 30,5 Case of service
sumption
Tab. 2-6
Electric power at nomi- 16,5 18 26 Consumption data
workpiece
Maximum power con- 19 20,5 29 Case of service
sumption
Tab. 2-7
Electric power at nomi- 19,5 21,5 30,5 Consumption data
workpiece
Maximum power con- 22,5 24,5 34 Case of service
sumption
Tab. 2-8
Residual current device If required use an all current suitable fault current circuit breaker
(RCD type B).
Electric check Check the laser device regularly, at least each 4 years, regard-
ing its electric safety.
Further information on this subject is contained in chapter
"Safety" of the operator’s manual, section „Electric energy“.
2‐20 Electrical connected loads 2012-10 20-10-02-A3-CR02

If you would like to operate the laser device with mains voltages
other than mentioned above, you must use a series transformer.
Contact TRUMPF, if you need further information on this subject.
5.1 Electrical connection
The laser device is optionally delivered with a mains cable (con-

nector CEE 63 A to DIN EN 60309).
Length 5 m or 10 m of usable length

Cable cross section 10 mm2
AWG 8
connection clamps Phase conductor cable lug M6
Protective conductor cable lug M8
Tab. 2-9
5.2 Electromagnetic compatibility
An incorrect connection of the laser device to the supply system

or to other electric devices can change the characteristics of the
laser device with regard to electromagnetic compatibility. Specifi-
cations for the connection of the lines are to be found in the
interface description „Interfaces of the laser devices“.
The laser device is only suited for connection to the electric
mains in an industrial environment.
5.3 Insulation resistance
The insulation resistance is the resistance measured between

the phase connection (L1, L2 or L3) and protective earth (PE) of
an electrical device. The TRUMPF laser devices can have an
insulation resistance < 1 MΩ upon delivery. Nevertheless, these
laser devices guarantee that the permitted contact voltage is not
exceeded.
The permitted insulation resistance for this laser type is given in
(see "Tab. 2-2", pg. 2‐19). If the value does not fall below the
value defined, the laser device can be registered as "OK".
20-10-02-A3-CR02 2012-10 Electrical connection 2‐21

Conditions
■ The device is disconnected from the mains during the meas-
urement.
■ The main switch is in ON position.
■ According to EN 60204, the insulation resistance must be
≥ 1 MΩ.
If a TRUMPF laser device has an insulation resistance < 1 MΩ
during the regular check of the electrical devices, proceed as fol-
lows:
Check regularly 1. Check the minimum permitted insulation resistance of the

laser device (see "Tab. 2-2", pg. 2‐19).
2. If the measured value is larger than the table value, register
the laser device as "OK" and label it.
3. If the measured value is smaller than the table value, elimi-
nate the cause of the lower value and repeat the measure-
ment.
A cause could be that after delivery, a modification affecting
the insulation resistance has been made to the laser device.
or
Ø If you cannot find the cause or if it is not possible to
eliminate it, contact the TRUMPF service department.
The contact details (telephone number, etc.) of the serv-
ice department can be found on the first page of the
operating instructions of the laser device.
2‐22 Electromagnetic compatibility 2012-10 20-10-02-A3-CR02

6. Cooling unit
6.1 External cooling circuit TruDisk 2001,

Temperature supply +5 °C .. +20 °C

Pressure ≤ 6 bar
Differential pressure Δp 1.5 bar ≤ Δp ≤ 6 bar
between supply and return
(see "Fig. 2-17", pg. 2‐24)
at the laser device
Minimum water requirement (see "Fig. 2-16", pg. 2‐24)
Water quality Cooling tower water according to VDI
3803, appendix B, table B3.
If the water is soiled, a prefilter ≤ 135
µm is recommended (filter level in the
device 250 µm).
Water additives Operation with water additives (e.g. frost
protection, algae protection ...) is possi-
ble if it is ensured that the materials
used in the cooling unit are not affected.
Water additives reduce the cooling
capacity.
Operation with water additives on possi-

ble:
■ at lower supply temperature
■ at reduced laser power
■ at increased flow.
Connections of supply and (see "Cooling water connections", pg.
return 2‐35)
Material V2A, V4A, brass/gunmetal, PVC-U,
EPDM, gunmetal, NBR, copper
Tab. 2-10
Note
Note that the differential pressure refers directly to the connec-
tions of the laser device. Connected hoses cause further pres-
sure loss. This one depends on the length and the diameter of
the hoses.
20-10-02-A3-CR02 2012-10 Cooling unit 2‐23

Cooling water requirement for the tube
dimensioning
Minimum water consumption characteristic Fig. 2-16
The characteristic curve shows the required water against the

supply temperature at maximum power consumption (e.g. serv-
ice). The characteristic curve serves for dimensioning of the pipe
system and the cooling unit.
Characteristic line of power loss Fig. 2-17
Here the flow quantity versus the minimum pressure difference

of the laser cooler (in case of opened internal valves) is shown.
Note that the pressure difference lies at the connections of the
laser device.
2‐24 External cooling circuit TruDisk 2001, TruDisk 2002, 2012-10 20-10-02-A3-CR02
TruDisk 2004
Determining dimensioning
data
Example Fig. 2-18
Note
Dimension the tube system for the external cooling water so
that the required differential pressure is applied directly at the
device connections.
1. Determine the maximum possible supply temperature of the
external cooling water.
2. Read off the minimum water requirement at the correspond-
ing characteristic curve of water requirement (Fig. "Example"
left).
- In the example: water consumption with maximum power
consumption at 20℃ supply temperature 1.9 m³/h.
3. Read off the pressure difference applicable for this flow
quantity between supply and return of the cooler at its char-
acteristic curve (Fig. "Example" right).
- In the example: 1.5 bar.
4. TRUMPF recommends to consider a factor of safety of 0.5
bar in order to compensate a slight soiling of the filter and
measuring inaccuracies on site.
To ensure the function of the internal solenoid valves, the
minimum pressure difference of 1.5 bar must be reached!
The determined values for the water requirement and the pres-
sure loss are dimensioned in such a way that the laser device
works reliably. If you operate the laser device with smaller val-
ues, you reduce the control reserve of the cooler. The conse-
quence may be that monitoring and fault messages are often
displayed due to overtemperature. The operation of the laser
device is interrupted by the messages.
20-10-02-A3-CR02 2012-10 External cooling circuit TruDisk 2001, TruDisk 2002, 2‐25
TruDisk 2004
TruDisk 2602
Temperature supply +5 °C .. +20 ℃

Pressure ≤ 6 bar
(see "Fig. 2-17", pg. 2‐24)
at the laser device
device 250 µm).
capacity.

ble:
return 2‐35)
Tab. 2-11
Note
the hoses.
2‐26 External cooling circuit TruDisk 2501, TruDisk 2602 2012-10 20-10-02-A3-CR02
dimensioning


laser device.
20-10-02-A3-CR02 2012-10 External cooling circuit TruDisk 2501, TruDisk 2602 2‐27
data
Example Fig. 2-21
Note
device connections.
left).
Temperature supply +5 °C .. +20 °C

Pressure ≤ 6 bar
(see "Fig. 2-17", pg. 2‐24)
at the laser device
device 250 µm).
capacity.

ble:
return 2‐35)
Tab. 2-12
Note
the hoses.
TruDisk 3306
dimensioning


laser device.
2‐30 External cooling circuit TruDisk 3001, TruDisk 3302, 2012-10 20-10-02-A3-CR02
TruDisk 3306
data
Example Fig. 2-24
Note
device connections.
left).
TruDisk 3306
TruDisk 4006
Temperature supply +5 °C .. +20 ℃

Pressure ≤ 6 bar
(see "Fig. 2-17", pg. 2‐24)
at the laser device
device 250 µm).
capacity.

ble:
return 2‐35)
Tab. 2-13
Note
the hoses.
dimensioning
Characteristic line for minimum water requirement Fig. 2-25
Characteris- Water requirement at 1% of

tic lineA the nominal laser power
(Standby)
[6 kW Cooling power]
Characteris- Water requirement at nominal ⇒ Characteristic curve for
tic line B operation calculating the economics
[19.5 kW Cooling power]
Characteris- Water consumption at maxi- ⇒ Characteristic curve for
tic line C mum power consumption dimensioning the pipe
(e.g. during service work) system and the chiller
[22 kW Cooling power]
Tab. 2-14
20-10-02-A3-CR02 2012-10 External cooling circuit TruDisk 4002, TruDisk 4006 2‐33
laser device.
data
Example Fig. 2-27
Note
device connections.
left).
In the example: water consumption with maximum power
6.5 Cooling water connections
6 7
5 9
8
3 4
2
1 O-rings 6 Screw-in part wrench dimension

2 Hose connection gland outer 7 Screw-in part external thread
diameter 8 Union nut internal thread
3 Hose connection gland wrench 9 Union nut key dimension
dimension
4 Hose connection gland external
thread
5 Screw-in part internal thread
Connection for cooling water supply and return Fig. 2-28
Pos. in Wrench /
Fig. thread dimension
Hose connec- outer diameter 2 25 mm
tion gland
wrench dimension 3 38 mm
external thread* 4 1 "
Screw-in part internal thread * 5 1 "
external thread* 7 1 1/2 "
Union nut internal thread * 8 1 1/2 "
Tab. 2-15
20-10-02-A3-CR02 2012-10 Cooling water connections 2‐35

*sealed via O-ring.
A hose gland (Mat.-No. 0382799) for the installation of the cool-
ing water hose is screwed into the screw-in part.
The union nut is fastened at the scew-in part to connect the
cooling water hose.
6.6 Data for chillers
If the operate the laser device together with a chiller, the chiller
must meet at least the requirements indicated in the following
table.
Cooling power TruDisk 2001, TruDisk 2002,

TruDisk 2004: ≥ 11 kW
TruDisk 3001: ≥ 17.5 kW
TruDisk 3302; TruDisk 3306: ≥ 16.5 kW
TruDisk 4002, TruDisk 4006: ≥ 19.5 kW
(Nominal power after degradation)
Minimum water circulation TruDisk 2001, TruDisk 2002,
quantity TruDisk 2004:
1.9 m³/h at 20 °C and 1.5 bar
TruDisk 2501; TruDisk 2602:
2.45 m³/h at 20 °C and 1.5 bar
TruDisk 3306:
2.8 m³/h at 20 °C and 1.5 bar
TruDisk 4002, TruDisk 4006:
3.2 m³/h at 20 °C and 1.5 bar
Pressure difference (see "Fig. 2-17", pg. 2‐24)
supply-return
Overflow valve required
Tab. 2-16
2‐36 Data for chillers 2012-10 20-10-02-A3-CR02

X in the laser device Z required delivery pressure of
Y connection lines the pump in the chiller
Fig. 2-29
The chiller pump must be designed for the total pressure drop
(pressure drop in the laser device + pressure drop of the con-
nection lines).
Example Pressure drop in the Pressure drop in Required feed pressure

laser device at 3000 l/h the connection of the pump in the
lines chiller
(see "Fig. 2-17", pg.
2‐24)
1.5 bar + 1 bar = 2.5 bar
Tab. 2-17
6.7 Laser cooling circuit
Cooling means Deionized water.

For the extraction of DI water, water of drinking
water quality must be used.
Quantity approx. 70 l (4x)
Conductivity < 10 μS/cm
Specifications on the laser cooling circuit Tab. 2-18
Cooling of externally-bought DI water from the cooling circuit of the laser can result in
components corrosion in components containing materials not resistant
to DI water. Corrosion products that enter the laser device
via the cooling circuit can cause damage in the laser.
TRUMPF shall only be liable in accordance with legal regula-
tions for damage caused by defects in devices or compo-
nents delivered by TRUMPF. TRUMPF cannot be held liable
for damage caused by foreign products.
20-10-02-A3-CR02 2012-10 Laser cooling circuit 2‐37

7. Ambient conditions
Temperature When +10 °C .. +45 °C

switching
on
Operation +10 °C .. +50 °C
Storage +5 °C .. +50 °C
Relative humidity Operation max. 100 % at 24 °C
Storage
Protection class Laser IP 54 in case of closed front doors
device
Operating IP 54
panel
Tab. 2-19
IP 54 The international protection IP 54 is only fulfilled when all hoods,

doors and covers are closed. If the environment is heavily loa-
ded with dust and aerosols, TRUMPF recommends to surround
the laser device by a structural containment which protects the
laser against influences of the environment also when it is
opened.
Dew point If warm and humid air reaches cold surfaces, condensation
water is formed at certain temperatures. This condensation water
can lead to faults of the electrical and optical components or
even to their failure.
Therefore, for avoiding condensation water, it is required that the
ambient conditions at the laser device are within certain limits.
Dew point temperature Fig. 2-30
In order to determine the ambient conditions, the ambient tem-

perature and the air humidity in the environment of the laser
2‐38 Ambient conditions 2012-10 20-10-02-A3-CR02

device must be measured. When operating the laser device,
there measuring values must be within the grey are in the dew-
point diagram.
If the required ambient conditions are not kept, a corresponding
environment must be created for the laser device artificially
(cabin, air conditioning).
20-10-02-A3-CR02 2012-10 Ambient conditions 2‐39

8. Emissions
Sound level Laser device LpA ≤ 70 dB(A) according to

DIN ISO 3744
Processing spot Depending on the application
Tab. 2-20
2‐40 Emissions 2012-10 20-10-02-A3-CR02

9. Position of the user
The following sections describe where persons stay in different

situations when handling the laser device. The situations are:
■ Switching the laser device on and off.
■ Operating the laser device
■ Maintenance of the laser device.
9.1 Position for switching on and off
DW-81015
Fig. 2-31
Note
Position the laser device in such a way the main switch can be
reached easily.
9.2 Position for operating the laser

device
Fig. 2-32
20-10-02-A3-CR02 2012-10 Position of the user 2‐41

If the laser device is switched on, all operating processes can be
carried out from the operating panel.
9.3 Position for setting the focusing

optics
Fig. 2-33
The position or the setting work at the focusing optics is at the

processing stations.
2‐42 Position for setting the focusing optics 2012-10 20-10-02-A3-CR02

9.4 Position for maintenance work
BR-81043
1 Laser cooler 4 Air cleaner 7 Fan at the control
2 Laser light cable 5 Pump module 8 Electric fuses
3 Focusing optics 6 Diode current supply 9 Connections
Fig. 2-34
20-10-02-A3-CR02 2012-10 Position for maintenance work 2‐43

10. First measures to be taken after
receipt of the laser device
10.1 Delivery of the laser device
Check all parts of the laser device and the accessories for trans-
port damages immediately after delivery.
Report transport damages immediately to the following authori-

ties:
■ The shipping agent.
■ The insurance agency which insured the transport.
■ The dispatch department of TRUMPF.
10.2 Commissioning
Only staff from TRUMPF or specially instructed persons are

allowed to put the laser device into operation.
DI-water Keep ready a sufficient quantity of deionized water for the com-
missioning (see "Laser cooling circuit", pg. 2‐37).
Adjusting the level difference
1 Head 2 Counter nut

Adjustment thread of an adjustable leg Fig. 2-35
1. Loosen counter nut (2).
2‐44 First measures to be taken after receipt of the laser 2012-10 20-10-02-A3-CR02
device
2. Set the adjustable leg at the head (1) to the correct position.
3. Tighten the counter nut.
All adjustable legs must be placed on the floor with about the
same force.
Removing the shipping brace of the

compressor
Means, Tools, Materials

■ Double-bit key
■ Hexagon screwdriver, 0.16 in
■ Slotted screw driver, 2.5 mm
1. Open the right front door of the laser device.
4
4 mm
4
2 DW-80007
Fig. 2-36
2. Disconnect all the plugs (1).
3. Pull off the hoses (2).
4. Remove the grounding cable (3).
5. Loosen the screws ( 4).
20-10-02-A3-CR02 2012-10 Commissioning 2‐45

Danger of injury by falling subassembly
WARNING
Legs or feet may be hit or crushed. Backache can be
caused or increased.
Ø Lift the subassembly with 2 persons.
Ø Place the subassembly on a stable support surface with an
appropriate height.
6. Remove the air cleaner from the laser device.
Fig. 2-37
7. Unscrew the screws of the two red shipping braces (arrows,
on the left side) downward.
8. Fasten the shipping braces on the right side of the frame
(arrows, on the right side).
9. Mount the air cleaner and establish the connections.
2‐46 Commissioning 2012-10 20-10-02-A3-CR02

11. Transport
Appropriate transport means for the movement of the laser

device within in a building or on the premises are:
■ Pallet jack
■ Fork-lift truck
■ Crane
■ Casters (Option)
11.1 Transport by means of pallet jack

Conditions
■ To move the laser device at the installation site:
− The laser device must be switched off.
− Laser light cables and supply lines must be laid in such a
way that sufficient motion reserve is available.
− It must be ensured that laser light cables and supply
lines are not damaged.
■ To change the installation site of the laser device:
− All lines which lead from other devices to the laser
device (e. g. from external controls) must be disconnec-
ted.
− The mains cable must be separated from the electrical
mains.
− All laser light cables must be separated from the laser
device.
− The cooling unit must be emptied completely, if during
transport or during the storage of the laser device there
can be temperatures below 0 °C.
For emptying the cooling unit a compressed air connec-
tion is required.
A detailed description for the emptying of the laser cooler
is to be found in chapter "Maintenance".
Note
A pallet jack is required for the transport of the laser device.
One person is required to actuate the pallet jack and to move
the laser device.
Minimum load capacity of the lift truck:

Type 4 C/4 8.2 kN (820 kg)
Type4 C/6 8.8 kN (880 kg)
20-10-02-A3-CR02 2012-10 Transport 2‐47

Parts of the body can get between pallet jack and the
CAUTION subject to be transported or between subject to be
transported and the ground!
Parts of the body can be broken or crushed.
Ø Observe the safety regulations when operating the pallet
jack.
Fig. 2-38
1. Placing the pallet jack in position
Incorrect positioning of the lift trucks can cause damage to

CAUTION material property.
Ø Insert the lift truck fork until the front wheels of the lift truck
are positioned in the opening.
Ø Lift the fork carefully.
Inserting the pallet jack Fig. 2-39
2‐48 Transport 2012-10 20-10-02-A3-CR02

2. Inserting the pallet jack
Note
The laser device may not be inclined more than about 10°.
3. Lift the laser device by means of the lift truck.
4. If you would like to transport the laser device over a longer
distance or over an uneven surface: Save the laser device
against slipping by means of a belt.
5. Move the lift truck with the laser device slowly to the destina-
tion so that it can be stopped at any moment.
6. Place the laser device carefully.
11.2 Transport by fork lift truck

Condition
■ Before transport:
ted.
mains.
device.
tion is required.
Minimum loading capacity of the fork-lift truck:
Type 4 C/4 8.2 kN (820 kg)
Type4 C/6 8.8 kN (880 kg)
20-10-02-A3-CR02 2012-10 Transport 2‐49

Fig. 2-40
1. Setting the lifting fork distance.

2. Place a padding map across the laser device to protect the
side of the laser device facing the forklift truck.
Parts of the body may get between fork lift truck and the
CAUTION item to be transported.
Parts of the body can be broken or crushed.
Ø There must not be any persons in the danger zone of the
fork lift truck.
Ø The laser device may only be transported by instructed per-
sons.
Ø Observe the safety regulation of the transport means.
Fig. 2-41
3. Positioning lifting forks.
2‐50 Transport 2012-10 20-10-02-A3-CR02

Note
The laser device may not be inclined more than about 10°.
4. Lift the laser device carefully by means of the fork-lift truck.
5. If you would like to transport the laser device over a longer
distance or over an uneven surface: Save the laser device
against slipping by means of a belt.
6. When moving, avoid:
− Abrupt start and stop.
− Quick cornering.
11.3 Transport by means of a crane

Condition
■ Before transport:
ted.
mains.
device.
tion is required.

■ Bars
− 2pieces
− Material :
Square bar steel (St37-2 1.0037 S235JR), width min.
28 mm
or
steel with circular cross section, ∅ approx. 40 mm
(use of round steel can cause damage to the paint)
− Length:
Type 4 C/4 > 1400 mm
Type 4 C/6 > 1700 mm
■ 4Lifting belts with loops at each end
20-10-02-A3-CR02 2012-10 Transport 2‐51

■ Expander device:to keep the lifting belts apart
Minimum carrying force of the crane:

Type 4 C/4 8.2 kN (820 kg)
Type4 C/6 8.8 kN (880 kg)
Preparation 1. Disconnect laser device from the electric mains.
Transporting the laser

device 6
1 2 3 4
1 Padding mat 4 Protection against slipping

2 Metal bars 5 Spacer
3 Lifting belts 6 Crane hook
Fig. 2-42
2. Put the padding mat (1) over the laser device so that the
front side and the rear side are protected where the lifting
gear is placed.
3. Put metal bars (2x) (2) through the base of the laser device.
They should protrude in the back and in the front with about
the same length.
4. Fasten the lifting belts (4x) (3) with the same length at the
metal rods.
5. Secure the lifting belts at the metal bars against slipping (4).
6. Fit a spacer (5) between the lifting belts. The spacers pre-
vent that the hoods of the laser devices are twisted.
7. Hook in the crane hook (6).
8. Ensure that the laser device is suspended horizontally in the
lifting gear.
2‐52 Transport 2012-10 20-10-02-A3-CR02

The suspended load may swing. Ropes, belts or chains
DANGER may tear or get loose!
Loads falling down may cause death or serious damage to
material property.
Oscillating loads may cause injuries and damage to
material property.
Ø Only use undamaged ropes, belts or chains that have the
necessary resistance to tearing.
Ø Only use spacers created for a sufficient pressure load.
Ø Secure ropes, belts or chains against sliding down.
Ø Only persons whose presence is absolutely necessary are
allowed to stay in the danger area of the crane.
Ø Persons staying in the danger area of the crane must wear
a hard hat.
Ø Observe the safety regulations for the crane!
Fig. 2-43
9. Lift the laser device carefully.
10. Move the crane in such a way that the laser device does not
oscillate.
11.4 Moving the laser device on casters

On horizontal surfaces it is possible to move the laser device

using the optionally fitted casters. The casters are not intended
for in-house transportation but only for small-scale displacement
of the laser device on its installation site.
20-10-02-A3-CR02 2012-10 Transport 2‐53

Conditions
■ To move the laser device at the installation site:
− The laser device must be switched off.
− Laser light cables and supply lines must be laid in such a
way that sufficient motion reserve is available.
− It must be ensured that laser light cables and supply
lines are not damaged.
■ To change the installation site of the laser device:
− all lines leading to the laser device from other installa-
tions (e.g. from the electric mains or external controls)
must be disconnected.
device.
A detailed description for the emptying of the laser
cooler is to be found in chapter "Maintenance".
Fig. 2-44
1. Release brakes at all 4 casters.
When moving too fast there can be high inertia forces

DANGER during cornering or stopping!
Risk of injury by moving mass. Persons may be crushed or
in extreme cases suffer fatal injuries.
Ø Only move on horizontal surfaces.
Ø Move slowly.
Ø Warn persons staying close to the transport path.
2‐54 Transport 2012-10 20-10-02-A3-CR02

2. Move the laser device.
Fig. 2-45
3. Engage the brakes at all 4 casters.
11.5 Packing the laser device

Preparation 1. Turn the laser device off°(see chapter " Operation").

2. Emptying the cooling unit of the laser device°(see chapter "
Maintenance").
3. Disconnect all electric connections from the laser device.
4. Mount the shipping brace for the compressor.
5. Disconnect the laser light cable°(see chapter " Mainte-
nance").
Fig. 2-46
6. Disconnect the operating panel from the cable and pack sep-
arately.
20-10-02-A3-CR02 2012-10 Transport 2‐55

Inner packing
Fig. 2-47
7. Place the laser device onto the pallet and fix the bar (1).
Pos. Designation Additional information

1 Bar 50 mm x 50 mm x 1500 mm
2 Anti-skid mat 100 mm x 900 mm
(3x)
3 Plywood panel 1600 mm x 1150 mm
Thickness: 15 mm - 18 mm
4 Hard foam panel 1600 mm x 1150 mm
(2x) Nopaplank R65, thickness: 50 mm, 65
kg/m³
5 Pallet 1950 mm x 1350 mm
with 3 runners, 80 mm x 100 mm x 1400
mm
Tab. 2-21
2‐56 Transport 2012-10 20-10-02-A3-CR02

1 Hard foam panel 2 Foamed film
Fig. 2-48
8. Place a hard foam panel on the laser device.
9. Put a hood of bubble wrap over the laser device.
1 Thermally insulating cover 2 Stretch film 3 Crossbeam

Inner packing Fig. 2-49
10. Putting a thermo cover on the laser device
20-10-02-A3-CR02 2012-10 Transport 2‐57

Laser device Material Dimensions Protective thermo
cover
TruDisk 2001 - 4006 PP/PET aluminum metallized, laminated 1900 x 1300 x 1750
with bubble wrap.
TruDisk 3001 (4C/S) - 8002 2200 x 1350 x 1700
TruDisk 10002 - 16002 3000 x 1450 x 1700
Tab. 2-22
11. Enwrapping the laser device with stretch film.

12. Lay the crossbeam (80 mm x 100 mm x 900 mm) on the
laser device.
Outer packing
Fig. 2-50
13. Fill the space on the right and behind the laser device with
hard foam panels.

1 Plywood panel- 1450 mm x 1750 mm
Side walls Thickness: 15 mm - 18 mm
2 Plywood panel- 2000 mm x 1750 mm
Front and back Thickness: 15 mm - 18 mm
wall
- Nopaplank R65, thickness: 50 mm, 65
Rear wall kg/m³
4 Air cushion 600 mm x 900 mm
- Nopaplank R65, thickness: 50 mm, 65
Side walls kg/m³
2‐58 Transport 2012-10 20-10-02-A3-CR02

6 Tightening Width:approx. 25 mm
straps Tensile strength : approx. 9.3 kN (950 kp)
number: 2
7 Plywood panel - 2000 mm x 1400 mm
Cover Thickness: 15 mm - 18 mm
Tab. 2-23
14. Attach the wooden walls.

15. Attach tightening straps.
16. Label the packaging:
"Transport in upright position only!".
20-10-02-A3-CR02 2012-10 Transport 2‐59

2‐60 Transport 2012-10 20-10-02-A3-CR02
Chapter 3
Description
1 Overview 3‐3
2 Laser 3‐4
2.1 Design 3‐4
2.2 Specifications 3‐4
3 Optical arrangement 3‐7

3.1 Components of the optical arrangement 3‐9
Central shutter (VZ) 3‐9
Shutter (V1, V2, ...) 3‐10
Shutter switch left 3‐11
Shutter switch (VW1, VW2, ...) with pilot 3‐12
laser
Physical splitter with fixed splitting 3‐15
ratio
Deflection (U1, U2, ...) 3‐15
LEM deflection 3‐16
20-10-02-A3-CR02 2012-10 Description 3‐1

Power and energy measuring sensor 3‐16
(LEM)
3.3 Wedge beam switch (option) 3‐18
3.4 Incoupling optics 3‐20
Incoupling optics LLK-D 3‐21
Incoupling optics LLK-B 3‐21
5 Focusing optics 3‐25
6 Control 3‐27
7 Mains distribution 3‐29
9 Cabinet cooler 3‐33
13 Panel computer (Option) 3‐38
14 Control panel (Option) 3‐39
15 Telepresence 3‐40
15.1 Direct connection over an analog modem 3‐40
15.2 Connection via VPN 3‐41
15.3 Connection via SSH 3‐41
3‐2 Description 2012-10 20-10-02-A3-CR02

1. Overview
1 Optical arrangement 5 Focusing optics 9 Mains distribution

2 Incoupling optics 6 Laser cooler 10 Control
3 Laser 7 Air cleaner 11 Operating panel
4 Laser light cable 8 Diode current supply
Fig. 3-1
20-10-02-A3-CR02 2012-10 Overview 3‐3

2. Laser
1 Folding mirror 4 Cavity

2 Rear mirrors 5 Output coupling mirror
3 Pump unit
Fitting position of the laser Fig. 3-2
2.1 Design
The main components of the laser are:

■ Pump unit.
■ Cavity with laser disk
■ Resonator, comprising folding mirror, rear mirror and output
coupling mirror.
The output coupling mirror is partially transmitting for laser light.
The cavity and the pump unit are cooled with deionized water
2.2 Specifications
TruDisk 2001 Wavelength of the laser light 1030 nm

Minimum laser power 80 W
Maximum laser power 2000 W
Beam parameter product 4 mm·mrad
Tab. 3-1

3‐4 Laser 2012-10 20-10-02-A3-CR02

Tab. 3-2

Tab. 3-3

Tab. 3-4

Tab. 3-5

Tab. 3-6

Tab. 3-7

Tab. 3-8

Tab. 3-9
20-10-02-A3-CR02 2012-10 Specifications 3‐5

Tab. 3-10
3‐6 Specifications 2012-10 20-10-02-A3-CR02

3. Optical arrangement
Fig. 3-3
The optical arrangement contains all components for guidance of

the laser light within the laser device until the beam enters the
incoupling optics. The laser light cable is connected to the incou-
pling optics.
The components of the optical arrangement are grouped and
arranged according to the respective machining task.
The components of the optical arrangement are mostly accom-
modated in transparent plastic cases. Between the components
there are metal beam guard elements of circular cross section.
The following picture shows an example of an optical arrange-
ment. The picture shows the main components available for opti-
cal arrangements. The meaning and function of the components
are explained below.
A representation of your optical arrangement is to be found in
the documentation delivered together with your laser device. To
understand the functions of your optical arrangement: (see
"Components of the optical arrangement", pg. 3‐9) .
20-10-02-A3-CR02 2012-10 Optical arrangement 3‐7

1
4
2
3 4
50
3
2 3
50
4
1 2
100
5
50
1
100 T1
U2 50
13 6
LASER
5
5 7
6
VW1 VW2 VW3
A41 A42 A43 VZ
A10
U1
8
LEM 1
A13
12 12 3 12 11 10 9
1 Laser light cable 6 Deflection for absorber 10 LEM

2 Incoupling optics 7 Deflection 90° 11 Central shutter (VZ)
3 Beam shielding 8 Holder for plasma sensor 12 Shutter switches
4 Physical splitter with adjustable 9 Deflection for LEM* 13 Deflection 90°
splitter ratio
5 Absorber
Optical arrangement (example) Fig. 3-4
*LEM: Power and energy measuring sensor

The laser light is fed in at the point to which the arrow designa-
ted “LASER” is pointing.
The central shutter VZ can block or enable the laser light for all
light paths.
The positions of the shutter switches VW determine to which
light path the laser light is guided.
3‐8 Optical arrangement 2012-10 20-10-02-A3-CR02

Further information on the functions of the optical arrangement
components is written below.
3.1 Components of the optical

arrangement
Central shutter (VZ)
DW-80008
1 Mirror moved out of beam 3 Absorber 5 Laser beam enabled

guideway 4 Mirror in beam guideway
2 Laser beam blocked
Fig. 3-5
The central shutter allows to block the laser beam emission (pic-
ture A) or enable it (picture B) for all light paths.
If the laser beam is enabled, it passes through the central shut-
ter as shown in partial picture B. If the laser beam is blocked,
the central shutter guides the laser beam into the absorber (3)
where it is transformed into heat.
At zero current, the central shutter blocks the light path.
20-10-02-A3-CR02 2012-10 Components of the optical arrangement 3‐9

The central shutter has two functions:
Operating function In the operating function the central shutter is controlled by oper-
ator-originated commands or laser programs as long as the
safety circuit is closed.
Safety function When the safety circuit is interrupted, the central shutter is
immediately closed. This is also performed if the signal for open-
ing is sent by the operator or the running laser program.
Information about functioning and wiring of the safety circuit is to
be found in the interface description safety circuit ASV.
Shutter (V1, V2, ...)
1 2 3 4 5
DW-80015
1 Laser beam blocked 3 Absorber 5 Mirror moved out of beam
2 Mirror in beam guideway 4 Laser beam enabled guideway
Fig. 3-6
The shutter can enable or lock an individual light path. When the
shutter enables the light path, the laser beam passes through it
as shown in picture B (see "Fig. 3-6", pg. 3‐10). When the shut-
ter closes the light path, the laser beam will be guided into an
absorber (picture A).
The light path controls the shutter. The light path can be adjus-
ted manually or by laser program.
When the shutter is controlled by an ASV board, it can be inte-
grated into a safety circuit. In this case it has not only an oper-
ating function, but also a safety function. What has been said
regarding the safety function for the central shutter will then also
apply analogously to the light path in which the shutter is loca-
ted.
3‐10 Components of the optical arrangement 2012-10 20-10-02-A3-CR02

Shutter switch left
2
3
1 4
1 Mirror moved out of beam 3 Mirror in beam guideway 4 Laser beam is deflected by 90°
guideway
2 Laser beam passes through in
a straight line
Fig. 3-7
The laser beam can be guided into one of two directions by

means of a beam switch.
If the mirror is in the beam guideway, the laser beam is deflec-
ted by 90° (picture B). If the beam is swiveled out of the beam
guideway, the laser beam passes through the beam switch in a
straight line (picture A).
The beam switch can be controlled by user commands or by
laser programs.

Shutter switch (VW1, VW2, ...) with pilot
laser
1 pilot laser 3 Pilot laser beam

2 Shutter switch mirror
Fig. 3-8
The casing of the shutter switch with pilot laser houses a semi-
conductor laser is (1). The semiconductor laser works as pilot
laser of the light path to which shutter switch is assigned. In con-
trast, the central pilot laser can be used in all light paths.
Advantage The pilot laser in the shutter switch can be used while the work-
ing laser light is being guided to a different light path. This
makes it possible to use the pilot laser at processing point, while
workpieces are being machined at a different point.
Switching on pilot laser The pilot laser can be switched on as soon as the shutter switch
mirror has been swiveled out of the beam guideway (shutter
closed (see "Fig. 3-8", pg. 3‐12)).
To switch on the pilot laser on the user interface is described in
chapter "Operation".
Laser classes The pilot laser has been classified as a Class 3Rcomponent.
This must be taken into account when it is operated, for exam-
ple by the service, after removal from the unit.
In standard operation, the pilot laser light emitted from the
focussing optics outlet corresponds to class 2.
Shutter switch functions A shutter switch is a switch with a safety function. Its design
does not differ from that of a usual switch. The difference lies in
the activation of the shutter switch by an ASV board. The shut-
ter switch is integrated into a safety circuit via the ASV board.

Thus, the shutter switch has two functions:
Operating function In the operating function, the central shutter is controlled by

operator commands or laser programs as long as the safety cir-
cuit is closed.
Safety function When the safety circuit is interrupted, the shutter switch is set
immediately to direct the laser beam into an absorber (see "Fig.
3-9", pg. 3‐14) (picture A). This also happens when a different
command comes from the operator or from the running laser
program.
Information about functioning and wiring of the safety circuit is to
be found in the interface description safety circuit ASV.
The number of shutter switches in an optical arrangement is usu-
ally identical to the number of light paths. The shutter switches
are arranged in series. They are activated in such a way that at
most one shutter switch is open (mirror in the beam guideway,
(see "Fig. 3-9", pg. 3‐14) (pictures B and C). This ensures that
when the safety circuit is interrupted the laser beam is always
directed into the absorber which is the last in the series.

A
DW-80011
A VW1 and VW2 closed B VW1 open C VW2 open

Fig. 3-9

Physical splitter with fixed splitting
ratio
DW-80010
Fig. 3-10
The beam splitter of fixed splitting ratio contains a partially trans-

mitting mirror which is positioned at a 45° angle to the beam
path. Part of the incident laser light (e.g. 50 %) is transmitted in
a straight line; the remaining laser light is deflected by 90°.
Deflection (U1, U2, ...)
Fig. 3-11
The deflection deflects the laser beam through 90° to the right or
left.

LEM deflection
Fig. 3-12
The LEM deflection deflects the laser beam via 2 mirrors by 90°.
An LEM can be attached to this deflection.
Power and energy measuring sensor (LEM)
Fig. 3-13
The LEM produces an electric signal which corresponds to the

momentary power of the laser. The power of the laser or the
energy of laser pulses can be determined by this.
The LEM is attached to the end mirror of the laser or to a
deflection of the optical arrangement. Through the end mirror, or

through the mirror of the deflection, a small part of the laser
power is coupled out and fed into the LEM.
If the laser device is provided with a laser power control, the
LEM measures the actual value of the laser power.
3.2 Selecting light path
The positions of the mirrors in the controllable components of

the optical arrangement (beam switches, shutter switches, shut-
ters) determine the light path.
DW-80012
Light path determined by VW2 Fig. 3-14
In this figure, the mirror of shutter switch VW2 has been swiv-
eled into the beam guideway. At this point, the laser beam is
deflected by 90° and coupled into the laser light cable connec-
ted to this light path.
DW-80013
Light path determined by VW1 Fig. 3-15
In this figure, the mirror of shutter switch VW1 has been swiv-
eled into the beam guideway. At this point, the laser beam is
deflected by 90° and coupled into the laser light cable connec-
ted to this light path.
20-10-02-A3-CR02 2012-10 Selecting light path 3‐17

DW-80014
Light path in the absorber Fig. 3-16
In this figure, the mirrors of the shutter switches VW1 and VW2
have been swiveled out of the beam guideway. The laser beam
passes through both shutter switches in a straight line and
enters the absorber, where it is converted into heat, until the
laser device is switched off.
In case of beam switches with safety function (shutter switches)
and shutters, the mirror is positioned such, after interruption of
the appertaining safety circuit, that the laser beam is guided into
an absorber or to a safe light path.
Light paths may be selected (excluding the light path in the

absorber):
■ Via the software interface of the laser device (see chapter
"Operation").
■ in laser programs (see chapter "Operation").
3.3 Wedge beam switch (option)
The wedge beam switch can be used optionally in optical

arrangements of the TruDisk XXX1 laser devices.
With a wedge beam switch in the beam guideway of a laser out-

put and a double core laser light cable (LLK), it is possible to
select the core diameter of the LLK to be used to guide the laser
light to the focusing optics:
■ via the inner core of 100 µm (1) for cutting applications.
■ via the outer core 400 µm or 600 µm (2) (depending on the
LLK) for welding applications.
3‐18 Wedge beam switch (option) 2012-10 20-10-02-A3-CR02

1 Laser beam in the inner core 2 Laser beam in the outer core
Fig. 3-17
The following picture shows a wedge beam switch and its com-
ponents.
1 Board SIO 3 5 Proximity switch, wedge in 9 LED shines, wedge outside

2 Plexiglass hood beam guideway beam guideway
3 Traction spring 6 Proximity switch, wedge in 10 LED is illuminated, wedge in the
beam guideway beam guideway
4 Switching lug
7 Wedge 11 Stepper motor
8 Scattered ligth sensor
Fig. 3-18
20-10-02-A3-CR02 2012-10 Wedge beam switch (option) 3‐19

The position of the wedge beam switch is determined by the
selected light path, e.g.:
■ Light path 1: the wedge of the wedge beam switch is not in
the beam guideway. The light beam is incident on the inner
core of 100 µm of the LLK. LED(9)is lit.
■ Light path 2: the wedge of the wedge beam switch is in the
beam guideway. The light beam is incident on the outer core
of 400 or 600 µm of the LLK. LED(10)is lit.
A scattered light sensor (8) measures the scattered light in the
wedge beam switch. If the scattered light increases due to a
dirty or defective wedge, monitoring or fault messages are dis-
played upon reaching the preset limit values. The laser is
switched off automatically if the measured scattered light rea-
ches the preset fault limit value.
Instead of a double-core LLK, a laser light cable with a fiber
core diameter of 100 µm can be used. The laser light cable with
a fiber core diameter of 100 µm is detected by the control sys-
tem, the position of the wedge beam switch cannot be changed.
3.4 Incoupling optics
Fig. 3-19
3‐20 Incoupling optics 2012-10 20-10-02-A3-CR02

The incoupling optics contains a lens which focuses the laser
beam to the beginning of the light guide in the laser light cable.
Incoupling optics LLK-D
Fig. 3-20
Incoupling optics LLK-B
Fig. 3-21
20-10-02-A3-CR02 2012-10 Incoupling optics 3‐21

4. Laser light cable
Fig. 3-22
Purpose The laser light cable is a flexible transmission medium for laser
beams. It allows spatial separation between laser and machining
station.
Design In the interior of the laser light cable there is light guide, which
guides the laser beam from the laser device to the focusing
optics. The light guide is surrounded by a plastic tube and a
steel casing. The steel casing protects the light guide from
mechanical stress. It limits the bending radius of the laser light
cable.
The steel casing is surrounded by an external plastic tube which
protects the laser light cable against environmental effects.
A safety device integrated into the laser light cable switches the
laser automatically off, when the optical wave guide is damaged
or the laser light cable at the laser or at the focusing optics is
pulled out.
Technical data LLK-D Standard lengths 10 m, 15 m, 20 m, 30 m,40 m,

50 m, 60 m, 70 m, 80 m, 90 m,
100 m
Min. permissible bending radius 200 mm
Cable core diameter 12.5 mm
Fiber core diameter 100 µm, 200 µm, 300 µm,
400 µm, 600 µm
Tab. 3-11
3‐22 Laser light cable 2012-10 20-10-02-A3-CR02

WS-71081
1 Protective glass 4 Cooling water connection plug
2 Optical plug, laser side cooling
3 Electrical plug, monitoring 5 Cables
6 Optical plug, machining side
Laser light cable, components Fig. 3-23
Technical dataLLK-B Standard lengths 10 m, 15 m, 20 m, 30 m,40 m,

50 m, 60 m, 70 m, 80 m, 90 m,
100 m
Min. permissible bending radius 200 mm
Cable core diameter 12.5 mm
Fiber core diameter 400 µm, 600 µm
Tab. 3-12
WS-00029
1 Optical plug, laser side 4 Cables

2 Protective glass 5 Optical plug, machining side
3 Electrical plug, Monitoring 6 Protective glass
Laser light cable, components Fig. 3-24
20-10-02-A3-CR02 2012-10 Laser light cable 3‐23

Monitoring The laser light cable is monitored on the whole length. The laser
device switches off immediately and no more laser light may be
emitted if a fault occurs in the laser light cable.
The fit of the two optical plugs is monitored as well. If an optical
plug is loosened, the laser device immediately switches off.
The integrated monitoring of the laser light cable is connected
with the safety circuit of the laser device by means of the electri-
cal plug.
Laying the LLK Outside the laser cabin, laser light cables must be installed
permanently.
To do so, use:
■ Cable clamps
■ Cable ducts
■ Other appropriate auxiliaries for fastening cables.
Inside laser cabins which are monitored by a safety circuit,
laser light cables can be laid freely and loosely.

5. Focusing optics
Fig. 3-25
The focusing optics focuses the laser light onto the processing
point. The high power density required for the material process-
ing is generated thereby.
Focusing optics are composed of modules according to the
requirements of the respective task.
Further information is to be found in the operating manual of
your focusing optics.
20-10-02-A3-CR02 2012-10 Focusing optics 3‐25

1
WS-00113
6
1 Receptacle for LLK plug 5 Splitter and deflection

2 Collimation 6 Lens with lens protection
3 Set ring for defocusing 7 Observation optics
4 Counterring 8 Eyepiece
Focusing optics (Example for welding) Fig. 3-26
3‐26 Focusing optics 2012-10 20-10-02-A3-CR02

6. Control
BR-81044
Fig. 3-27
The control unit controls all functions of the laser device. Apart
from this, it monitors numerous operational values and reports
when a value is outside the permitted range.
The control unit contains interfaces to higher-ranking control
units. They allow an external control of the laser device. Further
information about this is to be found in chapter 2 of this manual
and in the interface descriptions.
Controlling The most important functions are:

■ Switching the laser on and off
■ Controlling the optical arrangement
■ Controlling the laser power
■ Communication with external units (e.g. PLC).
Monitoring The control unit also monitors the following operational values:
■ Laser power
■ Temperature of the coolants
■ Temperatures within the area of the laser and of the optical
arrangement
■ Condition of the laser light cable
■ Safety contacts at the processing points.
Messages If an operational value is outside the permitted range, the con-

trol unit generates a monitoring message or a fault message.
The message is displayed on the screen. When a malfunction
occurs, the control unit stops the operation of the laser until the
cause of the malfunction is eliminated.
20-10-02-A3-CR02 2012-10 Control 3‐27

Configuration
1 Host processor (CPX) 5 Board ASV3 for central shutter 9 ASV3 board for shutter switches
2 Powerboard (PBL) 6 Monitoring LLK and TKO or shutter
3 DLC 2 board 7 Interface Intelligent Optics (IIO) 10 Parallel IO and realtime inter-
face
4 Board, analog input 8 STC 2 board
11 Slots for fieldbus boards
Control unit of the laser device Fig. 3-28
The control system is composed of individual electronic compo-

nents. The component parts of the control unit can differ from
the figure.
3‐28 Control 2012-10 20-10-02-A3-CR02

7. Mains distribution
BR-81046
Fig. 3-29
The mains distribution distributes the electrical energy to the indi-

vidual consuming devices.
20-10-02-A3-CR02 2012-10 Mains distribution 3‐29

1 Main switch 9 Pump push-button 16 Switch-on interface
2 Circuit breaker diode power 10 Push-button proportional valve 17 E-Stop interface
supply 11 Board CMD 18 EMERGENCY STOP relays
3 Circuit breaker laser cooler 12 dU/dt-limiter 19 Power pack 24 V (Option)
4 Circuit breaker compressor air 13 Frequency converter LCO 20 Power pack 24 V (3x)
cleaner
14 Mains choke 21 Contactor for frequency con-
5 Circuit breaker control power verter LCO
15 Interface CPX/control panel
packs
22 Contactor for diode power sup-
6 Mains filter ply
7 Electric fuses 24 V
8 Board PSB3
Fig. 3-30
Detailed information about the mains distribution can be found in

the circuit documents.
3‐30 Mains distribution 2012-10 20-10-02-A3-CR02

8. Laser cooler
Fig. 3-31
The laser cooler dissipates the heat arising in the laser through
a heat exchanger to an external cooling circuit. The temperature
of the laser circuit is regulated to a constant value.
If the supply temperature in the external cooling circuit exceeds
a certain value, an external chiller must be used in addition. You
will find the corresponding technical information in the chapter
"Installation conditions, transport".
20-10-02-A3-CR02 2012-10 Laser cooler 3‐31

1 Tank 3 Pump 5 Contamination filter
2 Fine filter 4 Heat exchanger 6 Proportional valve
Fig. 3-32
The laser is cooled by means of cooling water. The pump deliv-

ers the cooling water from the tank via the supply distributor to
the cooled components:
■ Pump unit and other cooled components of the laser
■ Absorber in the optical arrangement.
■ Focusing optics.
■ Diode current supply.
The water absorbs the heat in the components and flows
through the return collectors into the heat changer where the
heat is dissipated to the external cooling circuit. From the heat
exchanger the water flows back to the tank.
3‐32 Laser cooler 2012-10 20-10-02-A3-CR02

9. Cabinet cooler
Fig. 3-33
The cabinet cooler dissipates the heat arising in the interior of

the laser through a heat exchanger to the laser cooling circuit. In
this way, the temperature in the cabinet is regulated to a con-
stant value, independent from the ambient temperature.
1 Fan 3 Connections of the laser cool-

2 Heat exchanger ing circuit
Components of the cabinet cooler Fig. 3-34
20-10-02-A3-CR02 2012-10 Cabinet cooler 3‐33

10. Air cleaner
Fig. 3-35
Cavities and pump modules must constantly be supplied with dry

and cleaned air. An air cleaner is installed in the laser device for
this reason.
3‐34 Air cleaner 2012-10 20-10-02-A3-CR02

1
6
4 7
5 8
1 Intake filter 5 Active carbon filter

2 Heat exchanger 6 Compressor
3 Water separator + preliminary 7 Replacement filter cartridge for
filter active carbon filter
4 Microfilter 8 Microfilter
Fig. 3-36
The ambient air comes into the laser device through the intake
filter on the right side. The compressor feeds the air through the
cleaning system. The air is cleaned until clean air with a relative
humidity of < 30 % is obtained.
20-10-02-A3-CR02 2012-10 Air cleaner 3‐35

11. Diode current supply
Fig. 3-37
The diode power supply supplies the pump unit of the laser with
electrical power.
The diode power supply supplies the diode current in such a
way that the defined change in laser power with time is ach-
ieved.
The control system constantly monitors the diode power supply.
Operational values and status of the diode power supplies can
be indicated on the operating panel (Main activity> Diagnostics).
3‐36 Diode current supply 2012-10 20-10-02-A3-CR02

12. Operating panel
1
3
RP-00002
1 Touch screen 3 CONTROL ON button 5 Turn-and-push button
2 EMERGENCY STOP pushbutton 4 CONTROL OFF button
Fig. 3-38
Your laser device is normally operated via an operating panel

that is connected to laser device by means of a cable.
By means of the User interface with touch screen (1), and the
turn-and-push button (5), the software TruControl 1000 is oper-
ated for controlling the laser device.
In case of emergency, the emergency-stop pushbutton (2) ena-
bles a quick deactivation of the laser device.
The buttons CONTROL ON (3) and CONTROL OFF (4) allow
you to switch the control unit of the laser device on and off.

13. Panel computer (Option)
Fig. 3-39
Your laser device can be operated via a panel computer. The

program TruControl 1000 Remote to control the laser device is
installed on the panel computer.
3‐38 Panel computer (Option) 2012-10 20-10-02-A3-CR02

14. Control panel (Option)
Instead of an operating panel it is also possible to connect a

control panel to the laser device. The control unit of the laser
device can be activated and deactivated on the control panel.
Furthermore, it is possible to quickly switch off the beam source
in case of emergency by pressing an EMERGENCY STOP push-
button.
20-10-02-A3-CR02 2012-10 Control panel (Option) 3‐39

15. Telepresence
What does telepresence Telepresence is an optional TRUMPF service.

mean?
The TRUMPF staff can access the laser device via telephone
line or internet (VPN connection) and do the following actions:
■ Remote operation of the laser device.
■ Displaying operational values.
■ Troubleshooting.
■ Read-out of operational data and transferring them to
TRUMPF.
■ Changing the parameters.
■ Updating the software.
Support provided by With the telepresence option TRUMPF can assist you in
TRUMPF ■ using the laser device most efficiently for your application.
■ recognizing the necessity of preventive maintenance.
■ locating faults quickly and taking the appropriate steps for
eliminating them.
■ operating the laser device always with the most up-to-date
software.
Safety certificate The TRUMPF staff use the "TRUMPF Telepresence Portal" for
the telepresence.
The "TRUMPF Telepresence Portal" corresponds to the severe
safety requirements of the international certification standard for
the information security of management systems (ISO 27001,
certified to BSI - Germany's National Information Security Author-
ity).
15.1 Direct connection over an analog

modem
A telephone connection with one of the following is needed:

■ Signal shape: analog
■ Connection: RJ 12
An international modem is already included in the control unit of
the laser device.
Required information TRUMPF requires the following information to ensure a direct

connection:
■ telephone number of the modem-connection.
■ serial number of the laser device from TRUMPF.
3‐40 Telepresence 2012-10 20-10-02-A3-CR02

■ name of the contact person for the laser device.
■ telephone number for questions.
15.2 Connection via VPN
For further information regarding the connection via VPN, please

refer to the technical information "VPN connection".
The connection via a virtual private network (VPN) can be car-

ried out in the following ways:
■ VPN via internet
■ special connection as defined by the customer
Required information TRUMPF requires the following information to ensure connection

via VPN:
■ IP address of the VPN connection.
■ user name and password.
The following information concerning the server used are

required:
■ VPN software used
■ VPN connection information.
■ IP address of the operating unit of the laser device.
■ serial number of the laser device from TRUMPF.
■ IP address of the laser device from TRUMPF
■ name of the contact person for the laser device.
■ telephone number for questions.
15.3 Connection via SSH
Secure Shell (SSH) allows a safe, authenticated and encoded

data connection between the TRUMPF service department and
the laser devices of TRUMPF in the user's plant via an insecure
network (internet). For more information, please refer to the tech-
nical information "Telediagnosis via Internet using SSH".
For reasons of safety, the user should only allow the use of the
IP address 217.6.238.162 of the sender TRUMPF and lock all
other IP addresses.
20-10-02-A3-CR02 2012-10 Connection via VPN 3‐41

In order to establish a safe connection to the laser device, the
TRUMPF service department requires the following data from the
user:
■ public IP address of the firewall.
■ public port addresses and the 10-digit device numbers
assigned to the laser devices (see field "ser.-no." on the rat-
ing plate).
3‐42 Connection via SSH 2012-10 20-10-02-A3-CR02

Chapter 4
Operation
1 Operating elements and indicators 4‐3

1.1 Case 4‐3
2 Switching the laser device on and off 4‐7

2.1 Switching on by means of the operating 4‐7
panel
2.2 Switching on by means of the panel com- 4‐7
puter and the operating panel (option)
2.3 Switching off in case of malfunction and 4‐8
emergencies
2.4 Switching on after E-Stop 4‐9
of the operating panel
of the panel computer and the control panel
(option)
20-10-02-A3-CR02 2012-10 Operation 4‐1

3 Operating the laser device using TruCon- 4‐11
trol 1000
Select the light path in the parameter set 4‐11
Change the light path name 4‐13
3.2 Activating and deactivating the laser 4‐14
Switching the laser on and off 4‐14
Open or close the central shutter (VZ) in 4‐15
the parameter set
3.3 Responding to messages 4‐15
Resetting the message 4‐16
3.4 Generating pulse shapes 4‐17
3.5 Creating laser programs 4‐18
3.6 Programming light paths 4‐19
3.7 Pilot laser (option) 4‐19
Switching the switching functions of pilot 4‐20
laser on and off
Setting the pilot laser mode 4‐20
Switching the pilot laser in the light path 4‐22
on and off
4 External control of the laser device 4‐25

4.1 TRUMPF LaserNetwork (option) 4‐25
4‐2 Operation 2012-10 20-10-02-A3-CR02

1. Operating elements and indicators
1.1 Case
1 EMERGENCY STOP pushbut- 4 Laser warning lamp

ton 5 Key-operated switch
2 Signal lamp "Mains On" 6 Main switch
3 Signal lamp "Monitoring"
Fig. 4-1
EMERGENCY STOP The laser and the cooling unit are immediately switched off when
pushbutton the pushbutton EMERGENCY STOP is pressed. In particular, no
more laser light is emitted.
The EMERGENCY STOP pushbutton can be integrated in the
Emergency Stop circuit of a system. With this pushbutton, the
entire system can be cut off. More information can be found in
the interface description EMERGENCY STOP.
Signal lamp "Mains On" The signal lamp "Mains on" lights up:
■ when the laser device is connected to the power supply
and
■ the main switch is in ON position.
Signal lamp "Monitoring" The signal lamp "Monitoring" is lit when:

■ an operating value has exceeded the monitoring limit.
■ a malfunction has occurred.
■ the interlock unit has been interrupted.
If the signal lamp "Monitoring" is lit, a message is displayed. The
message contains information about cause and measures to
eliminate the problem.
Laser warning lamp The laser warning lamp is lit when:

■ laser light is emitted at the processing point.
■ the laser is ready for emitting laser light, even if no laser
light is emitted at the processing point yet ("laser on" status).
20-10-02-A3-CR02 2012-10 Operating elements and indicators 4‐3

Key-operated switch
0 0
I
WS-00016
A B
Fig. 4-2
Activation of the laser by an unauthorized person can be preven-

ted by means of the key-operated switch. To do so, turn the key
to the position 0 (chart A) and be withdrawn.
The key has to be inserted for operation. The key-operated
switch has to be turned to the right.
Main switch The main switch has 2 positions: ON and OFF.

For switching on the laser device, the main switch must be
brought to position ON
For switching off the laser device, the main switch must be
brought to position OFF
In position OFF:
■ the main switch seperates the laser device from the mains.
■ the mains switch can be protected against unauthorized
switching-on by means of padlocks.
Before maintenance and repair work, always protect the main
switch against unauthorized switching on.
Exceptions are admissible, if:

■ instructed persons or skilled electricians are in charge
and
■ the work cannot be carried out when the laser device is
switched off.
4‐4 Case 2012-10 20-10-02-A3-CR02

1.2 Operating panel
1
3
RP-00002
1 Touch screen 3 CONTROL ON button 5 Turn-and-push button
2 EMERGENCY STOP pushbutton 4 CONTROL OFF button
Fig. 4-3
Touch screen Touch screen means more or less: "a screen that you can
touch". The screen of the operating panel reacts to finger pres-
sure. Software functions, buttons and fields are selected by
touching the respective point on the user interface with the fin-
ger.
If the Operating panel is not connected, the EMERGENCY

WARNING STOP functions of the operating panel are inactive!
Ø Remove the unconnected Operating panel from the working
area or cover it.
EMERGENCY STOP The laser and the cooling unit are immediately switched off when
pushbutton the pushbutton EMERGENCY STOP is pressed. In particular, no
more laser light is emitted.
The EMERGENCY STOP pushbutton can be integrated in the
Emergency Stop circuit of a system. With this pushbutton, the
entire system can be cut off. More information can be found in
the interface description EMERGENCY STOP.
CONTROL ON button With the CONTROL ON button, the laser is switched on.
CONTROL OFF button With the CONTROL OFF button, the laser is switched off.
Turn-and-push button It is possible to operate the device using the turn-and-push-but-

ton or the touch screen.

Turning to the right or to the left causes depending on the situa-
tion:
■ the marking of positions in lists or tables.
■ the setting of numerical values in input fields.
Pressing the turn-and-push button causes:

■ the selection or activation of the marked element on the user
interface.
Alternatively, a panel PC is available. In this case, the CON-

TROL ON and the CONTROL OFF button and the EMER-
GENCY STOP push button are located on the control panel. Fur-
ther information can be obtained from TRUMPF upon request.
4‐6 Operating panel 2012-10 20-10-02-A3-CR02

2. Switching the laser device on and off
2.1 Switching on by means of the

operating panel
Condition
■ The following lines and cables are connected:
− electrical mains connection
− External cooling circuit.
− Laser light cable.
− control lines between Operating panel and the laser
device.
− control lines to periphery, if applicable.
1. To activate the external cooling unit, if existing: Open valves

in the inflow and return line of the external cooling circuit.
2. If a chiller is used: switch it on.
3. Turn the key-operated switch into position I.
4. Turn main switch of the laser device to the ON position.
5. Press the button CONTROL ON on the operating panel.
The signal lamp "Mains on" is lit and the operating panel is
switched on.
The laser device has been turned on.
2.2 Switching on by means of the panel

computer and the operating panel
(option)
Condition
■ The following lines and cables are connected:
− electrical mains connection
− External cooling circuit.
− Laser light cable.
− control lines between panel computer and laser device.
− control lines to periphery, if applicable.
1. To activate the external cooling unit: Open valves in the

inflow and return line of the external cooling circuit.
2. If a chiller is used: switch it on.
3. Turn the key-operated switch into position I.
20-10-02-A3-CR02 2012-10 Switching the laser device on and off 4‐7

4. Turn main switch of the laser device to the ON position.
The signal lamp "Mains on" lights up.
Control panel, ON button Fig. 4-4

5. Press ON at the control panel.
The control unit of the laser device is switched on. Running
noises of the laser device can be heard.
6. Switch the panel computer on.
After a few seconds the main screen of the TruControl 1000
program appears.
The laser device has been turned on.
Tip
If the laser device is operated without control panel, the ”Control
system on" signal has to be generated from an external control
unit. More information can be found in the interface description
EMERGENCY STOP.
2.3 Switching off in case of malfunction

and emergencies
Ø Press EMERGENCY STOP pushbutton at the operating

panel or at the front of the laser device.
Laser and cooling unit of the laser device is switched off. No
laser light in particular can be emitted after the EMER-
GENCY OFF button has been operated.
The control unit of the laser device remains switched on.
4‐8 Switching the laser device on and off 2012-10 20-10-02-A3-CR02

2.4 Switching on after E-Stop
1. Turn the pressed E-Stop push button into arrow direction.

The push-button is unlocked. Functions of the laser device
that are switched off, are switched again to readiness.
2. Pay attention to the monitoring and fault messages.
3. Eliminate the cause of faults (see chapter "Conduct in case
of service interruptions").
4. Select manual operation in TruControl 1000 and select the
button Reset.
The control is reset to the basic state.
The laser device is again ready for operation.
2.5 Switching off after work completion

by means of the operating panel
Note
You must proceed in the indicated order as otherwise software
and hardware damage may occur in the control unit of the laser
device.
RP-00102
Switching off the operating panel Fig. 4-5
1. Press the button CONTROL OFF on the operating panel.

The operating panel and the control unit are switched off.
2. Turn the main switch of the laser device to the OFF position.
20-10-02-A3-CR02 2012-10 Switching the laser device on and off 4‐9

3. If the laser device must be protected against unauthorized
use: Turn the key-operated switch to the left and remove the
key.
The laser device is switched off.
2.6 Switching off after work completion

by means of the panel computer and
the control panel (option)
Note
You must proceed in the indicated order as otherwise software
and hardware damage may occur in the control unit of the laser
device.
Switching the laser device

off
Fig. 4-6
1. Press the OFF button at the control panel.

After approx. 8 seconds the control system of the laser
device and the control panel switch off.
2. Turn the main switch of the laser device to the OFF position.
3. If the laser device must be protected against unauthorized
use: Turn the key-operated switch to the left and remove the
key.
4. Switch the panel computer off.
The laser device has been switched off.
4‐10 Switching the laser device on and off 2012-10 20-10-02-A3-CR02

3. Operating the laser device using
TruControl 1000
This section informs you on the most important functions of the

program TruControl 1000 for the control of the laser device.
The software manual TruControl 1000 contains further informa-
tion.
3.1 Selecting light path
The optical arrangement of the laser device mostly permits

selection between several laser light cables through which the
laser light can be conducted to the machining point. The light
path which the laser beam is to take can be selected in TruCon-
trol 1000.
The light path can be selected for each parameter set. The light
path and the pulse shapes are determined during the program-
ming stage.
Select the light path in the parameter set
1. Select main activity Man. operation.

2. Select the Pulse data tab.
3. Open the parameter set with .
20-10-02-A3-CR02 2012-10 Operating the laser device using TruControl 1000 4‐11
RP-00322
Fig. 4-7
4. Selecting light path.
The selection list is closed. The selection field shows the name
of the chosen light path.
The laser beam is transmitted through the chosen light path
when the laser is activated next time.
4‐12 Selecting light path 2012-10 20-10-02-A3-CR02

Change the light path name
Condition
■ User level ≥ 60
1
2
5 7
RP-00264
Fig. 4-8
1. Select main activity Technology. (1-2)

The Light path tab is opened.
2. Mark the light path. (3)
3. Select Change .(4)
The Edit light path dialog appears.
4. Select the Change namebutton.(5)
The soft keyboard appears.
5. Enter name and select the button Finish. (6)
6. SelectSave .(7)
The name of the light path has been changed.
20-10-02-A3-CR02 2012-10 Selecting light path 4‐13

3.2 Activating and deactivating the laser
Switching the laser on and off
Conditions
■ The laser device has been turned on.
■ The Laser button on the touch screen of the operating panel
is active.
■ There is no active fault message.
■ The parameter set or the laser program has been selected.

2. Select the Laser program tab.
or
Ø Select the Pulse data tab.
3. Select the parameter set or laser program with .
4. Select Laser .
The pump diode in the supply unit sends pump light to the
laser head through the pump light cable.

Ø Do not reach between focusing optics and workpiece.
Ø Wear safety goggles suitable for the wavelength of the laser
light (see notice signs).
5. Select Release.
The Trigger button changes its color from gray to yellow.
With the Trigger button, a laser program or parameter set is
started. With the central shutter closed, the laser beam is
guided into the absorber. With the central shutter open, laser
light is emitted at the processing point.
The central shutter in a laser program is controlled by the
laser program. In a parameter set, the central shutter must
be closed using the Shutter button. The Trigger button cau-
ses the generation of laser light or the start of a laser pro-
gram.
6. Select Stop.
The Stop button changes its color from yellow to grey.
4‐14 Activating and deactivating the laser 2012-10 20-10-02-A3-CR02

An operating mode without defined end (e.g. continuous
pulse, pulse train or endless loop in the laser program) is
correctly completed.
An operating mode with defined end (laser program or pulse
train) is interrupted. In this case, the monitoring message
"Program interrupted with Stop" appears. It can be deleted
with Reset .
Open or close the central shutter (VZ) in

the parameter set
The central shutter is opened or closed:

■ by means of corresponding commands in the laser programs.
■ with the Shutter button.
Note
The central shutter in the laser program is controlled by the laser
program.

Ø Do not reach between focusing optics and workpiece.
Ø Wear safety goggles suitable for the wavelength of the laser
light (see notice signs).

2. Select the Pulse data tab.
3. Select Shutter.
The Shutter button changes its color from grey to yellow.
With the central shutter (VZ) open, laser light can be trans-
mitted to the optical components via the selected light path.
4. Select Shutter.
The Shutter button changes its color from yellow to grey. No
laser light can be emitted from the laser device.
3.3 Responding to messages
The control unit monitors numerous operational values of your

laser device.
20-10-02-A3-CR02 2012-10 Responding to messages 4‐15

If an operational value reaches the monitoring or fault limit, the
icon for monitoring or fault message is displayed in the status
line of the user interface.
Symbol Meaning
Symbol for fault message
Symbol for monitoring message
Tab. 4-1
The message line displays the message code and the short text
of the message.
1 Symbol of the message 3 Message code and short text

2 Message line
Fig. 4-9
A fault message is displayed as soon as a monitored opera-

tional value leaves the permissible range and thus causes a crit-
ical condition.
The laser is deactivated if a fault message is displayed. It can-
not be switched on again until the cause for the critical condition
has been eliminated.
For further information about messages, please refer to chapter
"Conduct in case of service interruptions" and the software man-
ual TruControl 1000.
Resetting the message
Fault and monitoring messages can be reset with the Reset but-
ton. In case of a fault message, the fault must be eliminated
before resetting the message. If fault messages are active, the
reset starts an initialization of the control. This means: Switch-on
and test sequences are carried out until the laser device is ready
again.
Either
Ø Select the main activity Diagnostics.
Ø Select the message history with .
Ø Select Reset.
4‐16 Responding to messages 2012-10 20-10-02-A3-CR02

or
Ø Select title bar.
Ø Select the >Message tab.
Ø Press Reset to reset the fault message.
The message is reset.
3.4 Generating pulse shapes
The laser device can create any pulse shapes. A pulse shape
editor is integrated in TruControl 1000. Pulse shapes are cre-
ated, modified and managed with it.
4
2
3
AW-00029EN
1 Title bar 3 Context bar 4 Pulse shape diagram

2 Pulse data table
Pulse shape editor Fig. 4-10
The power points of the pulse shape can be entered graphically

or via a table.
Pulse shapes can:

■ be integrated in parameter sets and in laser programs.
■ be statical or scalable.
■ be taken over as reference or as copy in a parameter set.
20-10-02-A3-CR02 2012-10 Generating pulse shapes 4‐17

■ taken over as reference or as copy into a laser program.
■ be saved as templates
Information on pulse shapes and on the operation of the pulse
shape editor is to be found in the software manual TruCon-
trol 1000.
3.5 Creating laser programs
A laser program is a sequence of commands and settings which

are carried out automatically after starting.
A laser program editor is integrated in TruControl 1000. Laser
programs are created, modified and managed with it.
Laser programs can be called up:

■ by manual operation.
■ externally via a interface of the laser device.
Fig. 4-11
Laser programs consist of program lines.

Information on the operation of the laser program editor is con-
tained in the software manual TruControl 1000.
4‐18 Creating laser programs 2012-10 20-10-02-A3-CR02

3.6 Programming light paths
In connection with light paths, the following actions are possible

under TruControl 1000:
■ Programming light paths
■ Editing light path names (see software manual TruControl
1000)
■ Selecting light paths (see software manual TruControl 1000).
■ Managing light paths (see software manual TruControl 1000).
Definitions Programming a light path means:

■ Defining the position of switch mirrors and shutter mirrors in
the optical arrangement.
■ Storing the information on mirror positions in a data record
for the light path.
TRUMPF has already programmed all possible light paths for the
optical arrangement of your laser device. Each light path leads
through a laser light cable to a processing point. Two or more
laser light cables may belong to one light path when optical split-
ters are used.
Editing light path names Every light path can be given a user name.
Please refer to the software manual TruControl 1000 for further
information on authorization and processing.
Programming light paths Programming light paths should be done exclusively by the
TRUMPF service technicians (from user level 70). This is only
necessary if the optical arrangement of the laser device was
changed in such a way that other light paths become possible or
previous light paths are no longer possible.
3.7 Pilot laser (option)
A pilot laser is optionally provided in the laser device and sends

visible, red light with low power through the beam guideway.
This allows you to observe the light path and operations at the
processing point. When the pilot laser is switched on, the sym-
bol for the pilot laser is displayed in the message line.
Fig. 4-12
20-10-02-A3-CR02 2012-10 Programming light paths 4‐19

Switching on pilot laser When the pilot laser is switched on, is determined:
■ by the pilot laser mode set in the system settings.
■ by the shutter switch state (shutter switch closed or open).
■ by the state of the safety circuit (safety circuit interrupted or
closed).
Switching the switching functions of pilot

laser on and off
If the switching functions of the pilot laser are switched on or off

by TruControl 1000, the pilot laser are switched on or off for all
existing light paths. The pilot laser can be switched on or off for
individual light paths in the light path overview (see "Switching
the pilot laser in the light path on and off", pg. 4‐22).
1. Select main activity Set-up.

2. Use to select Switching functions.
3. Checkmark the box for switching the pilot laser.
The pilot laser is active. Remove the checkmark to switch the
pilot laser off.
Setting the pilot laser mode
Condition
■ User level ≥ 10
Note
The pilot laser is switched off irrespective of the set pilot laser
mode if the single channel safety circuit (ASV3, connector X24)
is used for internal functions (for ex. protection of the laser light
cables in the user's compartment) AND if the single channel
safety circuit is interrupted.
4‐20 Pilot laser (option) 2012-10 20-10-02-A3-CR02

Fig. 4-13
1. Select main activity Set-up. (1-2)

2. Open the system settings with . (3-4)
3. Mark the signal "PilotLaserMode". (5)
4. Select Change .(6)
5. Select the mode. (7)
The following table describes the modes in the system set-
tings.
Mode Meaning
0 Pilot laser constantly off.
1 Pilot laser is switched on if the shutter switch is closed.
2 The pilot laser is switched on if the safety circuit is interrupted.
3 The pilot laser is active, when
■ its switching functions are activated (see "Switching func-
tions of the pilot laser are switched on and off")
OR
■ External signal PILOT_LASER_ON is set.
■ AND
shutter switch is closed.
20-10-02-A3-CR02 2012-10 Pilot laser (option) 4‐21

Mode Meaning
OR
■ AND
the safety circuit is interrupted.
OR
Boun- The pilot laser is switched off irrespective of the set pilot laser
dary mode:
condi- ■ if the single channel safety circuit (ASV3, connector X24) is
tion
used for internal functions (for ex. protection of the laser
light cables in the user's compartment)
AND
if the single channel safety circuit is interrupted.
Tab. 4-2
6. Select Apply.
The pilot laser mode has been set.
Switching the pilot laser in the light path

on and off
In the light path overview, the user can switch the pilot laser for
the individual light paths on and off.
Note
If the connector at the X24 of the ASV board is used for internal
functions (for ex. protection of the laser light cables in the user's
compartment), the pilot laser is switched off as soon as the one-
channel safety circuit is interrupted irrespective of the adjusted
pilot mode.

1
Fig. 4-14
1. Select main activity Production. (1-2)

2. Open the light path overview with . (3-4)
3. Select the button for the pilot laser in the Pilot column of the
desired light path. (5)
The Overview - pilot laser dialog is displayed.
Dialog overview - Pilot laser Fig. 4-15
4. Switch on the pilot laser in the respective light path with .
20-10-02-A3-CR02 2012-10 Pilot laser (option) 4‐23

or
Ø Switch off the pilot laser in the respective light path with
.

4. External control of the laser device
4.1 TRUMPF LaserNetwork (option)
Optionally, the laser device can be equipped with TRUMPF

LaserNetwork (TLN) components.
Components of the TRUMPF LaserNetwork (TLN) are:

■ Multi-PLC Interface (MPI)
■ Interface LaserNetwork (ILN)
■ Ethernet
MPI The Multi PLC Interface is a software interface of the laser

device for exchanging control signals with a maximum of 32
external control units. The external control units are connected
with the laser device through field bus components.
MPI can be used efficiently if the laser power of a laser device
has to be requested by various control units.
ILN The interface LaserNetwork contains signal lines for:

■ light path coding.
■ two-channel safety circuits.
Ethernet The laser device can be connected to other devices in a local

network (LAN) via Ethernet.
Detailed information can be found in the Technical Information
TRUMPF LaserNetwork and other documents available from
TRUMPF.
20-10-02-A3-CR02 2012-10 External control of the laser device 4‐25

4‐26 TRUMPF LaserNetwork (option) 2012-10 20-10-02-A3-CR02
Chapter 5
Maintaining the laser device
2 Material 5‐5
2.1 Wearing parts 5‐5
2.2 Cooling water additives 5‐5
2.3 Tools and auxiliaries 5‐5
Blow-out device 5‐7
Compressed air quality class 2 according 5‐7
to DIN ISO 8573-1
2.4 Consumables 5‐8
2.5 Disposal 5‐8
3 Opening and closing the laser device 5‐9

3.1 Opening and closing doors 5‐9
3.2 Remove covers 5‐9
3.3 Open and close hood 5‐10
3.4 Open the hood to the user's compartment 5‐11
20-10-02-A3-CR02 2012-10 Maintaining the laser device 5‐1

4 Hose connections 5‐12
4.1 Connecting the hose 5‐12
4.2 Disconnecting the hose 5‐12
5 Removing the securing device from the 5‐13

stop valve
6 Maintenance list 5‐14
7 Laser 5‐16
7.1 Identifying the pump module 5‐16
7.2 Replacing the pump module 5‐18

8.1 Dismounting and Mounting of Laser Light 5‐26
Cable
Removing LLK-D 5‐27
Removing an LLK-B 5‐51
8.2 Maintaining laser light cable 5‐57
Cleaning the protective sleeve along with 5‐57
Replacing the protection bushing with pro- 5‐58
tective glass at the LLK-D
Clean protective sleeve along with cover 5‐60
slide on LLK-B
Replacing the protective sleeve along with 5‐61

9.1 Replacing the diode power supply 5‐63

10.1 Topping up cooling water 5‐69
10.2 Cleaning the cooling circuit 5‐70
Cleaning procedure and change of cool- 5‐72
ing water
10.3 Replacing filter element in the fine filter 5‐84
10.4 Cleaning the contamination filter 5‐86
10.5 Checking the cooling unit for tightness 5‐89
5‐2 Maintaining the laser device 2012-10 20-10-02-A3-CR02

10.6 Emptying and filling the cooling unit 5‐90
Emptying the cooling unit of the laser 5‐90
device
Filling the cooling unit 5‐99

11.1 Completely replacing the air cleaner 5‐107
11.2 Replace the filter cartridge for water separa- 5‐108
tor and microfilter
11.3 Filter cartridge in the intake filter 5‐109
11.4 Replacing filter cartridge in the activated car- 5‐111
bon filter
11.5 Changing the filter mat 5‐113
12 Electrical system 5‐114

12.1 Identifying blown electrical fuses 5‐114
12.2 Replacing a microfuse 5‐116
12.3 Switch on Circuit breaker 5‐117

13.1 Clean the screen of the operating panel 5‐118
20-10-02-A3-CR02 2012-10 Maintaining the laser device 5‐3

1. General notes
The correct maintenance is an important condition for a faultless

operation of the laser device and for the quality of the working
result.
The laser device requires little maintenance. All important func-
tions are electronically monitored. A monitoring message, which
is indicated by the laser device, can call for maintenance work.
Check regularly the condition of your laser device. Carry out
maintenance work as a precautionary measure when you detect
signs of wear or dirt.
Check regularly the laser light cable for damaged sheath. The
laser light cable must be replaced in case of a damaged sheath.
While carrying out maintenance work on the laser device

DANGER you can come into contact with parts which are dangerous
to persons or property.
Improper or incautious procedures can cause injuries or
damage to property.
Ø Maintenance work may be carried out only by instructed per-
sons.
Ø Any work on the electrical equipment must be carried out
only by a trained electrician.
Ø You must observe the warning instructions of these mainte-
nance instructions.
Ø Before starting maintenance work, switch off the laser
device.
Note
The laser device must be switched on during maintenance work
only if it is necessary for maintenance or control purposes. You
will be informed about this in the corresponding passages of this
manual.
Assistance in case of Contact the TRUMPF service department, if there are any prob-
problems lems you cannot resolve. The service address can be found at
the beginning of the operating instructions.
5‐4 General notes 2012-10 20-10-02-A3-CR02

2. Material
2.1 Wearing parts
Subas- Designation Material Recommended

sembly no. stock
Cooling Filter in the tank 1224876 1
unit
Filter element in the 1464769 1
fine filter
Spare sieve for con- 1445470 1
tamination filter.
Air Air cleaner, complete 1453560 1
cleaner
Filter fleece at the cab- 0991551 1
inet
Electrics Fuse set 1510403 1
Tab. 5-1
2.2 Cooling water additives
Country Easy-Kit Cu-3, material no.

Standard 1653112
USA (US) 1653113
Canada (CA) 1653114
Belgium (BE) 1653119
Netherlands (NL) 1653120
Tab. 5-2
The Easy-Kit is available in 5 different country-specific versions

(USA (US), Canada (CA), Belgium (BE), Netherlands (NL) and
Standard for all other countries), because the included cleaning
biocide differs from country to country.
2.3 Tools and auxiliaries
Symbol Designation Dimensions, further specifications

Double-bit key for opening the doors and the hoods
Slotted screw driver 2.5 mm, 3 mm
20-10-02-A3-CR02 2012-10 Material 5‐5

Symbol Designation Dimensions, further specifications
Crosstip screw driver PH1, PH 2
Hexagon screwdriver 4 mm, 5 mm
Torx screwdriver T25
Torque screwdriver 250 Ncm

to tighten the protection sleeve with
cover slide
Material no.: 1533390
Fork wrench 9 mm, 19 mm, 30 mm
Pan for cooling water
Cleaning accessories for TruDisk for emptying the laser circuit

Cloth for wiping up spilled water
Safety gloves rubber, to be worn when handling

deionized water
Cleaning brush soft bristles
clean water jug from plastic for filling the tank of the laser cooler
Cleaning set for optical compo- tools and material for cleaning work
nents on optical components
Tools and auxiliaries for maintenance work Tab. 5-3
5‐6 Tools and auxiliaries 2012-10 20-10-02-A3-CR02

Blow-out device
Fig. 5-1
Aid to blow the DI-water out of:

■ the plugs of the laser light cable
■ the pump module.
The blow out equipment can be purchased as an option from
TRUMPF Material no.: 1367022.
Quality of the supplied Substance of con- Class according to Limit value

compressed air when using tents DIN ISO 8573-1
the blow-out device Dust 3 Particle size : < 5 µm
Particle density: < 500
per m3
Pressure dew point 3 -20 °C
Oil 3 < 1 mg/m³
Tab. 5-4
Pressure: max. 6 bar
Compressed air quality class 2 according

to DIN ISO 8573-1
Particles Water Oil

Max. particle size Max. particle density Pressure dew point Residual oil content
5 μm 100 pro m3 -40 °C 0.1 mg/m3
Compressed air quality class 2 according to DIN ISO 8573-1 Tab. 5-5
20-10-02-A3-CR02 2012-10 Tools and auxiliaries 5‐7

2.4 Consumables
For maintenance work on your laser device you need the follow-
ing extras:
■ Lens cleaning paper (obtainable from photo shops) or cotton
wool for cleaning optical glasses.
■ Deionized water (DI water) as cooling water for the internal
laser cooler circuit. The required quantity is indicated. For the
extraction of DI water, water of drinking water quality must
be used.
■ Tap water as cleaning agent for filter inserts.
■ Use compressed-air only for blowing out the filter inserts.
■ Methanol as cleaning agent for optical glasses.
Methanol is inflammable and toxic when you inhale or

CAUTION swallow it.
Ø Keep methanol away from fire and other ignition sources.
Ø Do not smoke.
Ø Ensure sufficient fresh air supply.
Ø Do not inhale methanol vapor.
2.5 Disposal
Some maintenance work will produce waste material that must

be disposed of. Instructions for an appropriate disposal are given
in the corresponding passages.
The instructions for disposal of waste material are recommenda-
tions, derived from regulations applied at place and time when
these operating instructions have been prepared. As operator of
the laser device, however, you are obliged to inform yourself
about the regulations concerning waste disposal and to observe
these regulations.
Unless the regulations applicable do no stipulate otherwise, the
waste material is to be disposed of as follows:
Protective sleeve with cover Refuse.

slide
Seals, O-Rings Refuse.
Lens cleaning paper Refuse.
Cooling water without addi- Sewerage system.
tives
Filter material Refuse.
Electric fuses Refuse.
Tab. 5-6
5‐8 Consumables 2012-10 20-10-02-A3-CR02

3. Opening and closing the laser device
Dangerous electric voltage in the interior of the laser

DANGER device!
gized.
3.1 Opening and closing doors
Fig. 5-2
3.2 Remove covers
2.
1.
Fig. 5-3
20-10-02-A3-CR02 2012-10 Opening and closing the laser device 5‐9

Note
Side walls and back walls are connected with the laser device
through a grounding cable. When removing or inserting side wall
and back walls please pay attention to grounding cable.
3.3 Open and close hood
Pinch points at edges of hood and device frame, especially

WARNING on left and right side of the laser device.
Hand bones may be broken.
Ø Do not close the hood until you are sure that no other per-
son has his/her hands on the squeezing point.
Fig. 5-4
5‐10 Open and close hood 2012-10 20-10-02-A3-CR02

3.4 Open the hood to the user's
compartment
DW-81083
Fig. 5-5
20-10-02-A3-CR02 2012-10 Open the hood to the user's compartment 5‐11

4. Hose connections
4.1 Connecting the hose
Fig. 5-6
1. Slide the hose into the coupling.

2. After first making contact, push the hose into the coupling as
far as possible.
The hose is permanently connected to the hose coupling.
4.2 Disconnecting the hose
1.
2.
1.
Fig. 5-7
1. Press the hose coupling ring in direction of the hose cou-

pling.
The hose coupling lock is unlocked.
2. Pull the hose out of the hose coupling.
5‐12 Hose connections 2012-10 20-10-02-A3-CR02

5. Removing the securing device from
the stop valve
The stop valves are secured against unintentional opening with a

nut retention.
1.
3.
2.
Fig. 5-8
20-10-02-A3-CR02 2012-10 Removing the securing device from the stop valve 5‐13
6. Maintenance list
Maintenance work must be carried out cyclically or if a message

has occurred. In the following table, the required maintenance
works are listed.
Component Measure Interval News release

Laser
Pump module Replacing the ■ None Pump module
pump module ■ A pump mod- failed
ule has
failed.
■ A pump mod-
ule produces
insufficient
pump light.
Laser light cable (LLK)
LLK Mounting and ■ None Fault of a laser
dismounting ■ With visible light cable
damages
Protective Clean or change ■ None None
sleeve with ■ When mount-
cover slide ing the laser
light cable
■ With too low
power on the
workpiece
Laser cooling unit
Tank Topping up DI None Tank level too
water low
Clean if there Every year None
are deposits
Laser circuit Cleaning of the Every year Service dialog
laser circuit
Fine filter Replace None Flow rate too
low
Contamination Clean or change Depends on the Temperature in
filter water quality the laser device
too high
All components Check for leaks After mainte- None
with cooling nance or repair
water work
Cooling Fill for operation None None
Drain for trans-
port and storage
Air cleaner
Shipping brace Mount for trans- None None
port
Dismount for
operation
For the laser devices TruDisk 2002, TruDisk 2004, TruDisk 2602,
TruDisk 3302, TruDisk 3306, TruDisk 4002, TruDisk 4006, the follow-
ing is valid:
5‐14 Maintenance list 2012-10 20-10-02-A3-CR02

Component Measure Interval News release
Air cleaner, Replace Every 20,000 h None
complete
Filter fleece on Replace Every 20,000 h None
the right of the
cabinet
For the laser devices TruDisk 2001, TruDisk 2501, TruDisk 3001, the
following is valid:
Air cleaner, Replace Every 10,000 h None
complete
Filter cartridge Replace Every 5,000 h None
in water separa-
tor and prefilter
in the micro fil-
ter
Filter cartridge Replace Every 5,000 h Replacing the
in active carbon activated carbon
filter filter
in intake filter
Filter fleece on Replace Every 5,000 h None
the right of the
cabinet
Electrical system
Mains distribu- Replacing a None None
tion fuse
Operating panel
Screen Cleaning If soiled: none
Maintenance list Tab. 5-7
20-10-02-A3-CR02 2012-10 Maintenance list 5‐15

7. Laser
A pump unit which generates pumped light for excitation of the

laser is assigned to each cavity of the laser device.
Depending of the nominal power of the laser device, it is possi-
ble that not all locations on the pump unit are equipped with
pump modules. Instead of pump modules, there are dummy
modules inserted in the locations. You can easily recognize the
dummies since there are no cooling water hoses connected to
them.
Failure There are the following reasons for replacing pump modules:
■ A pump module has failed.
In this case, a fault message is displayed that specifies the
failed pump module.
The failed pump module is electrically bridged. Then you can
operate the laser device for a certain time. Replace the failed
pump module before expiry of the indicated time period. If
this time is over, the operation of the laser device can only
be continued after replacement of the failed pump module.
■ The pump light of a pump module is too low (for ex. reduced
performance at the end of service life). It is also possible that
several pump modules must be replaced due to aging.
This may be the case when a message is repeatedly dis-
played: "Controller action too high"
Qualification Pump modules may only be replaced by instructed persons.

Contact the TRUMPF Service Department, if you need further
information on this.
Order You must proceed in the indicated order.
7.1 Identifying the pump module
Before replacing a pump module, the pump module which has

failed or has become aged must be identified.
If a pump module has failed , a message is displayed on the
screen indicating the pump module which has failed. A failed
pump module can also be identified with the help of the operat-
ing software.
In general, an aged pump module is more difficult to identify.
The operator, depending on his training and experience, decides
which pump module must be replaced. A skilled user can iden-
tify the current performance data of the pump modules from the
diagnosis pages of the operating software.
5‐16 Laser 2012-10 20-10-02-A3-CR02

Condition
■ The laser device including the laser control must be switched
on.
Identifying the failed pump 1. Select the main activity >Maintenance & Commissioning in
module the operating software.
TruControl 1000, List of maintenance work Fig. 5-9
The list of maintenance work is displayed.

2. Select >Pump modulein the list of the maintenance work.
3. Select the Details button.
Display of bridged pump modules (example) Fig. 5-10
The pump module bridging circuit dialog appears. A failed

pump module is marked with a red square (in the example:
pump module 3).
20-10-02-A3-CR02 2012-10 Laser 5‐17

Identifying the failed pump Note
module
In the background, the software of the laser device checks
permanently the condition of the pump modules. If a pump
module malfunction is detected, a message appears. The
message indicates the aged pump module which has been
detected.
If there are often messages indicating a high controller
action, this may be an indication of aged pump modules. In
this case, the diagnosis pages of the software have to be
evaluated to define the condition of the pump modules.
If you, as the user, are trained in the evaluation of the diag-
nosis pages, you can identify an aged pump module. Other-
wise, contact the TRUMPF Service Department.
4. Identify the failed pump module in the service dialog.
or
Ø Inform the TRUMPF service department.
The service department can determine a failed pump module
with the help of the telepresence.
5. Replace the pump module as described below (see "Replac-
ing the pump module", pg. 5‐18) as soon as a failed pump
module has been identified.
7.2 Replacing the pump module
Conditions
■ The laser device is connected to the mains, main switch in
position ON. The laser control can be switched on.
■ The ambient air is oil- and dust-free.
■ The pump modules to be replaced are identified (see "Identi-
fying the pump module", pg. 5‐16)

■ Spare pump module, Material no.: 1485410
■ Hexagon screwdriver: 3.0 mm
■ Absorbent cloth to wipe up drained cooling water.
■ Blow-out gun for compressed air.
■ The compressed air must fulfill the following requirements:
− Pressure: < 6 bar.
− Compressed air quality class 2 according to DIN ISO
8573-1 (see "Tab. 5-5", pg. 5‐7),
or
5‐18 Laser 2012-10 20-10-02-A3-CR02

■ Blow-out device and compressed air according to com-
pressed air quality class 3 to DIN ISO 8573-1 (see "Blow-out
device", pg. 5‐7).
Preparing the laser device 1. Press OFF key on the operating unit.
Tip
If you use a panel PC or another PC instead of an operating
panel of TRUMPF, the OFF button is located on the control
panel where also the EMERGENCY STOP button is placed.
2. Switch off the control.
3. Turn the key-operated switch to position 0.
Fig. 5-11
4. Open the hood of the laser device.
5. Take the spare pump module out of the transport box for
pump modules.
6. Place the replacement pump module in the package on a
clean surface.
The pump module to be replaced can be removed now.
20-10-02-A3-CR02 2012-10 Laser 5‐19

Removing the pump module
Pump unit with pump modules PM 1 .. PM 6 Fig. 5-12
Note
Do not remove the pump module from the pump unit for a
period longer than necessary. Thus, work quickly and close
the available opening of the pump unit in case of interrup-
tions.
The pump modules are sensitive to electrostatic discharge

CAUTION (ESD)!
The pump modules can be destroyed: considerable damage
to property.
Ø Do not touch the contacts located on the mounting side of
the pump module.
Ø Avoid electrostatic charging, e.g. by grounding or suitable
clothing.
5‐20 Laser 2012-10 20-10-02-A3-CR02

The pump modules and pump unit contain sensitive optical
CAUTION components!
If the optical components are soiled, it can cause damage
to the pump modules or the pump unit: considerable
damage to property.
Ø Handle the pump module in clean surroundings only.
Ø Do not touch the laser exit opening.
Ø Avoid soiling of the pump unit.
Fig. 5-13
7. Pull the plug.
Note
It is possible that some water comes out during the next
working step.
8. Disconnect the cooling water hoses.
Tip
Press the ring on the hose connection towards the module.
Then press the hose slightly into the module. Afterwards it
can be pulled out easily.
9. Wipe up leaking cooling water.
10. Loosen both screws on the connection side of the pump
module.
11. Remove the pump module and place it on a clean surface.
20-10-02-A3-CR02 2012-10 Laser 5‐21

Fig. 5-14
12. Take the replacement pump module carefully out of the
packaging and place it near the removed pump module.
Remove the replacement

pump module from the
transport protection
Pump module with transport protection Fig. 5-15

13. Loosen the fastening screws.
Mounting the replacement 14. Remove the pump module from the transport protection
pump module
5‐22 Laser 2012-10 20-10-02-A3-CR02

180°
Placing the pump module, guide pin Fig. 5-16

15. Place the pump module in the correct position on the pump
unit
Tip
The pump modules PM 2, PM 4 and PM 6 are mounted rota-
ted by 180° compared to the other pump modules. The
replacement pump module has the correct position if the
screws can be tightened. Otherwise the screws cannot be
tightened. If the screws cannot be tightened, rotate the pump
module by 180°.
Do not apply any force. If the pump module is placed in
the correct position, the mounting steps can be carried out
without applying any force.
16. Hold the pump module in mounting position against the car-
rier plate.
17. Screw in the screws one after another until they are fas-
tened tightly (do not tighten too strongly (approx. 1.5 Nm)).
The screw heads are flush with the surface.
The pump module must make contact with the carrier plate.
18. Remove the plugs from the cooling water connections of the
new pump module and insert them at the removed pump
unit.
19. Observe the flow direction of the cooling water when con-
necting the cooling water hoses. Do not interchange the
hoses! The hoses and connection are marked with colors.
Press the hoses into the connections on the pump module
as far as they will go.
20. Connect the electric plug.
Protecting the removed 21. Place the removed pump module on the transport protection
pump module and fasten the screws. For this purpose slightly tighten the
screws.
20-10-02-A3-CR02 2012-10 Laser 5‐23

Check for impermeability
DW-81080
Visual check for tightness Fig. 5-17
22. Check whether the pump module has contact to the marked
area (see arrows) of the carrier plate.
Pump module has no contact to the carrier plate? Rea-
sons for this can be a soiled sealing surface or the
screws are not tightened.
Ø Loosen the screws and remove the pump module.

Ø Check whether the sealing surfaces on the pump module
and on the pump unit are clean. Clean the sealing surfa-
ces, if necessary.
Ø Re-attach the pump module and tighten the screws
(approx. 1.5 Nm).
23. Switch on control unit.
Pump button Fig. 5-18

24. Briefly press the pump pushbutton several times, then for a
longer period.
The pump button is located in the user's compartment of the
laser device.
Cooling water will flow through the pump units.
5‐24 Laser 2012-10 20-10-02-A3-CR02

25. Check the connections of the replacement pump module for
leaks.
Seal the leaks, for example:
Ø Insert the cooling water hose deeper into the connection.

Ø Inform the service department of TRUMPF if you cannot
solve the problem yourself.
Making the laser device 26. Close the cover of the laser device.
ready for use 27. Turn the key-operated switch to position I.
The laser device is ready for use..
Dewatering the replaced

pump module
Loss of warranty in case of a not dewatered pump module!

CAUTION
If a dewatering is not done, the pump module may suffer
irreversible transport damage: considerable damage to
property.
Ø Dewater the pump module.
28. Remove the plug from the cooling water connections.

29. Blow through the cooling water connections of the pump
module for about 10 seconds using compressed air.
Required quality of the compressed air: see above (auxiliary
means, tools, materials)
Residual cooling water is blown out of the cooling water
channel of the pump module.
30. Seal the cooling water connections by means of the plugs of
the new pump unit.
Packing the removed pump 31. Pack the pump module with the transport protection in the
module enclosed bag.
32. Seal the bag.
33. Put the bag in the transport case.
Here the pump module is protected against mechanical
stresses and can be transported safely.
34. Send the pump module back to TRUMPF.
20-10-02-A3-CR02 2012-10 Laser 5‐25

8. Laser light cable
8.1 Dismounting and Mounting of Laser

Light Cable
A laser light cable must be removed and fitted:

■ if you want to transport the laser device.
■ if you want to replace a laser light cable by another one, e.g.
with different length.
Note
Laser light cables are optical precision parts, which are pro-
duced with maximum accuracy and with observance of the
utmost cleanliness. During the use of the laser light cables,
avoid contamination and mechanical stress (shocks, impacts) of
the optical plugs.
LLK-Ds must be removed or mounted by instructed persons

only.
In the following cases, modification of the software configuration

of the laser device is required when changing laser light cables:
■ If standard laser light cables with a fiber core diameter
≥ 200 µm are exchanged against fibrillated fiber laser light
cables < 200 µm.
■ If fibrillated fiber laser light cables with a fiber core diameter
< 200 µm are exchanged against standard laser light cables
≥ 200 µm.
⇒ Please contact the technical service of TRUMPF so that a
service technician can carry out the changes.
ILN available If laser device exits are equipped with the Interface
LaserNetwork (ILN) option, the following parts are additionally
built in:
■ LLK coding cable with clamps
■ ILN3
In this case, observe the sections marked with "ILN available".
ILN not available If the laser device exits are not equipped with the Interface
LaserNetwork option, skip the sections marked with “ILN availa-
ble”.

Removing LLK-D
Work steps
■ Preparation.
■ Disconnect the LLK-D from the laser side.
■ Loosen the LLK-D from the focusing optics.
■ Remove and wind up the LLK-D.
■ Final procedures.
Condition
■ If the exits of your laser device are equipped with the option
Interface LaserNetwork (ILN), the laser light cables can be
replaced during operation. If they are not equipped with ILN,
the laser device must be switched off and locked against
unintentional restart.

■ Two protective caps per removed laser light cable.
■ Connectors for each coupling optical unit from which a laser
light cable is removed.
■ Plugs for all openings at the focusing optics from which the
laser light cables are removed.
■ Hexagon screwdriver, 4 mm.
■ Blow-out device (see "Blow-out device", pg. 5‐7).
Preparation
DW-81083
Fig. 5-19
1. Open the hood to the user's compartment.
20-10-02-A3-CR02 2012-10 Dismounting and Mounting of Laser Light Cable 5‐27

1 Field bus cable (Option) 5 Bushings for further LLKs
2 LLK coding cable (Option) 6 Holder
3 LLK-D 7 Slotted sleeves
4 IFO cable
Fig. 5-20
2. Remove the support on the bushing from the LLK-D to be
replaced.
Now it is possible to disconnect the LLK-D from the laser
side.
5‐28 Dismounting and Mounting of Laser Light Cable 2012-10 20-10-02-A3-CR02

Disconnecting the LLK-D
from the laser side
1 Field bus cable 3 LLK coding cable 5 Monitoring plug

2 LLK-D 4 IFO cable 6 Hose coupling (2x)
Incoupling optics with LLK-D Fig. 5-21
3. Pull out the monitoring plug (5).

4. Disconnect both hose couplings (6).
5. Additionally, remove the following cables if the LLK-D is not
replaced but removed permanently.
− IFO cable (4)
− LLK coding cable(3)
− Field bus cable (1)

2.
1.
4. 3.
Fig. 5-22
6. Unscrew the securing connector.

7. Push the locking slide upward.
Notes
■ Do not tilt or turn the optical plug.
■ Never touch the light guide end or the glass body of the
protective sleeve with fingers.
■ Avoid dirt on the plug or the light guide.
■ Do not knock the plug against anything. The light guide
might break.
8. Press the securing ring towards the incoupling optics and
pull out the connector of the LLK-D.

Fig. 5-23
9. Put the protective cap on the LLK-D plug.
3.
4.
1.
2.
Fig. 5-24
10. Insert connector into opening of incoupling optics.

11. Push the locking slide downward.
12. Screw in the securing connector.
ILN available Note

LLK-D and LLK coding cable must always be installed
together in order to avoid mistakes.
LLK-D and LLK coding cable must be connected by mechan-
ical means. For this purpose, TRUMPF delivers the cables
together with clamps.
1 Clamp 2 Screw
Fig. 5-25
13. Loosen the screw (2) of the clamp (1).
The LLK-D is disconnected from the laser side.

Loosen the LLK-D from the Note
focusing optics
If the focusing optics is fitted on a swivelable mount, it
should be brought to a possibly horizontal position for the fol-
lowing activities. So it is prevented that dirt gets to optical
components which are temporarily exposed when detaching
the connections.
Fig. 5-26
14. Remove the cooling water hose to the focusing optics.
1.
2. 3.
Fig. 5-27
15. Press down the locking pin, press the slide collar towards
the focusing optics and pull out the plug. Ensure that you will
not tilt or turn it.
If you tilt the plug, there is a risk that the cover slide
becomes damaged.
16. Put the protective cap on the LLK-D connector.
17. Insert the plug into opening of focusing optics.
18. Loosen the screw of the clamp (only if ILN is available).

Fig. 5-28
19. Attach protective shells on both plugs of the LLK-D.
The LLK-D is loosened from the focusing optics.
Remove and wind up the 20. Take the LLK-D on the whole length out of the guidings,
LLK-D mounting clips, clamps etc.
Note
While winding up the cable, be careful not to knock the opti-
cal plugs against any objects. Else the light guide may be
damaged.
21. Wind up the LLK-D to a ring with a diameter of approx. 80
cm.
Removal of the LLK-D is complete.

Dewater the optical plug of
the LLK-D
1 Closure cap 3 Sealing nipple

2 Closure cap with supply hose 4 Hose coupling
Fig. 5-29
Loss of warranty in case of not dewatered optical plugs of

CAUTION the LLK-D!
If a dewatering is not done, the LLK-D may suffer transport
damage: material damage.
Ø Dewater the optical plugs of the LLK-D.
22. Provide the blow-out device.

23. Put closure caps (1 and 2) on the sealing nipples (3) of the
optical plugs.
24. Connect the blow-out device hose to the supply hose.
Tip
Use an appropriate connecting piece for connecting them.
The connecting pieces are supplied with the blow-out device.
If there is no appropriate connecting piece available, the
sealing nipples must be removed from the optical plug and
connected directly to the blow-out device.
25. Rotate the switch on the blow-out device to position I and
leave it for 10 seconds in this position.

26. Rotate the switch on the blow-out device to position 0.
27. Remove the hose of the blow-out device.
28. Remove closure caps (1 and 2) from the sealing nipples of
the optical plugs (3).
Note
Both optical plugs of the LLK-D must be dewatered.
29. Stow the blow-out device.
The optical plugs of the LLK-D are dewatered.
Remove the cooling water

hoses from the supply and
return connections of the
cooling water distributor.
Fig. 5-30
30. If cooling water hoses have to be removed:
Disconnect the cooling water hoses from the cooling water
distributor LLK-D
If you do not attach another LLK-D immediately.
Final procedures 31. Make sure that protection caps or plugs are mounted on all
openings.
32. Attach support of bushing at laser device again.
33. Close the hood to the user's compartment.
Removal of the LLK-D is complete.
Mounting the LLK-D
Ensure that the cooling of the LLK-D is running for 5 minutes

after switching off the laser.

Work steps
■ Laying the LLK-D.
■ Preparing the laser device
■ Connecting the LLK-D to the laser device.
■ Connecting the LLK-D to the focusing optics.
Condition

■ Double-bit key
■ Hexagon screwdriver, 4 mm
Laying the LLK-D 1. The LLK-D connector is packed in protective shells. Do not
remove these protective shells, until you have laid the LLK-D.
Packaging Connector Use

Large Protective Incoupling connector Connection of the LLK-D
shell to the laser device
Large Protective Outcoupling connec- Connection of the LLK-D
shell tor to the focusing optics
Tab. 5-8
2. Outside the laser cabin, laser light cables must be installed

permanently.
To do so, use:
− Cable clamps
− Cable ducts
− Other appropriate auxiliaries for fastening cables.
3. Inside of laser cabins which are monitored by a safety cir-
cuit, laser light cables can be laid freely and loosely.
4. To avoid mistakes:
If a ILN is included, connect the LLK-D to the respective LLK
coding cable using clamps.
Note
Ensure that the LLK-D is installed without tensile stress,
buckles and torsional strain. The bending radius must not be
smaller than 200 mm.

5. Install the LLK-D, the LLK coding cable (if available) and the
cooling water hoses by means of guides or mounting clips
towards the processing optics.
Preparing the laser device
DW-81083
Fig. 5-31
Fig. 5-32
7. Remove the required support from the bushing.

2.
1.
4. 3.
Fig. 5-33
8. Remove plug from the opening of the incoupling optics.
Connecting the LLK-D to the

laser device
2
1
1 Protective shell 3 Protection foil

2 Seal
Fig. 5-34
9. Remove protective shell from the optical plug, break the seal
and remove the protection foil.
Notes
■ Ensure that the openings from which the caps were
removed do not become soiled.
Fig. 5-35
10. Pull the protective cap from the incoupling connector.

1.
1.
2.
3.
4.
Fig. 5-36
keep it pressed during the inserting process. Plug optical
plug into incoupling optics as far as it will go.
Note
It is absolutely necessary that the optical plug of the LLK-D
is inserted in the incoupling optics as far as possible.
13. Plug in the securing connector and tighten it.

Connecting hoses and
connectors
Fig. 5-37
Note
Do not tilt the cooling water hoses when connecting them.
14. Connect the following cables and hoses:
− Field bus cable to socket Profibus (1) (slots located on
the bottom of the user's compartment).
− LLK coding cableto socket X125 (2).
− IFO cable to socket X225 (3).
− Monitoring plugto socket X1 (4).
− Cooling water hoses to hose couplings (5).
Note
The clamp has to be max. 150 mm away from the plug of
the LLK coding cables.

1 Clamp 2 Screw
Fig. 5-38
15. Connect the LLK-D and the respective LLK coding cable
using the clamp (see Interface description Interface LaserNet-
work).
The LLK-D is connected to the incoupling optics and the
monitoring electronics.
Closing the LLK bushing at

the laser device

3 LLK-D 7 Slotted sleeves
4 IFO cable
Fig. 5-39
16. Insert the LLK-D and, if available, the LLK coding cable, IFO
cable and field bus cable in the slotted sleeves (7).
17. Fasten the holder (6).
Connecting the LLK-D to the Note

focusing optics

the connections.
1.
2. 3.
Fig. 5-40
the focusing optics and remove the protective cap of the pro-
cessing optics.
20. Remove protective shell from the optical plug, break the seal
and remove the protection foil.
Notes
21. Remove the protective cap from the optical plug.
2. 1.
3. 4.
Fig. 5-41
22. Plug the optical plug into the focusing optics. Put the pin of
the optical plug in the fitted slot of the focusing optics.
the focusing optics and insert the optical plug into the focus-
ing optics as far as possible.
24. Check whether the optical plug engages correctly into the
focusing optics and cannot be pulled out.

25. Check whether the slide collar has close contact with the
optical plug in order to avoid the penetration of dirt.
ILN available 26. Connect the LLK-D to the respective LLK coding cable using
clamps.
Note
The clamp has to be as close as possible to the plug of the
LLK coding cable, in any case it has to be in the laser pro-
tective enclosure. More information can be found in the Test
procedure “Interface LaserNetwork LLK coding cable”, which
is enclosed with each LLK coding cable.
27. Check connection (see Interface description "Interface Laser-
Network (ILN)").
Connecting the cooling

water hoses
2
1 Supply hose 2 Return hose

Fig. 5-42
28. Connect the supply hose (1) to the focusing optics.

29. Connect the return hose (2) to the connector.
The LLK-D is now connected to the focusing optics.
Final procedures 30. If there is no ILN, switch on the laser device and control.
31. Check newly established cooling water connections for leaks.
− in the connection room LLK.
− at the focusing optics.
The LLK-D and the respective LLK coding cable, in case that
ILN is available, are installed.
Mounting the LLK-D
Work steps
■ Laying the LLK-B.
■ Preparing the laser device.
■ Connecting the LLK-B to the laser device.

■ Connecting the LLK-B to the focusing optics.
Condition
replaced during operation. If they are not equipped with ILN
unintended restart.

■ Double-bit key.
■ Hexagon screwdriver, 2,5 mm, 4 mm.
■ Slotted screw driver, 2 mm.
Laying the LLK-B 1. The plugs of the LLK are packed in protective shells. Do not
remove these protective shells, until you have laid the LLK.
Packaging Connector Use

Large protective Incoupling connector Verbindung des Laserlicht-
shell kabels mit dem Lasergerät
Small protective Outcoupling connec- Verbindung des Laserlicht-
shell tor kabels mit der Fokussier-
optik
Tab. 5-9
2. Outside the laser cabin, laser light cables must be installed

permanently.
To do so, use:
− Cable clamps
− Cable ducts
− Other appropriate auxiliaries for fastening cables.
3. Inside of laser cabins which are monitored by a safety cir-
cuit, laser light cables can be laid freely and loosely.
4. To avoid mistakes:
If an ILN is included, connect the LLK-B and the appertain-
ing LLK-coding cable mechanically using clamping pieces.
Note
Ensure that the LLK-B is laid without tensile stress, buckles
and torsional stress. The bending radius must not be smaller
than 200 mm.
5. Install the LLK-B and LLK-coding cable (if available) by
means of guides or mounting clips towards the processing
spot.

Preparing the laser device
DW-81083
Fig. 5-43
Fig. 5-44
7. Remove the required support from the bushing.
Fig. 5-45
8. Withdraw the plug from the opening of the incoupling optics.

Connecting the LLK-B to the
laser device 2
WS-00035
1 Protective shell 3 Protection foil
2 Seal
Fig. 5-46
9. Remove the protective shell from the optical plug, break the
seal and remove protection foil.
Notes
WS-00031
Fig. 5-47
10. Loosen the threaded pin and remove protection cap from the
incoupling plug.

Fig. 5-48
keep it pressed during the inserting process. Plug the optical
plug into the incoupling optics as far as possible.
Note
It is absolutely required that the optical plug is inserted into
the incoupling optics as far as possible.
13. Plug in the securing connector and tighten it.

Connecting hoses and
connectors
Fig. 5-49
Note
Do not tilt the cooling water hoses when connecting them.
14. Connect the following cables and hoses:
− Field bus cable to socket Profibus (1) (slots fitted on the
floor of the user compartment).
− LLK coding cable socket X125 (2).
− IFO cable to socket X225 (3).
− Monitoring plugto socket X1 (4).
Note
The clamping piece has to be max. 150 mm away from the
plug of the LLK-coding cable.

1 Clamp 2 Screw
Fig. 5-50
15. Connect the LLK-B and the appertaining LLK-coding cable
with the clamping piece (see interface description Interface
LaserNetwork).
The LLK-B is connected to the incoupling optics and the
monitoring electronics.
Closing the LLK bushing at

the laser device

3 LLK-B 7 Slotted sleeves
4 IFO cable
Fig. 5-51
16. Insert the LLK-B and, if available, the LLK-coding cable, IFO-
cable and Fieldbus cable in the slotted sleeves (7).
17. Fasten holder (6).
Connecting the LLK-B to the 19. Remove the protective shell from the optical plug, break the
focusing optics seal and remove protective foil.
Notes
■ If the focusing optics is fitted on a swivelable mount, it
should be brought to a possibly horizontal position for the

following activities. So it is prevented that dirt gets to
optical components which are temporarily exposed when
detaching the connections.
1 2
2 mm
4
5
4 mm
6
Fig. 5-52
20. Loosen the threaded pin (2) and remove protective cap (1)
from the optical plug.
21. Remove the plug (3) from the opening of the focusing optics.
22. Position the optical plug in such a way that the pin on the
optical plug (5) gets into the fitting groove of the focusing
optics (4).
23. Plug the optical plug into the focusing optics.
24. Tighten the clamping screw (6) at the focusing optics. When
doing so press the optical plug against the focusing optics.
The LLK-B is connected to the focusing optics.
ILN available 25. Clamp together the LLK-B and the corresponding LLK-coding
cable using the clamping piece.

Note
The clamping piece must be fitted as close as possible to
the plug of the LLK-coding cable, in any case inside the
laser proctection cabin. Further information is to be found in
the test instructions „Interface LaserNetwork LLK-coding
cable“ enclosed to any LLK-coding cable.
26. Check connection (see Interface description "Interface Laser-
Network (ILN)").
Final procedures 27. If no ILN is available, switch on laser device and control.
28. Check newly established cooling water connections in the
user's compartment for tightness:
The LLK-B and the corresponding LLK-coding cable, if ILN avail-
able, are fitted.
Removing an LLK-B
Work steps
■ Preparation.
■ Disconnect the LLK-B from the laser side.
■ Disconnect the LLK-B from the focusing optics.
■ Remove and wind up the LLK-B.
Condition

■ Two protective caps per removed laser light cable.
■ Connectors for each coupling optical unit from which a laser
light cable is removed.
■ Plugs for all openings at the focusing optics from which the
laser light cables are removed.
■ Hexagon screwdriver, 2.5 mm, 4 mm.
■ Slotted screw driver 2 mm.

Preparation
DW-81083
Fig. 5-53

3 LLK-B 7 Slotted sleeves
4 IFO cable
Fig. 5-54
2. Remove the support on the bushing from the LLK-B to be
replaced.
Now it is possible to disconnect the LLK-B from the laser
side.

Remove the LLK-B from the
laser device
1 Field bus cable 3 LLK coding cable 5 Monitoring plug

2 LLK-B 4 IFO cable
Incoupling optics with LLK-B Fig. 5-55
3. Pull out the monitoring plug (5).

4. Additionally, remove the following cables if the LLK-B is not
replaced but removed permanently.
− IFO cable (4)
− LLK coding cable(3)
− Field bus cable (1)

Fig. 5-56
5. Unscrew the securing connector.

6. Push the locking slide upward.
7. Loosen the set screw.
Notes
■ Do not tilt or turn the optical plug.
■ Avoid dirt on the plug or the light guide.
■ Do not knock the plug against anything. The light guide
might break.
8. Pull out the LLK-B connector.

WS-00030
Fig. 5-57
9. Put protective cap on the optical plug and tighten the threa-
ded pin.
Fig. 5-58
10. Insert connector into opening of incoupling optics.
11. Tighten the set screw.
13. Screw in the securing connector.
ILN available Note

LLK-B and LLK coding cable must always be installed
together in order to avoid mistakes.
LLK-B and LLK coding cable must be connected by mechan-
ical means. For this purpose, TRUMPF delivers the cables
together with clamps.

1 Clamp 2 Screw
Fig. 5-59
14. Loosen the screw (2) of the clamp (1).
The LLK-B is disconnected from the laser side.
Loosen the LLK-D from the Note

focusing optics
the connections.
4 mm
2 3
2 mm
4
Fig. 5-60
15. Loosen the locking screw (1) at the processing optics.

16. Pull out optical plug without canting or turning it.
17. Put the protective cap (2) on the optical plug and tighten the
setscrew(3).
18. Insert the plug (4) into opening of the processing optics.
19. Loosen the screw of the clamp (only if ILN is available).
Fig. 5-61
20. Attach protective shells on both plugs of the LLK-B.
The LLK-B is disconnected from the focusing optics.
Remove and wind up the 21. Take the LLK-B on the whole length out of the guidings,
LLK-D mounting clips, clamps etc.
Note
While winding up the cable, be careful not to knock the opti-
cal plugs against any objects. Else the light guide may be
damaged.
22. Wind up the LLK-B to a ring with a diameter of approx. 80
cm.
Removal of the LLK-B is now complete.
Final procedures 23. Make sure that protection caps or plugs are mounted on all
openings formed.
24. Attach support of bushing at laser device again.
Removal of the LLK-B is complete.
8.2 Maintaining laser light cable
Cleaning the protective sleeve along with


■ Cleaning swabs and methanol from the optics cleaning kit
(material no. 0779603).
20-10-02-A3-CR02 2012-10 Maintaining laser light cable 5‐57

Notes
■ Never touch the cover slide with the fingers.
■ Ensure that the cover slide is not scratched.

CAUTION swallow it.
Ø Do not smoke.
Cleaning the cover slide
1
2
1 Protection sleeve 2 Cover slide

Fig. 5-62
1. Moisten the cleaning swabs with methanol.

2. Slowly wipe across the cover slide until it is clean.
Note
If scratches or burnt-in particles are on the cover slide, the
protective sleeve with cover slide must be changed, (see
"Replacing the protection bushing with protective glass at the
LLK-D", pg. 5‐58).
3. Used cleaning swabs must be disposed of as residual waste.
Replacing the protection bushing with

protective glass at the LLK-D

■ Protective sleeve with cover slide for LLK-D (Material-No.
1342948).
■ Cleaning set for optical components (Material-No. 0779603).
5‐58 Maintaining laser light cable 2012-10 20-10-02-A3-CR02

Notes
■ Never touch the light guide (2).
■ Ensure that the light guide is neither soiled nor damaged.
■ With the protection sleeve (3) removed, hold the opening of
the optical plug downward so that no dirt particles can fall on
the end of the light guide.
■ Do not touch the cover slide of the new protective sleeve.
■ Make sure that no dirt particles enter the new protective
sleeve.
4
5
1 2
1 Optical plug of the LLK-D 3 Protective sleeve with cover 5 Mounting key
2 Light guide slide 6 Notch
4 Protecting cap
Replacing the protective sleeve along with the cover slide Fig. 5-63
Removing defective
protective sleeve along with
cover slide
Fig. 5-64

1. Screw off the protection sleeve along with cover slide using
the notch on the mounting key as screw driver.
Note
If you remove the protective sleeve laterally, there is a risk
that light guide becomes damaged.
2. Remove the protective sleeve cautiously in direction of the
beam from the optical plug.
Mounting a new protective

sleeve along with the cover
slide
Fig. 5-65
3. Remove protective cap from the mounting key.
Note
TRUMPF recommends to use a torque screwdriver to tighten
the protective sleeve (see "Tools and auxiliaries", pg. 5‐5).
4. Fasten new protective sleeve with the mounting key.
5. Check new cover slide for soiling and clean it, if necessary
(see "Cleaning the protective sleeve along with the cover
slide on the LLK-D", pg. 5‐57).
6. Dispose of the mounting key and the old protective sleeve as
residual waste.
Clean protective sleeve along with cover

slide on LLK-B

■ Lens cleaning paper and methanol from the optics cleaning
set (material no. 779603).

CAUTION swallow it.
Ø Do not smoke.
1 Protection bushing 2 Protection glass

Fig. 5-66
Notes
■ Never touch the cover slide (2) with the fingers.
■ Ensure that the cover slide is not scratched.
■ If scratches or burnt-in particles are on the cover slide,
the protective sleeve with cover slide must be changed.
(see "Replacing the protective sleeve along with the
cover slide on the LLK-B", pg. 5‐61) .
1. Moisten the lens cleaning paper with methanol.
2. Slowly wipe across the cover slide (pos. 2) until it is clean.
3. Used lens cleaning paper must be disposed of as refuse.
Replacing the protective sleeve along with


■ Protective sleeve with cover slide Material no.( 1272174)
■ Mounting key for protective sleeve Material no.( 566618)

Fig. 5-67
Notes
■ Never touch the optical wave guide (2).
■ Ensure that the optical wave guide is neither soiled nor
damaged.
■ With the protection sleeve (3) removed, hold the opening
of the optical-plug downward so that no dirt particles can
fall on the end of the wave guide (2).
■ Do not touch the cover slide of the new protective sleeve.
■ Make sure that no dirt particles enter the new protective
sleeve.
1. Screw off the protective sleeve ( 3) using a mounting key (4)
2. Remove the protective sleeve cautiously in direction of the
beam from the optical plug.
If you remove the protective sleeve laterally, there is a risk
that wave guide becomes damaged.
3. Hold new protection sleeve by the inner protective cap (6)
and remove outer protective cap (5).
4. Hold the new protection sleeve by the inner protective cap,
slide it cautiously onto the optical plug (1) in the direction of
beam and twist it onto the screw.
5. Pull off the inner protective cap and fasten the protective
sleeve using the mounting key (4).
6. Check new cover slide for soiling and clean it, if necessary
7. Dispose of the wrapping material and the old protective
sleeve as residual waste.

9. Diode current supply
9.1 Replacing the diode power supply
Condition
■ Laser device is switched off and protected against restart.

■ Double-bit key
■ Torx screwdriver, T25.
■ Slotted screw driver, 4 mm.
■ Cloth
or
■ Collecting pan for cooling water.

DANGER device!
gized.
Preparation 1. Open the right front door of the laser device.
20-10-02-A3-CR02 2012-10 Diode current supply 5‐63

Remove the diode power
supply
Fig. 5-68
2. Plug off the connectors at the front of the diode power sup-
ply.
− CAN bus connector (2x).
− Mains power supply.
− Connector top left.
3. Unscrew the fastening screws (4x).
Note
Take care that no cables or hoses under the diode power
supply become damaged when removing the diode power
supply.

DW-81074
Fig. 5-69
4. Pull out the diode power supply by about 5 cm.
5. Pull the collecting basin underneath.
Note
The two cooling water connectors must be removed simulta-
neously in order to avoid a larger amount of water running
out of the connections.
Treated, deionized water (DI water) is used as cooling

CAUTION water!
Cooling water can be aggressive against skin and textiles.
Ø Do not bring the cooling water in eyes, nose or mouth.
Ø Avoid that cooling water comes into contact with your cloth-
ing.
Ø The cooling water can be washed off with tap water.
Ø Wear protective gloves, safety goggles and protective cloth-
ing.
6. Simultaneously remove the two cooling water connectors.

A small quantity of cooling water flows out.
7. Collect the draining cooling water with a cloth.

WARNING
appropriate height.
8. Remove the diode power supply from the laser device.
Install the diode power Note

supply
Take care that no cables or hoses under the diode power
supply become damaged when inserting the diode power
supply.
9. Insert the replacement diode power supply into the housing,
leaving a free space of 5 cm.
10. Simultaneously connect the cooling water hoses.
11. Completely insert the diode power supply into the housing
and fasten it with screws.
12. Plug the connectors.
1 Rotary switch for CAN bus address

Fig. 5-70
13. Set the rotary switch situated on the DPS to the value of the
removed DPS.

14. Close the right front door of the laser device.

10. Laser cooler
The following service work on the laser cooler can be necessary:

■ Topping up cooling water.
■ Cleaning the tank.
■ Cleaning procedure and change of cooling water
■ Cleaning the contamination filter.
■ Replacing filter element in the fine filter.
■ Checking the cooling unit for tightness.
■ Emptying and filling the cooling unit.
1 Tank 3 Contamination filter

2 Fine filter
Fig. 5-71
In order to avoid deposits and soiling of the laser circuit, observe

the following:
■ Check regularly the quality of the cooling water.
■ Keep the doors and the hood closed.
■ Keep the cover of the tank closed.
■ In case of deposits or soiling of the laser cooling circuit,
clean the cooling circuit and change the filter element in the
fine filter.
■ Observe the maintenance intervals.
■ Before connecting new components (e.g. focusing optics
PFO), purge them with DI water (< 10µS/cm).
■ New components must be free of oil and grease.
5‐68 Laser cooler 2012-10 20-10-02-A3-CR02

10.1 Topping up cooling water

Cooling water must be topped up if:

■ A message is displayed on the monitor of the operating
panel stating that the water level in the tank is too low.
■ The tank level has dropped below the minimum mark.
Condition
■ Key-operated switch in position 0.

■ Double-bit key.
■ Water jug.
■ Deionized water (DI water prepared from water in drinking
water grade).
Conductivity < 10 μS/cm.
■ Wear Protective gloves for protection against DI water, pro-
tective clothing and safety goggles.
Note
If the tank must be filled with a lot of cooling water (more than
half the tank volume), an anti-corrosive must be added (see
"Cooling water additives", pg. 5‐5).
1. Open the right and the middle door on the rear of the laser
device.
Deionized water (DI water) is used to fill the tank!

CAUTION
ing.
Ø You can wash off the cooling water with tap water.
Ø Wear protective gloves, protective clothing and safety gog-
gles.
2. Loosen the knurled nut on the tank cover and remove the
cover.
20-10-02-A3-CR02 2012-10 Laser cooler 5‐69

Fig. 5-72
3. Top up with DI water until the water level reaches the 100 %
mark.
4. Press the pump button for approx. 1 min.
5. Check the water level and fill in cooling water up to the 100
% mark.
6. Close the tank cover and tighten the knurled nut.
7. Close the right and the middle door on the rear of the laser
device.
8. Turn the key-operated switch to position I.
The laser device is ready for use.
10.2 Cleaning the cooling circuit
Reason The cooling water in the tank must be changed after one year at
the latest. Before the tank can be filled with fresh cooling water,
a cleaning procedure must be carried out with a cleaning bio-
cide.
The symbol in the status line of TruControl 1000 and the
maintenance symbol in the dialog Maintenance & Commission-
ing indicate that the laser circuit has to be cleaned.
5‐70 Cleaning the cooling circuit 2012-10 20-10-02-A3-CR02

Fig. 5-73
The change of water must be acknowledged in the dialog Main-

tenance & Commissioning. The change of water must be noted
on the label "Additives for cooling water" attached to the tank.
Cooling water additives For the laser device series TruDisk (4C), TRUMPF has only
approved the cooling water additives specified in the table (see
"Tab. 5-10", pg. 5‐71). The exact procedure for changing the
cooling water is described in this section.
A package contains:
■ Data sheets and safety instructions regarding the cooling
water additives.
■ Information and instructions.
■ Safety gloves
■ 2 bottles of cooling water additives.
Cooling water Quantity Dosing for each Maintenance inter- Bottle Functions
additive use vals cap
Water Care Copper 1 bottle 1 bottle Every year yellow Copper
anticorrosive
STABREX ST40 1 bottle 1 bottle Every year red Cleaning biocide
STABREX ST70
STABREX ST70
FOR KITS
NALCO 93033B
NALCO 93033
Authorized cooling water additives Tab. 5-10
20-10-02-A3-CR02 2012-10 Cleaning the cooling circuit 5‐71

The package (Easy-Kit) is available in 5 country-specific ver-
sions. The suitable Easy-Kit can be obtained from TRUMPF,
(see "Cooling water additives", pg. 5‐5).
Note
Due to the limited useful life (see "Expiry date" indicated on the
bottles), it is recommended to adapt the order quantity to your
requirements.
Dosing The dosing is indicated in bottles, the required quantity must not
be measured.
Disposal of the cooling The user must aggree on the disposal of the cooling water with
water the responsible local disposal authority.
Cleaning procedure and change of cooling

water
In the following section, the cleaning procedure and the change

of cooling water is described.
The following steps are necessary:

■ Preparation
■ Carrying out the cleaning procedure.
■ Empty the optics chamber.
■ Emptying the tank, Cleaning the tank.
■ Emptying the fine filter.
■ Emptying the pump.
■ Filling the tank.
■ Deaerate the pump.
■ Checking the cooling unit for tightness.
■ Check the conductivity value of the cooling water, rinse the
system, if necessary.
■ Acknowledge the cleaning procedure in TruControl 1000.
■ Note on the label of the tank that the cleaning procedure has
been carried out.

■ Double-bit key
■ Cleaning cloth for wiping leaked cooling water.
■ Deionized water, 70 l.
Conductivity < 10 μS/cm
■ Disposal gloves, gloves, safety goggles, protective clothing to
protect you against DI water and cooling water additives.

■ Collecting pan with a capacity of about 70 l.
■ Cooling water additives, material no.: (see "Tab. 5-10", pg.
5‐71).
■ If necessary, filter element in the tank, material no.: (see
"Wearing parts", pg. 5‐5).
■ Water-resistant pencil to note the cleaning procedure on the
label of the tank.

CAUTION water!
ing.
ing.
The package "Easy-Kit" contains cooling water additives

CAUTION which have a caustic effect on the skin, the eyes and
textiles!
The chemical substances can be aggressive against skin
and textiles.
Ø Do not bring the chemical substances in eyes, nose or
mouth.
Ø Make sure that the chemical substances do not come into
contact with your clothing.
Ø The chemical substances can be washed off with tap water.
ing.
Ø Observe the safety instructions included in the package
"Easy-Kit".
Preparation 1. Wear protective gloves, safety goggles and protective cloth-

ing.
2. Turn the key-operated switch in position 0.
device.
4. Remove the cover on the right side.

Fig. 5-74
5. Place the collecting pan on the floor in front of the laser
device.
6. Loosen the 2 knurled nuts and remove the tank cover.
7. Check the tank for soiling and deposits.
8. If there visible deposits and signs of soiling:
Carry out the the steps 15 to 41 before filling in the cleaning
biocide.
Fig. 5-75
9. Fill the complete bottle of cleaning biocide (red cap) com-
pletely in the tank.

10. Close the tank cover and tighten the knurled nuts.
11. Switch the control unit on and turn the key-operated switch
to position I.
Carry out the cleaning Note

procedure
The conductivity monitoring can have an adverse effect on
the operating during the cleaning procedure.
Fig. 5-76
12. Select the Cond. monitoring off button.
The laser is operational during the cleaning procedure.

Fig. 5-77
13. Let the cooling unit run for 2 h. In dialog >Maintenance and
commissioning, check whether the cooling unit is switched
on:
− The display (arrow) must be lit in green.
The cooling water with the cleaning biocide circulates
through the laser circuit. Possibly existing germs are killed.
The cleaning procedure has been carried out.

Emptying the optics
chamber
Fig. 5-78
15. Remove the plug from the bottom of the distributor.
Air gets into the cooling circuit. The cooling water from the
optics chamber flows into the tank of the laser cooling unit.
16. Wipe off leaked cooling water with a clean cloth.
17. Re-attach the plugs.
The optics chamber is emptied.
Emptying the tank 18. Remove the sealing cap from the hose No. 1.
Fig. 5-79
19. Remove the cooling water completely from the tank.
21. Dispose of the cooling water according to the disposal regu-
lations.
22. Put on the disposal gloves.

23. Clean the inside of the tank (walls and bottom) using DI
water and a clean cloth.
Do not use cleaning additives.
Fig. 5-80
24. Remove the filter of the tank and check if it is soiled.
25. If necessary, clean the filter under flowing tap water (drinking
water quality) using a fluff-free cloth.
26. Install the filter.
27. Re-attach the sealing cap on the hose No. 1.
The tank is emptied.
Emptying the fine filter 28. Open the hook-and-loop fasteners on the filter element.
29. Loosen filter cup with the filter spanner.
Note
Only touch the filter element when wearing clean gloves!

DW-81056
Fig. 5-81
30. Take off the filter cup.
31. Remove the filter cup and drain the cooling water from the
filter cup into collecting pan.
33. Introduce the filter element carefully into the filter cup.
34. Reattach the filter cup.
The fine filter is emptied.
Emptying the pump
Fig. 5-82

35. Put the blue hose with the no. 2 in the collecting pan and
pull out the plug.
The cooling water flows out of the pump.
37. If no more cooling water runs out of the pump: Reattach the
plug.
The pump is empty.
Filling the tank
Fig. 5-83
mark.
40. Close the tank cover.
The tank is filled now.
Ventilating the pump
Fig. 5-84

41. Loosen the vent screw on the pump head. When water
leaks, close the vent screw.
Ventilation of the pump is completed.
Checking the cooling unit 42. Open the hood to the user's compartment.
for tightness

43. Briefly press the pump button in the laser device several
times, then for a longer period.
44. Check the connections for leaks.
45. Seal the leaky points, if necessary.
46. Wipe off drained cooling water with a clean cloth.
48. In dialog >Maintenance and commissioning >Cleaning laser
circuit, check whether the pump is really switched on.
49. Let the cooling unit run for 10 minutes.
Cooling water flows into the fine filter, through the pump
units and the connected focusing optics. The cooling circuit
is purged.

Check the conductivity value
of the cooling water.
Fig. 5-86
50. Checking the conductivity value: >Maintenance and commis-
sioning >Cleaning laser circuit.
51. If the conductivity value of the cooling water is ≥ 20
μS/cm after rinsing:
Repeat the steps beginning with "Emptying optics chamber"
un the conductivity after rinsing has reached the value
≤ 20 μS/cm.
or
Ø If the conductivity value of the cooling water is ≥ 20
μS/cm after rinsing:
If necessary, top up with DI water until the water level
reaches the 100 % mark(see "Topping up cooling water",
pg. 5‐69).

textiles!
and textiles.
mouth.
ing.
"Easy-Kit".
Fig. 5-87
52. Fill the complete bottle of copper anticorrosive (yellow cap)
completely in the tank.
Acknowledging the change 53. Using a water-proof marker, note down the cleaning on the
of water and noting it label of the tank.
54. Close the doors on the laser device.
55. Acknowledge the cleaning in TruControl 1000: >Maintenance
& Commissioning >Cleaning cooling circuit.
The maintenance work is finished.

10.3 Replacing filter element in the fine
filter
The filter element in the fine filter must be replaced if a mes-

sage appears indicating the following:
■ The pump has reached its power limit.
■ Differential pressure not in the allowed range.
■ And other causes can be excluded.
Condition

■ Gloves to protect against cooling water.
■ Disposal gloves for protection of the filter element
■ Absorbent cloth.
■ Filter element, Material no.: (see "Wearing parts", pg. 5‐5).
Note
Make sure the filter element is not contaminated. The protective
film the new filter element must be opened immediately before
insertion into the filter. The filter element must only be deposited
on an absolutely clean surface.
Preparing the laser device 1. Open the right and the middle door on the rear of the laser
device.
2. Open the hook-and-loop fasteners on the filter element.

Replacing the filter element
DW-81056
Fig. 5-88

CAUTION
ing.
gles.
4. Remove the filter cup along with the filter element.

5. Carefully take the filter element out of the filter cup and let it
dry in an appropriate vessel.
Fig. 5-89
7. Put on the disposal gloves to protect the new filter element
against soiling (grease, germs).
8. Open the protective film of the new filter element and insert
the new filter element.
9. Remount the fine filter in reverse order.
Check for impermeability 10. Open the hood to the user's compartment.

11. Briefly press the pump button in the laser device several
times, then for a longer period.
12. Check tightness of the fine filter.
If the fine filter is leaky, check seat and condition of the O-
ring. In case of damage or wear, replace the O-ring.
Final procedures 13. Check the DI water level in the tank. Fill in DI water up to
the 100 % mark (see "Topping up cooling water", pg. 5‐69).
device.
10.4 Cleaning the contamination filter

Condition

■ Double-bit key
■ Pipe wrench
■ Cleaning brush
■ Blow-out gun and compressed air.
■ Cleaning cloth for wiping leaked cooling water.
■ Collecting pan with a capacity of about 5 l.
■ upon demand:
Spare sieve for contamination filter., Material no.: (see
"Wearing parts", pg. 5‐5).

Fig. 5-91
1. Shut the stop valves of the external circuit.

2. Put tray on the floor in front of the drain hoses.
Fig. 5-92
3. Open stop valves of the drain hoses.
Cooling water drains off and the pressure in the external cir-
cuit is reduced.
device.
DW-81058
Fig. 5-93

5. Slowly loosen the filter insert in the contamination filter.
A small quantity of water which can be wiped off with a
cleaning cloth may come out.
Fig. 5-94
6. Clean the outside of the filter elements under running water
using a soft brush.
7. Check the seal ring of the filter insert and replace it, if nec-
essary.
8. Screw in and tighten filter element again.
9. Close the stop valves of the drain hoses.
Fig. 5-95
10. Open stop valves of the external cooling circuit.
11. Check contamination filter for tightness. If it leaks, retighten
the screws of the filter insert or, if necessary, replace the
seal ring.
12. Mount the cover on the left side.

10.5 Checking the cooling unit for
tightness
Conditions
■ The laser device has been turned on.
■ The external cooling circuit is connected and supplied with
the working pressure of the cooling water.

■ Double-bit key
device.

5. Press the pump button for 1 minute.
The pump pumps cooling water through the cooling circuit.
6. Observe all the components, hoses and tubes of the laser
circuit while the pump is working.
7. If cooling water leaks, even in a small quantity, find the leaky
point and seal it, for example:
− Seal the hose connections or replace them.
− Replace O-rings, e.g. in the filter cup of the fine filter.
− Loosen the quick-acting couplings, re-attach or replace
them
− Fasten the sealing clamps.
− Fasten the spigot nuts.
8. If a part that contains or supplies water is damaged:
Informing the TRUMPF service department.
10. Stow the pump button.
device.

10.6 Emptying and filling the cooling unit
Emptying the cooling unit of the laser

device
All tanks and hoses, filled with water while operating the laser
device, must be emptied completely in the following situations:
■ before transport or storage of the laser device at low temper-
atures (danger of frost)
■ in case of transport by aircraft
■ The maintenance intervals must also be complied with if the
laser device is not used; or empty the cooling system.
Conditions
■ The laser device has to be connected to the power supply
system.

■ Double-bit key
■ Pipe wrench
■ Disposal gloves, gloves, safety goggles, protective clothing to
protect you against DI water and cooling water additives.
■ Collecting pan having a capacity of about 70 l
■ Cloth to wipe up drained off cooling water.
■ Blow-out accessories (contains hose bridge and blow-out
adapter), (see "Tools and auxiliaries", pg. 5‐5)
■ Compressed air source with a volume flow of 500 l/min and
at a pressure of 0.5 bars on the blow-out adapter. The qual-
ity of the compressed air must correspond to class 2 accord-
ing to DIN ISO 8573-1 (see "Tab. 5-5", pg. 5‐7).
Note
The user must aggree on the disposal of the cooling water with
the responsible local disposal authority.The cooling water from
the external cooling circuit can be disposed of in the sewerage
system provided that it does not contain any additives (e.g. anti-
freezing agents or biocides).
5‐90 Emptying and filling the cooling unit 2012-10 20-10-02-A3-CR02

Preparation 1. Open the hood to the user's compartment.
device.
3. Remove the cover from the left side of the laser device.
Emptying the external 4. Shut off the in-house water connections in the supply and
cooling circuit return of the external cooling circuit. The stop valves of the
cooling water connections remain open.
5. Either
Ø Place the collecting pan on the floor in front of the drain
hoses.
or
Ø Hang drain hoses in the sewerage system.
Fig. 5-97
6. Open stop valves of the drain hoses.
The cooling water drains off.
Fig. 5-98
7. If no cooling water runs out any longer:
disconnect the cooling water hoses.
The remaining cooling water drains out of the cooling water
connections.
20-10-02-A3-CR02 2012-10 Emptying and filling the cooling unit 5‐91

Fig. 5-99
8. Put tray on the floor in front of the laser device.
Fig. 5-100
9. Put the hose number 6 in the pan and remove the sealing
cap.

DW-81058
Fig. 5-101
10. Cleaning the contamination filter (see "Cleaning the contami-
nation filter", pg. 5‐86).
11. If no more water comes out of the cooling water connections:
Re-attach the sealing cap.
12. Close all stop valves and cooling water connections.
The external circuit is emptied.
Emptying the laser circuit

CAUTION water!
ing.
ing.

Fig. 5-102
13. Put tray on the floor in front of the laser device.
Fig. 5-103
14. Place the hoses with the numbers 1 and 2 in the collecting
pan and remove the sealing caps.

Fig. 5-104
15. Pull out the sealing plug on the first connection of the cool-
ing water distributor towards the focusing optics (2x).
Air gets into the laser circuit. The treated DI water in the
optical arrangement flows into the tank of the laser cooler.
Note
Leave the hoses in the pan.
Fig. 5-105
16. Connect the openings to the hose with a diameter of 8 mm.
Fig. 5-106

17. Connect the cooling water connection for LLK-D connector in
the user's compartment with a hose bridge (arrow).
Fig. 5-107
18. Open the connection (arrow).
Note
The compressed air source must have a volume flow of
500 l/min at a pressure of 0.5 bar on the blow-out adapter.
The quality of the compressed air must correspond to class 2
according to DIN ISO 8573-1 (see "Tab. 5-5", pg. 5‐7).
Blow-out adapter Fig. 5-108

19. Connect the blow-out adapter to the compressed air source.

Fig. 5-109
20. Connect the blow-out adapter to the open connection of the
cooling unit.
21. Switch the compressed air source on and wait until no more
cooling water comes out (0.5 bar, 2 min).
Fig. 5-110
22. Remove the blow-out adapter and close the open connection
(arrow).

Fig. 5-111
23. Open the connection (arrow).
24. Connect the blow-out adapter to the open connection of the
cooling unit.
25. Switch the compressed air source on and wait until no more
cooling water comes out (0.5 bar, 2 min).
26. Remove the blow-out adapter and close the open connection
(arrow).
Emptying the fine filter 27. Open the hook-and-loop fasteners on the filter element.
Note
Only touch the filter element when wearing clean gloves!
DW-81056
Fig. 5-112
29. Take off the filter cup.

30. Remove the filter cup and drain the cooling water from the
filter cup into collecting pan.
32. Introduce the filter element carefully into the filter cup.
33. Reattach the filter cup.
The fine filter is emptied.
Final procedures 34. Remove the jumpers.
35. Attach the plug on the cooling water distributor to the focus-
ing optics.
36. Attach the sealing caps on the hoses with the numbers 1 to
2 and stow the hoses in the laser device.
37. Mount the side wall, close the hood and the doors.
38. The user must aggree on the disposal of the cooling water
with the responsible local disposal authority.The cooling
water from the external cooling circuit can be disposed of in
the sewerage system provided that it does not contain any
additives (e.g. anti-freezing agents or biocides).
This completes the emptying of the laser device.
Filling the cooling unit
Conditions
system.
■ External cooling water lines are connected.

■ Deionized water, approx. 70 l.
■ Conductivity < 10 μS/cm
■ Cooling water additives, material no.: (see "Tab. 5-10", pg.
5‐71).
■ Gloves, safety goggles, protective clothing to protect you
against DI water and cooling water additives.
■ Fork wrench, 9 mm
■ Pipe wrench
■ Cloth to wipe up drained off cooling water.
Preparation 1. Open the right and the middle door on the rear of the laser
device.
2. Removing the left cover

Checking connections Note
When the laser device was emptied, connections were dis-
connected This is why all connections that were disconnec-
ted must be checked before filling the cooling unit.
1 Connection 4 Contamination filter

2 Fine filter 5 Drain hoses (3x)
3 Connection
Fig. 5-113
4. Check whether the connections are complete and connected
or closed correctly.
1 Plug on the cooling water 2 Stop valves

distributor to the focusing
optics
Fig. 5-114
5. Check whether all stop valves are closed and secured.

Fig. 5-115
6. Check whether all plugs are inserted.
Filling the laser circuit

CAUTION
ing.
gles.
7. Loosen the knurled nuts on the tank cover and remove the
cover.

Fig. 5-116
mark.
Fig. 5-117
9. Loosen the vent screw on the pump head. When water
leaks, close the vent screw.
Ventilation of the pump is completed.
Check for impermeability 10. Switch on the laser device.

13. Briefly press the pump button in the user's compartment sev-
eral times, then for a longer period.
DI water flows through the components of the laser cooling
circuit.
14. Check the connections for leaks.
15. Seal the leaky points, if necessary.
16. Wipe off drained cooling water with a clean cloth.
Topping up DI water Note

The filling of the cooled components has caused the water
level in the tank to drop. If the water level has fallen below
the 100 % mark, DI water has to be topped up.
mark.
Filling in anticorrosive

textiles!
and textiles.
mouth.
ing.
"Easy-Kit".

Fig. 5-119
18. Fill the complete bottle of anticorrosive (yellow cap) com-
pletely in the tank.
20. Let the cooling unit run for 1 minute.
Filling the external circuit
Fig. 5-120
22. Open domestic water connections and cooling water connec-
tions at inlet and return of external cooling circuit.
Water flows into the external circuit.

DW-81058
Fig. 5-121
23. Check impermeability of contamination filter.
25. Mount the cover on the right side
device.
The internal and external circuits are full.

11. Air cleaner
Fig. 5-122
Maintenance intervals For the laser devices TruDisk 2002, TruDisk 2004, TruDisk 2602,
TruDisk 3302, TruDisk 3306, TruDisk 4002, TruDisk 4006 the fol-
lowing is valid:
Spare part Material no. Maintenance interval

Air cleaner, complete 1453560 20.000 h
Filter mat in the cabinet door 0991551 20.000 h
Tab. 5-11
For the laser devices TruDisk 2001, TruDisk 2501, TruDisk 3001,
the following is valid:
Spare part Material no. Maintenance inter-

val
Air cleaner, complete 1453560 10.000 h
Water separator + preliminary filter- 0991071 5.000 h
Filter cartridge on
Filter cartridge on Microfilter 0991082 5.000 h
Filter cartridge on Active carbon fil- 5.000 h
-
ter
Filter cartridge on Intake filter 1426112 5.000 h
Filter mat in the cabinet door 0991551 5.000 h
Tab. 5-12
5‐106 Air cleaner 2012-10 20-10-02-A3-CR02

11.1 Completely replacing the air cleaner

Condition

■ Double-bit key.
■ Crosstip screw driver, PH 2.
■ Air cleaner (material no. 1453560).
Removing the air cleaner
The compressor of the air cleaner can be hot immediately

WARNING after operation.
Risk of burns on the hands.
Ø Wait until the compressor has cooled down.
1. Open the right front door of the laser device.
4
4 mm
4
2
DW-80007
Fig. 5-123
2. Disconnect all plugs (1).
3. Remove the hoses (2).
4. Remove the grounding cable (3).
5. Unscrew the screws (4).
20-10-02-A3-CR02 2012-10 Air cleaner 5‐107

WARNING
appropriate height.
6. Remove the air cleaner from the laser device.

Installing a new air cleaner 7. Install the new air cleaner in reverse order.
8. Remove the shipping brace before commissioning. (see
chapter "Installation conditions, transport").
11.2 Replace the filter cartridge for water

separator and microfilter
The following steps are identical for:

■ Water separator + preliminary filter
■ Microfilter
Condition
■ Removal of the air cleaner is now complete.

■ Filter cartridge for Water separator + preliminary filter (Mate-
rial no. 0991071).
■ Filter cartridge for microfilter (Material no. 0991082).
5‐108 Air cleaner 2012-10 20-10-02-A3-CR02

4.
2.
3.
1.
Fig. 5-124
1. Remove the hose below the filter casing (if existing).

2. Lift up the filter casing and turn to the left.
3. Pull the filter casing downward.
4. Unscrew the filter cartridge.
5. Screw in the new filter cartridge and close the filter casing in
reverse order.
11.3 Filter cartridge in the intake filter

Condition
■ Removal of the air cleaner is complete.

■ Fork wrench, 19 mm.
■ Filterpatrone für Intake filter (Material no. 1426112).
20-10-02-A3-CR02 2012-10 Air cleaner 5‐109

The compressor of the air cleaner can be hot immediately
WARNING after operation.
Risk of burns on the hands.
Ø Wait until the compressor has cooled down.
19 mm
Fig. 5-125
1. Loosen spigot nuts (1) and remove communication line (2).
Fig. 5-126
2. Unscrew the filter cover together with the filter cartridge.
5‐110 Air cleaner 2012-10 20-10-02-A3-CR02

3. Unscrew the filter cartridge from the filter cover.
4. Screw down the new filter cartridge on the filter cover.
5. Remount the filter cover together with the filter cartridge.
6. Remount the communication line.
11.4 Replacing filter cartridge in the

activated carbon filter
Condition
■ Removal of the air cleaner is now complete.

■ Filter cartridge for the active carbon filter
(Fixed on the frame of the air cleaner).
Replacing filter cartridge
3.
1.
2.
Fig. 5-127
1. Lift up the filter casing and turn to the left.

2. Pull the filter casing downward.
3. Unscrew the filter cartridge.
20-10-02-A3-CR02 2012-10 Air cleaner 5‐111

4. Screw in the new filter cartridge and close the filter casing in
reverse order.
Enter the serial number into 5. Switch on the laser device.
the maintenance assistant 6. In the program TruControl 1000:
Select >Maintenance/Start-up.
7. SelectActive carbon filter.
8. Select maintenance work.
The dialog box Maintenance active carbon filter is opened.
Fig. 5-128
Note
The serial number is engraved in the bottom of the filter car-
tridge.
9. Enter the serial number (10-digit) of the removed filter car-
tridge in the field serial number activated carbon filter.
Note
The serial number is printed on the packaging of the filter
cartridge.
10. Enter the serial number of the new filter cartridge in the field
Serial number of replacement filter.
11. Select acknowledge replacement.
Dialog box maintenance active carbon filter is closed.
12. Re-install the air cleaner.
5‐112 Air cleaner 2012-10 20-10-02-A3-CR02

11.5 Changing the filter mat


■ Filter mat (material no. 0991551).
Fig. 5-129
1. Take off the diaphragm.

2. Take out the filter fleece.
3. Insert new filter fleece.
4. Reattach the diaphragm.
20-10-02-A3-CR02 2012-10 Air cleaner 5‐113

12. Electrical system
Maintenance work of the electrical system confines itself to

changing fuses or switching on circuit breakers when they are
disconnected due to a malfunction.
A blown fuse has to be changed. A circuit breaker that has dis-
connected itself must be switched on again. This is indicated by
the failure of partial functions or through corresponding mes-
sages on the operating panel.
12.1 Identifying blown electrical fuses

Conditions
system.
■ The mains switch of the laser device must be in position ON.
■ The control of the laser device is switched on..

■ Double-bit key

DANGER device!
gized.
Preparing the laser device 1. Open the left front door.

2. Open the middle front door.
5‐114 Electrical system 2012-10 20-10-02-A3-CR02

You obtain access to the mains distribution.
1 Circuit breaker 2 Microfuses

Fig. 5-130
Determining a blown
microfuse
F1 F2 F3 F4 F5
F6 F7 F8 F9 F10
DW-81070
Fig. 5-131
3. Check the LEDs on the PSB board.
LED to fuse Function

F1 Option
F2 Laser control unit/central processor
F3 Cabinet fan
F4 Fan slide-in control module
F5 Inverter of service socket
F6 Air cleaner
F7 Power supply laser
F8 Activation power supply
F9 Control board mains distribution
F10 User area
Tab. 5-13
LEDs of the intact fuses are lit when a consumer is connec-

ted.
20-10-02-A3-CR02 2012-10 Electrical system 5‐115

If one of the LEDs is not lit, the corresponding fuse is defec-
tive.
4. Turn the laser device off.
Determining the blown 5. A blown circuit breaker can be identified by the position of
circuit breaker the switch. (see "Switch on Circuit breaker", pg. 5‐117)
12.2 Replacing a microfuse

Conditions
■ The burnt-out microfuse has to be identified.(see "Identifying
blown electrical fuses ", pg. 5‐114)

DANGER device!
Ø The laser must be switched off when fuses are changed.
1. Pull out the burnt-out fuse.

2. Eliminate the cause of the microfuse blowing. Otherwise, it
may occur that the replaced microfuse will blow again when
the device is switched on again.
Note
The replacement fuse must be suitable for the same current.
A list with the values of the fuses is attached to the cover
sheet near the microfuses.
3. Replace burnt-out fine fuse by a new fine fuse of the same
type.
4. Switch on the laser device.
5. Check LEDs.
6. If other LEDs are not lit, replace also the corresponding
microfuse.
7. Close the middle front door
8. Close the left front door.
5‐116 Electrical system 2012-10 20-10-02-A3-CR02

12.3 Switch on Circuit breaker

Conditions
■ The blown circuit breaker must be identified. (see "Identifying
blown electrical fuses ", pg. 5‐114)

DANGER device!
Ø Circuit breakers may be switched on only while the device is
turned off.
Fig. 5-132
1. Eliminate the cause that made the circuit breaker trip. Other-
wise, the circuit breaker might trip again as soon as the
device is switched on.
2. Turn the black switch of the tripped circuit breaker upwards.
3. Close the middle front door
4. Close the left front door.
20-10-02-A3-CR02 2012-10 Electrical system 5‐117

13. Operating panel
13.1 Clean the screen of the operating

panel

■ Soft cloth
■ Neutral cleaning agent
or
■ alcohol
WS-76099
Fig. 5-133
Ø Clean the screen with a soft cloth.

or
Ø in case of heavy soiling, humidify the cloth with neutral
cleaning agent or alcohol.
5‐118 Operating panel 2012-10 20-10-02-A3-CR02

Chapter 6
Conduct in case of service

interruptions
1 Service interruptions 6‐2

1.1 Measures in case of service interruptions 6‐2
2 Identifying causes 6‐3
3 Monitoring and faults 6‐4

3.1 Monitoring 6‐4
3.2 Fault 6‐5
4 Dealing with messages 6‐7

4.1 Structure of a message 6‐7
4.2 Message history 6‐9
Display the message history 6‐9
Setting the message filter 6‐9
Searching message 6‐10
Type of message 6‐11
20-10-02-A3-CR02 2012-10 Conduct in case of service interruptions 6‐1

1. Service interruptions
TRUMPF laser devices are equipped with extensive monitoring

functions that ensure reliable operation. In case of anomalies
from normal operation, messages are displayed which indicate
necessary measures, if possible.
However, during operation of the laser device, events may occur
which cause service interruptions. In this case, the causes of the
service interruption must be eliminated before operation can be
continued.
1.1 Measures in case of service

interruptions
Work on the laser device might bear risks for you or others.
DANGER
If such risks are not avoided, they can lead to death,
serious injuries or considerable damage to property.
Ø Causes for service interruptions may only be remedied by
persons who are sufficiently familiar with the laser device.
Ø Switch off laser device and secure it against being switched
on again, if it is not absolutely necessary to switch it on.
Ø Before touching parts which are live during operation, check
whether they are dead.
Ø Wear personal protective equipment if required for the corre-
sponding action (e.g. laser safety goggles, safety gloves).
Ø Observe the safety instructions and warnings of these oper-
ating instructions and of other documents.
1. Identify the cause of the service interruption.

2. Carry out recommended measures according to the instruc-
tions of the manual, if applicable.
Contact the TRUMPF service department if you cannot
find or eliminate the cause. Indicate the following:
Ø Number of the displayed message.

Ø The events which lead to the service interruption.
The TRUMPF service department will carry out all necessary

work in order to allow you to operate the laser device as soon
as possible.
6‐2 Service interruptions 2012-10 20-10-02-A3-CR02

2. Identifying causes
Different factors outside and inside the laser device can be taken
into consideration as causes for service interruptions. Before tak-
ing measures, you should know as much as possible about the
cause of service interruption.
Causes of a service interruption may be the following, e.g.:

■ Unsatisfactory machining results due to:
− Defective workpieces
− Soiled protective glasses of the focusing optics.
■ Errors in programs:
− Pulse shapes..
− laser programs.
− Light paths..
− Sequential programs in the external controls (PLC etc.).
■ Error in wiring of interfaces in case of external control of the
laser device.
■ Operating error
■ Malfunctions in the laser device
Having identified the cause, take appropriate measures to elimi-
nate it. Please contact the customer service of TRUMPF if you
need assistance.
20-10-02-A3-CR02 2012-10 Identifying causes 6‐3

3. Monitoring and faults
3.1 Monitoring
Numerous operational values of the laser device are monitored.

Examples:
■ Laser power.
■ Position of the switch mirrors and shutter mirrors
■ Temperature and flow of the cooling water
The operational values are constantly measured and compared
to nominal values or limit values. If an operational value is out-
side the permissible range, the control unit of the laser device
generates a monitoring message.
Monitoring message The yellow display "Monitoring" is illuminated in the main dialog
of TruControl 1000.
Fig. 6-1
1 Reporting subassembly 3 Number of the message

2 Sign "Monitoring" 4 Short text of the message
Monitoring message is displayed Fig. 6-2
Reporting subassembly Subassembly (board) of the control unit that generates the mes-
sage.
6‐4 Monitoring and faults 2012-10 20-10-02-A3-CR02

Symbol "Monitoring" The symbol monitoring indicates a monitoring message in the
symbol bar.
There is a further symbol that belongs to the category of moni-
toring messages:
Symbol Category Meaning

Light path monitoring Work can continue.
Tab. 6-1
Number of the message The number corresponds to the message code which is sent
from the control to the operating panel. Via the display of the
message memory it is possible to call up the message text:
⇒ Select main activity Diagnostics.
The message memory is displayed.
Short message text The short text gives the operator one-line information on the
cause of the message.
Note
When a monitoring is displayed you can still operate the laser
device. You should eliminate the cause at the next opportunity. If
you do not remedy the cause, it may be possible that a moni-
tored operational value exceeds the fault limit in the near future
(see section Fault).
In case of a fault you can only continue to operate the laser
device, when the cause is eliminated..
3.2 Fault
When a monitored operational value is far outside the permissi-

ble range, a critical condition will probably have been reached
which does not allow the operation of the laser device to be con-
tinued. This is why fault limits are set which the operational val-
ues are compared to.
If an operational value exceeds a fault limit:

■ the laser is deactivated automatically.
■ a fault message is displayed on the screen.
Fault message In the main dialog TruControl 1000 the red display "Fault" is illu-
minated.
20-10-02-A3-CR02 2012-10 Fault 6‐5

Fig. 6-3
1 Reporting subassembly 3 Number of the message

2 Sign "Fault" 4 Short text of the message
The fault message is displayed Fig. 6-4
There is a further symbol belonging to the category fault mes-

sages:

Light path fault Light path is blocked.
Tab. 6-2
Note
In case of malfunction, the laser device cannot be operated until
the cause of the malfunction has been eliminated and the laser
device has been reset. For more information on this, please refer
to the section “How to respond to messages” in chapter "Opera-
tion".
6‐6 Fault 2012-10 20-10-02-A3-CR02

4. Dealing with messages
4.1 Structure of a message
In order to display a message text:
Displaying a message text 1. Select the main activity Diagnostics.

2. Call the message history with .
The message history is displayed.
Meldungstext anzeigen Fig. 6-5

3. Mark the message. (1).
4. Select Display.(2).
The following display will be shown on the operating panel:
20-10-02-A3-CR02 2012-10 Dealing with messages 6‐7

1 Date, time, message code, 3 Message text 5 Scroll bar
board 4 Number of causes 6 Context bar
2 Short text of the message
Fig. 6-6
Display
Date and time of the message is displayed (1). Additionally,
the message code and the name of the board that has cre-
ated the message are displayed.
Short text
The short text (2) is the same as in the main dialog of Tru-
Control 1000.
Message text
The message text (3) consists of cause, effect and measure.
The Effect describes the effect of the reported state on the
laser device. A specific Measure belongs to each Cause. An
effect may have several causes. One of these causes is indi-
cated in this area. With the button Next cause all the causes
can be displayed in succession. The Details contain informa-
tion for the TRUMPF service department. Details can be
called with a user level ≥ 70.
Scroll bar
Use the scroll bar (5) to scroll the message text vertically if it
is too long to be displayed in the display window.
Display of the causes
Display of the number of causes for a message (4).
6‐8 Dealing with messages 2012-10 20-10-02-A3-CR02

4.2 Message history
All messages are entered in a message history so that they can

still be read even after resetting the laser device. This function is
useful for diagnostic purposes.
Display the message history
1. Select the main activity Diagnostics.

2. Select the message history with .
Setting the message filter

3. Select Change filter.
The filter settings are displayed.
Message filter Fig. 6-7

4. Check the boxes for the message types to be displayed in
the message list.
5. Select Apply.
The filter settings are displayed.
20-10-02-A3-CR02 2012-10 Message history 6‐9

Searching message
There are Expert dialogs in all secondary activities of the main

activity Diagnosis. Expert dialogs contain extended dialogs for
diagnosis purposes for the TRUMPF service or for trained users
of the laser devices.
In extended diagnosis dialogs, the buttons for laser operation
and function activation/deactivation are only active starting from
user level ≥ 70.
Expert dialogs are loaded by pressing the button Expert dialog.

RP-00183
Expert dialog button Fig. 6-8
3. Select Expert dialog.
The dialog box Search message text is opened.
4. Enter the message code and select Search.
The message is displayed.
6‐10 Message history 2012-10 20-10-02-A3-CR02

Type of message
The categories are marked with symbols.

Fault Laser is switched off.
Message must be acknowledged by
means of Reset.
Monitoring Work can continue.
Message must be acknowledged by
means of Reset.
Light path fault Light path is blocked.
Must be acknowledged by means of
Reset light path or Reset laser.
Light path monitoring Work can continue.
Must be acknowledged by means of
Reset light path or Reset laser.
Maintenance Maintenance work must be carried
out.
Information Information message (status in the

laser device changed.)
Logbook A change in configuration has been

made (for example, a laser program
has been transmitted).
Tab. 6-3
20-10-02-A3-CR02 2012-10 Message history 6‐11

6‐12 Message history 2012-10 20-10-02-A3-CR02

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Operator's manual

TruDisk 2001, TruDisk 2002,

TruDisk 2001, TruDisk 2002,

Original operator's manual

TRUMPF Laser GmbH

TRUMPF Laser GmbH

For "partly completed machinery" in accordance with the EC

© TRUMPF Laser GmbH

What do the operating These operating instructions contain important information on

Other regulations In addition to the operating instructions, also observe the

Operation The operating instructions are found in chapter 4. It describes

Maintenance Chapter 5 informs you on maintenance work that you, as the

Interruptions of operation Chapter 6 describes finally how to proceed in case of interrup-

20-10-02-A3-CR02 2012-10 Before you proceed ... I

1 General notes 1‐3

2 Information on special risks 1‐7

3 Warning instructions 1‐15

4 Designated use of the laser device 1‐16

5 Laser beam exit ports 1‐17

6 Location and function of the safety devi- 1‐19

20-10-02-A3-CR02 2012-10 Table of contents 0‐1

Chapter 2 Installation conditions, transport

1 Scope of delivery 2‐4

3 Weight, floor at the installation site 2‐14

5 Electrical connected loads 2‐19

6 Cooling unit 2‐23

0‐2 Table of contents 2012-10 20-10-02-A3-CR02

7 Ambient conditions 2‐38

9 Position of the user 2‐41

10 First measures to be taken after receipt of 2‐44

20-10-02-A3-CR02 2012-10 Table of contents 0‐3

3 Optical arrangement 3‐7

0‐4 Table of contents 2012-10 20-10-02-A3-CR02

5 Focusing optics 3‐25

7 Mains distribution 3‐29

8 Laser cooler 3‐31

9 Cabinet cooler 3‐33

10 Air cleaner 3‐34

11 Diode current supply 3‐36

12 Operating panel 3‐37

13 Panel computer (Option) 3‐38

14 Control panel (Option) 3‐39

1 Operating elements and indicators 4‐3

2 Switching the laser device on and off 4‐7

20-10-02-A3-CR02 2012-10 Table of contents 0‐5

3 Operating the laser device using TruCon- 4‐11

4 External control of the laser device 4‐25

0‐6 Table of contents 2012-10 20-10-02-A3-CR02

1 General notes 5‐4

3 Opening and closing the laser device 5‐9

4 Hose connections 5‐12

5 Removing the securing device from the 5‐13

6 Maintenance list 5‐14

8 Laser light cable 5‐26

20-10-02-A3-CR02 2012-10 Table of contents 0‐7

9 Diode current supply 5‐63

10 Laser cooler 5‐68

11 Air cleaner 5‐106

12 Electrical system 5‐114